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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 1
ITER CODACPlant Control Design Handbook
October 2008
Anders Wallander & Luigi ScibileCHD Department
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 2
The Plant Control Design Handbook (PCDH) defines standards, specifications and interfaces applicable to ITER Plant Systems Instrumentation & Control (I&C)
I&C standards are essential for ITER to• Integrate all Plant Systems into one integrated control system • Maintain all Plant Systems after delivery acceptance• Contain cost by economy of scale (spare parts, expertise)
The PCDH is applicable to all Procurement Arrangements
PCDH Objectives
ITER International Organization (IO)• Develop• Support• Maintain• Enforcethese standards
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 3
• The development of PCDH started from the conceptual design• The process to get consensus within an intercontinental group takes time • The purpose of the official release IDM v.3 in July was to communicate current thinking, not to provide a contractual document• Therefore the current version is conceptual
• We have inserted “hold-points” in the first PA• The first ones elapse in April 2009 (hard deadline)• Next release of PCDH IDM v.4 before April 2009
• PCDH is a living document and will be released throughout the lifetime of ITER• The list of standards and specifications will be extended and will evolve• PCDH shall address obsolescence management
History and Future of PCDH
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 4
CODAC Systems (WBS 4.5)
Interlock Safety
Plant SystemHost (PSH)
Main Control Room
CODAC Networks
Central Interlock Network
Central Safety Network
Central Safety SystemsCODAC Central Interlock System
Plant Operation Zone
Plant Conventional Control System
Subsystem Controller
Equipment
Sensors / Actuators
Sensors /
Plant Safety System
Subsystem Controller
Equipment
Sensors / Actuators
ITER_CODAC_PCDH_Figures_Visio_0002
Plant Interlock System
Subsystem Controller
Equipment
ActuatorsP
roc
ure
me
nt
Bo
un
dry
Pla
nt
Sys
tem
Systems (WBS 4.6)
Systems (WBS 4.8)
I&C structure• Segregation of ITER I&C into 3
tiers and 2 layersConventional Control • Control and monitoring for all
ITER PSInterlock • Protects the investment• Independent network and I&CSafety • Protects personnel, and
environment • Independent network and I&C • Two train systemsPlant Operation Zone (POZ)• Communication, command
and control boundary for Tokamak plant
Three tiers, two layers
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 5
A CODAC Plant System has one and only one Plant System Host
Product Breakdown Structure
What are the Plant Systems?
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 6
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 7
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 8
Plant System Host
Provided by IO with standard software
• Provides single point of entry for asynchronous communication• Supports set of standard field-buses to Local Controllers• Data driven (Plant System customization is done by self-description) • May come on different platforms to address scalability
PCDH chapter 5.4.1
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 9
Plant System Host
Mini CODAC
Provided by IO with standard software
• Tool to verify functionality and interface at factory and on site (FAT, SAT)• Provides SCADA functionality including HMI• Can be used as platform for developing higher level Plant System functionalities later integrated in proper CODAC
PCDH chapter 2.8.9
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 10
Plant System Host
Mini CODAC
Local Controller and Field Buses
Selected from catalogue of standard components
• Can be “slow” control (PLC) or “fast” control (embedded)
PCDH chapter 5.4.2-5
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 11
Plant System Host
Mini CODAC
Local Controller and Field Buses
High Performance Network I/F
Selected from catalogue of standard components
• High Performance Networks (HPN) are• SDN – Synchronous Databus Network• TCN – Time Communication Network• EDN – Event Distribution Network• AVN – Audio/Video Network
• Not all Plant Systems require HPN• Interface boards/drivers provided for selected platforms PCDH chapter 4.3
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 12
Plant System Host
Mini CODAC
Local Controller and Field Buses
High Performance Network I/F
Actuators, sensors, signal conditionings
Selected by Plant System DeveloperPCDH will provide recommendations
PCDH chapter 5.4.7
Plant System Instrumentation & Control
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 13
Plant System Instrumentation & Control
Cubicles
Selected from catalogue of standard components
• Racks• Chassis• Power Supply• Cooling• Terminal strips• …
PCDH chapter 5.4.8
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 14
Plant System Instrumentation & Control
Cubicles
I&C Bridge
Provided by IO
• Patch Panel connecting to ITER infrastructure (mainly fiber optics)• Wall mounted or in “CODAC hutch” close to I&C cubicles• Specifies cables and connectors• Plant System developer provides cables from cubicle to I&C bridge
PCDH chapter 4.3.4
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 15
Plant System Instrumentation & Control
Cubicles
I&C Bridge
Cabling
Rules and Recommendations
• cables and connectors• internal and external• naming & labeling• grounding & earthing• electrical isolation• cable distances• EMC• radiationPCDH ch. 5.4.9 & Electrical Design Handbook
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 16
Plant System Instrumentation & Control
Software environment and development process
Specified by IO
• Operating Systems on the different platforms (PSH, PLC, Embedded)• Communication middleware• Open source SCADA/software framework• Format and schemas for Self description data
• Programming languages on the different platforms• Programming standards• Methodology• Naming rules• Design and development tools• Testing tools• Configuration control
PCDH chapter 5.5
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 17
Interlock Systems
Covered by PCDH
• Main system requirements
– Highest level interlock functions shall be designed to a high integrity level conforming to a Safety Integrity Level (SIL) 3 according to the standard IEC 61508
– The Central Interlock System shall acquire the critical digital signals from the Plant Interlock Systems and deliver outputs to Plant Systems (either via the corresponding “Plant Interlock Systems” or via direct interlocks) on the basis of boolean logic on the full set of inputs and on the latched outputs.
– The Central Interlock Systems are classified as non-SIC
– The interlock protective actions shall be graded at three levels:
• Level 1 interlock events (Fast shutdown) • Level 2 interlock events (Fast Controlled Pulse Shutdown)• Level 3 interlock events (Inhibit)
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 18
Interlock Systems
• Equipment required:
Covered by PCDH
PCDH chapter 6
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems (2oo3 redundancy)
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 19
Safety Systems
Covered by PCDH
• Main system requirements
– The CSS for Nuclear risk and Personnel access shall be classified as a SIC system classed as implementing safety functions of category B (IEC 61226) with systems of class 2 (IEC 61513)
– The CSS for conventional risks shall be designed to a high integrity level conforming to a Safety Integrity Level (SIL) 3 (IEC 61508).
– Safety functions of category A shall be implemented via hardwired logic with systems of class 1.
– No Common Cause of Failure
– Multiple line of defense
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 20
Safety Systems
• Equipment required:
Covered by PCDH
PCDH chapter 7
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 21
Plant System I&C – Life Cycle
PCDH chapter 2.4 and 3
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 22
Build to print Procurement Arrangement
Plant System I&C – Life Cycle
IO -> <- DA
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 23
Plant System I&C – Life Cycle
Detailed design Procurement Arrangement
IO -> <- DA
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 24
Plant System I&C – Life Cycle
Functional specifications Procurement Arrangement
IO -> <- DA
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 25
Plant System I&C – Life Cycle
Check points
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 26
A proper long term plan shall be developed in the next months
Short-term Schedule
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 27
Cooperation agreement CERN Machine ProtectionInterlock & Safety Support (Framework contract, in-sourcing)CODAC Engineering Support (Framework contract, in-sourcing)SW Tools for packaging and trainingCustomization/improvements CODAC comm middleware and SCADA func.Supply Mini CODAC application layer modulesSupply customized Mini CODAC systems for NB, Cryo, PS, etc.Design and supply CODAC networksStudy scientific data streamingPrototype Data Acquisition and Data Streaming ArchitecturePrototype and case study for plasma feedback controlPrototype Plasma Control System ArchitecturesPrototype CODAC SupervisorPrototype Integration of Pulse Execution SystemAnalysis of fault scenarios for machine protectionPrototype evaluation of highly available interlock architecturesFormal models for Instrumented Central Safety SystemsSupply of Central Interlock System
Some ideas for 2009-2011
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 28
Conclusions
• The Plant Control Design Handbook (PCDH) defines standards, specifications and interfaces applicable to ITER Plant Systems Instrumentation & Control (I&C)
• PCDH is applicable to all Procurement arrangement having any I&C
• PCDH covers hardware, software and development process
• PCDH contains mandatory standards and recommendations
• Next release of PCDH is due in April 2009• PCDH is a living document and will be released on a
regular basis throughout the lifetime of ITER
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 29
Conclusions
ITER IO is committed to • develop • support • maintain • enforce PCDH standards in order to successfully • integrate • maintain • contain the cost of the ITER control system
First prototype in IO lab Sep’08
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 30
END
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 31
Backup Slides
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 32
20192018201720162015201420132012201120102009
Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1 Q4Q3Q2Q1
Contract strategy (1/2)
I&C Support for Plant Systems
CODAC Support
Central Interlock and Safety Systems Support
I&C Plant Systems DevelopmentI&C Plant Systems DevelopmentI&C Plant Systems DevelopmentI&C Plant Systems realization (~ x100)
CODAC sub-systems DevelopmentCODAC sub-systems DevelopmentCODAC sub-systems DevelopmentCODAC sub-systems realization (~x 10)
Central Safety Systems realization (x 3)
Central Interlock Systems realization (x 3)
In fund, contracts placed by ITER IOIn kind, contracts placed by ITER DAsTask agreements, most probably no contracts with with Industry
Assistance Contracts
Central Safety Systems realization (x 3)Central Safety Systems realization (x 3)
Central Interlock Systems realization (x 3)Central Interlock Systems realization (x 3)
Start Integrated commissioning
First Plasma
Procurement Contracts
Start of Tokamak assembly
Prototypes realization (x 10)Prototypes realization (x 10)
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 33
Contract strategy (1/2)
• Support:– Technical Specifications– Engineering design– Engineering studies
• Performance evaluations• Safety studies• Modeling and simulations• Pre-construction drawings• PID and Functional drawings • Security engineering• technical reviews
– Provisioning and logistics– Quality Assurance – Contract preparation– Planning and Scheduling– Verification and Validation– Commissioning coordination
• Realization:– Final Design– Software (SW) development– Procurement of equipment– Hardware (HW) assembly– SW & HW Integration– Configuration and data management– Overall documentation
• Detailed design documents• PID and Functional drawings• Construction drawings• As built folders• Installation procedures• Commissioning procedures• Operation manuals• Maintenance manuals
– Factory and site acceptance– Site installation– Site Commissioning
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 34
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 35
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 36
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 37
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 38
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 39
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 40
• Highly reliable and available PLC systems (SIL3)
• Some hardwired systems
• Various type of transducers and actuators
• Various type of networks: TCP/IP, field buses, monitored hardwired links.
• Supervisory systems
• Short term data storage
• Operator synoptic via CODAC + Gateway
• Equipment required:
Interlock Systems
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 41
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 42
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 43
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 44
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 45
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 46
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 47
Safety Systems
• Equipment required:
• Highly reliable and available PLC systems (Class 2)
• Hardwired logic (Class 1)
• Various type of transducers
• Various type of networks: TCP/IP, Safety field buses, monitored hardwired links.
• Supervisory systems
• Long term safe data storage
• Safety operator’s desks
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CODAC contracts today
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ITER CODAC Plant Control Design Handbook – Barcelona - 27 Oct 2008 Page 49
Self-description dataflow: development
PS description
1
Devel tools project files
2PSH static configuration
2
PS devices programs + static configuration
3
PS parameters
4
PS dynamic parameters
5
PS devices dynamic parameters
6PS data
7
PS data
8
PS response
9
Problem report
10Regular transfer
11
PS requirements and needs
12
PS development progress 12
CODAC test data
12