Pilz Network Rail Innovation & Collaboration

Transcription

1 Pilz Network Rail Innovation & Collaboration COTS PLC technology in rail signalling LX PLC project David Collier, Pilz UK Business Development Tahir Ayub, Senior Design Authority Engineer, Network Rail July 3rd 2014

2 Level crossings The Signalling Innovations Group (Infrastructures Projects) has been collaborating with Pilz UK on a project to make a business case to the rest of Network Rail for the use of PLC at level crossings MCB-OD type (fully automated level crossing with RADAR and LIDAR obstacle detection) This transition has been initiated by: renewal of over 464 level crossings in CP5 of which two thirds are obstacle detector crossings supporting the National Operating Strategy a drive for efficiencies in capital expenditure and whole life cost of assets concerns about the age of relay technology, specifically a constrained supply chain and reduced reliability Route Asset Managers don t want relays COTS availability of PLCs which meet the safety and environmental requirements of a railway environment 2

3 What are Network Rail attempting to achieve? 3

4 PLC requirements 4

5 Evolution of technology in train movement control Rooted in a traditional past..faster trains..increased traffic density..safety demands CP5 3.2bn budget but massive volume challenge driving need to innovate with COTS PLC technology to substitute relays and interoperate with CBI Interlocked mechanically, everything tightly coupled, inflexible, limited distances Decoupled station data Using SSI and computer-based Interlocking (CBI) with special software..proprietary..costly Decoupled electromechanically using electrical/pneumatic actuators, greater usability & scalability Decoupled user interface using fail-safe relay circuits, bulky, complex wiring, expensive, aging technology, maintenance issues

6 Industrial safety technology on railways Why safety PLC? Tried & tested for decades, in many applications Meet IEC standard (firware/software relevant) Standardised solutions - Simple & flexible programming (vs. fixed hard-wiring) - Low investment, development & operating costs - Space saving, can be mounted trackside in cubicle Meet standards for environmental requirements with regard to temperature, EMC & mechanical load - no need for special air conditioning / heating / filtering System architectures for control systems up to SIL4 as per CENELEC 5012x are possible Wide availability of PLC suppliers & programmers Future-proof concepts - Expandable and scalable (modular I/O) - Decentralised control systems (CPUs, I/O headers) - Open & proven, safe Ethernet-based communication - Obsolescence managable via backward compatibility

7 PSS 4000-R PSS 4000 for railway PSS 4000 railway modules PSS 4000 PLC system has been used widely in machine safe automation, process safety, mine winders, bridges, tank farms...and in European rail The system from the automation world has been expanded to meet the special requirements of the railway Compact & modular safety controllers and remote I/O modules Head modules and I/O modules with railway approval (safety: CENELEC, TÜV SÜD Rail) SIL 2 / SIL 3 as product feature Overall system SIL 4-capable

8 Suitability of safety PLC for rail safety application Some safety PLCs are rated / certified for rail applications: Ambient temperature: Vibration: Single shock: Continuous shock: Voltages: EMC: -40 C to +70 C Hz, 0.35 mm; Hz, 5g Hz, 0.23g 5g /11 ms; 5 g / 30 ms 10 g / 16 ms; 25g / 6 ms 24Vdc, 60Vdc EN rolling stock EN signalling and communication Safety: EN RAMS EN50155 rolling stock EN software EN safety related electronics in signalling

9 Level crossings today... 9

10 Level crossings tomorrow 10

11 For those routes looking to replace relays, PLCs can fulfil this substitution

12 Standard circuits for level crossings... A functional specification that has evolved Old relay circuits tell us most of but not the whole story, since they have evolved to compensate for relay behavioural characteristics Network Rail are using System Modelling Language (SysML) to produce specifications for use with rail integration and software standards such as EN / EN The Systems Modeling Language (SysML) is a general-purpose modelling language for systems engineering applications. It supports the specification, analysis, design, verification and validation of systems

13 Benefit of using Software editors for control and signalling Ability to express common logic into software code and lock functionality Complex, hard-wired relay logic can be converted into PLC code using various IEC programming languages (LD, IL, STL...) PLC code for specific applications can be encapsulated and locked within Function Blocks (FB) for repeated use and rapid implementation, thereby reducing ongoing development costs for repeat applications, and providing tracability / responsibility Ladder Logic Instruction List Structured Text (LD) (IL) (STL) IEC programming languages Encapsulated function blocks (FB) for repeatable use Minimisation of verification / validation tasks and costs More office based testing (FAT) and less site acceptance testing (SAT) Quicker commissioning, shorter possession time 13

14 Function Blocks are the key Network Rail currently issues standard circuits for relay logic They can do the same with locked, approved Function Blocks The integrators will be issued with function blocks to create applications Integration of Function Blocks to create office testable safety functions, using PLC hardware configuration tool integrate function blocks 14

15 Translation of relay logic to PLC code Network Rail working on the specification for modular Function Blocks for LX Pilz & Network Rail translating this into PLC Function Blocks which are then integrated in test rigs

16 SIL apportionment and architectures SIL 2 One controller, single channel I/O SIL 3 One controller, homegoneous or diverse inputs, dual power supply, dual ouptuts SIL 4 Redundant system Safety PLC system SIL 0 4 via composite failsafe approach (EN 50129) Probability of dangerous failure figures are available for THR calculations MTBF figures are available for MTTR availability calculations

17 Network Rail approach to changing standards

18 Network Rail Pilz LX PLC demo rigs demonstrate signallers view

19 Showcasing LX PLC capability at Rail Live

20 Applications outside UK Appenzell railway - Hofegg, Herisau level crossing Traffic lights Wig wags Acoustic warning signal Barrier drive system Train detection Remote fibre optic 2.5km fibre optic Track side cabinet at level crossing ILTIS and PLC at signal box

21 Applications - Central block adaption: Connection relay/electronic signal box Deutsche Bahn plan to phase out relay logic, it will take time, and many existing relay stations have some life left in them and need to be interfaced to Computer Based Interlocking, and possibly to Radio Block Centres as part of ETCS lines Traditional method of interfacing remote CBI and remote relay Alternative method, using PLCs & safe communication protocol Remote electronic interlocking with digital I/O Remote relay interlocking Remote electronic interlocking with digital I/O Remote relay interlocking Proprietary Time Division Multiplexer TDM Additional adaptation and decoding relay logic PLC hardware with safe comms built in COTS modem to modem PLC hardware with safe comms built in 21

22 Application, SIL 4 for signal box connection RSB Relay signal box ESB Electronic signal box PLC Processing unit I with local I/Os PLC Processing unit II with local I/Os Digital I/O Communication system e.g. DSL Digital I/O Decentralised I/Os Decentralised I/Os PAS4000 Tool 22

23 What next in the UK for PLCs in rail safety? Field trial at MCB-OD LX with Network Rail oversight and collaboration with system integrators / contractors Expanded collaboration with supply chain System integrators Panel builders Contractors Assisting Network Rail in change management People and processes Training Other target applications Other types of LX TDM substitution Rolling stock Maintenance depots Key technical challenges? EN & EN documentary/organisational requirements People & process changes

24 CMSE, InduraNET p, PAS4000, PAScal, PASconfig, Pilz, PIT, PLID, PMCprotego, PMD, PMI, PNOZ, Primo, PSEN, PSS, PVIS, SafetyBUS p, SafetyEYE, SafetyNET p, the spirit of safety are registered and protected trademarks of Pilz GmbH & Co. KG in some countries. We would point out that product features may vary from the details stated in this document, depending on the status at the time of publication and the scope of the equipment. We accept no responsibility for the validity, accuracy and entirety of the text and graphics presented in this information. Please contact our Technical Support if you have any questions. Thank you very much for your time! David Collier Pilz Automation Technology Pilz House, Little Colliers Field, Northants, NN18 8TJ Telephone: , Mobile: Keep up-to-date on Pilz