Download B913 PLC and IOC Test Plan

LCLS B913 Vacuum System PLC and IOC Test Plan
25 Nov 2008
Matt Boyes
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Program PLC and IOC
Visually comb through PLC code looking for errors
a. Produce list of tags, aliases, and hardware addresses
b. Verify that hardware addresses on list match system drawings
Test that IOC code (EDM) does the correct things to the PLC – in office
a. Push all control buttons on IOC and verify that correct tags are activated
b. Force input statuses to verify PLC logic and IOC configuration
i. Verify that PLC code and IOC bits agree
ii. Verify that interlocks function as expected
iii. Check that electronic fuse reset works
c. Failure mode tests. Force all channels on all input modules to 1, and then:
i. Unplug each module and verify that module status goes red and
that all inputs from that module go to zero
ii. Unplug each ControlNet cable and verify that entire crate goes red
and that all inputs from that crate go to zero
iii. Power off each slave crate and verify that all inputs from that crate
go to zero
iv. Power off master crate and verify that all outputs from master crate
go to zero
v. Reboot master crate and verify that startup state is as expected
d. Test that PLC behaves as expected with no devices connected to it – all
logic circuits are in expected states
Prepare PLC for production environment
a. Install battery
b. Set clock
c. Save ladder logic to flash memory
d. Reconfigure IP address and network settings
Connect PLC to controllers, all loads disconnected
Test that PLC and IOC (EDM) have correct status and control for each device
a. Pumps: On/off control, on/off status, set point status, pressure, voltage
b. Gauges: On/off status, set point status, pressure
c. Valves: Open/close control, input status, interlock status, interlock reset
Configure all gauge controllers and pump controllers
a. Gauge controllers
b. Pump controllers
Make sure PLC recovers from power failure correctly
a. Correct software loads from memory
b. Initial state: bypasses persistent across reboot, no latches
Final interlock checkout and certification
a. Valve interlocks
When possible, check out all hardware inputs that could not be tested during
initial testing
a. Pneumatic valves
b. PPS status inputs
3 – Procedure for verifying PLC code in office
1. Print hard copy of PLC tag list with tag name, array name, and hardware address
2. Verify each tag in the PLC code and in EPICS
a. Analog input tags:
i. Force the input tag to some arbitrary value (5)
ii. Verify that the array tag listed on the tag list also changes
iii. Verify that the PV also changes (EDM)
b. Digital input tags
i. Force the input tag to 1 (if it’s currently zero)
ii. Verify that the array tag listed on the tag list also changes
iii. Verify that the PV also changes (EDM)
c. Digital output tags
i. Force the output to 0 or 1, opposite its current state
ii. Verify that the array tag listed on the tag list also changes
iii. Verify that the PV also changes (EDM)
d. Soft tags: PLC -> EPICS
i. Force the tag to change somehow in the PLC
ii. Verify that the PV also changes (EDM)
e. Soft tags: EPICS -> PLC
i. Change PV value to change the PLC tag
ii. Verify that the PLC tag changes
4 d – Reconfigure network settings for production environment
1. Connect PC to PLC with serial cable; establish DF1 connection in RSLinx 2.5 or
newer
2. Set IP address, gateway, DNS, etc for production environment
3. Use RSLinx to set mode to autoconfigure or 100Full? Remove and reinsert
Ethernet module from crate. Verify that RSLinx shows that the card is set
correctly
4. Plug in an Ethernet cable to the module and verify that RSLinx shows 100M/full.
5. Verify that the correct IP address, etc are shown
6 a – Procedure for pump controller test
1. Turn power to all pump and gauge controllers on. Turn off pump high voltage for
the controller to be tested. If possible, turn off all power supply channels and
gauge high voltages.
2. For the controller of interest, verify the following on the front panel of the
controller, in RSLogix and in EDM
a. PSTAT1,2,3,4 = faulted
b. Pumps 1 and 2 power = off
c. Pumps 1 and 2 pressure = 0
d. Pumps 1 and 2 voltage = 0
e. Pump interlocks complete
3. Force interlock output for pump 1 to faulted in RSLogix. Verify that pump
interlock faults on front panel of controller, in RSLogix, and in EDM. Remove
force when done.
4. Force interlock output for pump 2 to faulted in RSLogix. Verify that pump
interlock faults on front panel of controller, in RSLogix, and in EDM. Remove
force when done.
5. Channel 1 tests:
a. Turn on channel 1.
b. Manipulate settings for set points 1 and 2 to cycle their status. Verify on
front panel (1,2) and in RSLogix and EDM (PSTAT1, PSTAT2).
c. Verify on status on front panel, RSLogix, and EDM.
d. Verify pressure readout on front panel, RSLogix and EDM.
e. Verify voltage readout on front panel, RSLogix and EDM.
f. Turn off channel 1.
6. Channel 2 tests:
a. Turn on channel 2.
b. Manipulate settings for set points 1 and 2 to cycle their status. Verify on
front panel (3,4) and in RSLogix and EDM (PSTAT1, PSTAT2).
c. Verify on status on front panel, RSLogix, and EDM.
d. Verify pressure readout on front panel, RSLogix and EDM.
e. Verify voltage readout on front panel, RSLogix and EDM.
f. Turn off channel 2.
6 b – Procedure for gauge controller test
1. Turn power to all pump and gauge controllers on. Turn off gauge high voltage for
the controller to be tested. If possible, turn off all power supply channels and
gauge high voltages.
2. For the controller of interest, verify the following on the front panel of the
controller, in RSLogix and in EDM
a. PSTAT = faulted
b. High voltage CC and A = off
c. Gauge CC, A, B1, B2 pressure = 0
3. Channel CC tests:
a. Connect dummy load to channel CC
b. Turn on channel CC.
c. Manipulate settings for pressure set point to cycle its status. Verify on
front panel, RSLogix, and EDM.
d. Verify HV status on front panel and EDM.
e. Verify pressure readout on front panel, RSLogix and EDM.
f. Turn off channel CC and disconnect dummy load.
4. Channel A1 tests:
a. Connect dummy load to channel A1
b. Turn on channel A1.
c. Manipulate settings for pressure set point to cycle its status. Verify on
front panel, RSLogix, and EDM.
d. Verify HV status on front panel and EDM.
e. Verify pressure readout on front panel, RSLogix and EDM.
f. Turn off channel A1 and disconnect dummy load.
5. Channel B1 tests:
a. Connect dummy load to channel B1
b. Manipulate settings for pressure set point to cycle its status. Verify on
front panel, RSLogix, and EDM.
c. Verify gauge status on front panel and EDM.
d. Verify pressure readout on front panel, RSLogix and EDM.
e. Disconnect dummy load from channel B1.
6. Channel B2 tests:
a. Connect dummy load to channel B2
b. Manipulate settings for pressure set point to cycle its status. Verify on
front panel, RSLogix, and EDM.
c. Verify gauge status on front panel and EDM.
d. Verify pressure readout on front panel, RSLogix and EDM.
e. Disconnect dummy load from channel B2.
6 c – Procedure for valve controller test
1. Channel assignment tests. For each input to valve controller:
a. Cycle status of input signal with dummy load or by forcing PLC tags;
verify in RSLogix and front panel
b. Check EPICS bypass function in RSLogix and on front panel
2. EPICS Control Test, Local Control Test, and Interlock Summary/Reset Test
a. Make up all valve logic inputs, either with dummy loads or PLC forces
b. Reset interlocks
c. Fault one valve input and make it up again
d. Verify that interlock chain status is faulted in RSLogix, EDM, and on
front panel of valve controller
e. Verify that interlock reset button on front panel of valve controller resets
interlock chain.
f. Verify that interlock chain status is made up in RSLogix, EDM, and on
front panel of valve controller
g. Fault one valve input and make it up again
h. Verify that EDM interlock reset button resets interlock chain
i. Switch valve controller to remote mode
j. Open and close valve from EDM. Verify the open/close commands in
RSLogix. Verify that output to solenoid changes.
k. Verify that valve can not be opened and closed from front panel of valve
controller
l. Switch valve controller to local mode
m. Open and close valve from front panel of valve controller. Verify the
open/close commands in RSLogix. Verify that output to solenoid
changes.
n. Verify that valve can not be opened and closed from EDM.
o. Switch valve controller to J-Box mode
p. Verify that front panel buttons and EDM open/close buttons do not change
output to solenoid.
q. Switch valve controller to Closed mode
r. Verify that front panel buttons and EDM open/close buttons do not change
output to solenoid.
3. Interlock checks
a. Make up all valve logic inputs, either with dummy loads or PLC forces
b. Reset interlock summary and verify that valve can be opened
c. Fault one input and verify that interlock chain breaks in RSLogix, EDM,
and front panel. Verify that valve can not be opened
d. Bypass faulted input and verify that interlock chain completes and that
valve can be opened
e. Remove bypass and verify that valve cannot be opened
f. Repeat steps a, b, c, d, and e for each input
4. Valve test
a. Connect j-box and valve or dummy j-box and dummy valve to valve
controller
b. Change air pressure switch status and verify in RSLogix, EDM, and on
front panel
c. Verify that J-Box permit is present in J-Box mode and in no other modes
d. Change open switch status and closed switch status and verify in RSLogix,
EDM, and on front panel
7 a – Gauge Controller Configuration
See attached document
7 b – Pump Controller Configuration
See attached document
9 a – Valve Interlock Checkout
For each interlocked valve:
1. Valve interlock logic test:
a. Make up all valve logic inputs, either by connecting to gauges reading low
pressure, or by connecting dummy loads at below-threshold pressures, or
using PLC forces
b. Reset interlock summary and verify that valve can be opened
c. Verify that interlock summary is made up in EDM and on front panel of
summary box
d. Fault one input and verify that interlock chain breaks in EDM and on front
panel. Verify that valve can not be opened
e. Bypass faulted input and verify that interlock chain completes and that
valve can be opened
f. Remove bypass and verify that valve cannot be opened
g. Repeat steps a, b, c, d, e, and f for each input
h. Remove all dummy loads or PLC logic forces and restore devices to initial
states.