IBL CO2

UNICOS CPC6 based control system

Lukasz Zwalinski – PH/DT/PO

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Presentation overview

• I/O requirements

• Standardization

• System architecture

• Selected hardware control components

• Rack construction and USA15 available place

• Software principals

• Software development

• User interface

• Access control

• Software user tools

• Planning

I/O number evaluation per plant

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

I/O TypeMARCO

I/O NumberIBL

I/O Number for 1 unit

DI 32x 30x + 18xSpares = 48x

DO 32x 32x

AI4-20mA: 20x

RTD: 14x

4-20mA: 20x +

manifolds 10x + 5xSpares = 35x

RTD: 14x + 4xSpares

+ Detector and manifolds

7x + 6xSpares = 31x

AO 8x 4x + 4xSpares = 8x

Standardization approach

EN-ICE

PH-DT-PO

PH-DT-DI

EN-CV-DC CO2

HARDWAREIndustrial electrical components

Control hardware equipmentNomenclature conforming ISA/ANSI standard

HARDWAREIndustrial electrical components

Control hardware equipmentSchneider PLC standard

SOFTWARESoftware components

Experience of CO2 plants at CERNCORA & SR1

Electrical diagnostic tools

FRAMEWORKUNICOS

PVSSIEC61512-1 standard

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

System architecture

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

IBL

CE

RN

Te

ch

nic

al

Ne

two

rk

CERN GPN

OWS OWS OWSDIP ?

Premium CPU + PROFIBUS card

IBL plant A

CCC

Local MODBUS TCP/IP

Pneumatic lines

PROFIBUS

FESTO

WAGO I/Os

Premium CPU + PROFIBUS card

IBL plant BLocal MODBUS TCP/IP

Pneumatic lines

PROFIBUS

FESTO

WAGO I/Os

Hardwired interlocking

EN/CV Terminal server

Detector Control System

ATLAS DSS

System architecture

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Hardware control system components agreed with:( PH/DT/PO + PH/DT/DI + EN/CV/DC )

• Schneider Premium PLC (very well known by EN/CV/DC)

• WAGO I/O modules - very high packing density and good economy compared to PLC native I/O

• 24V DC Power Supplies: Industrial, redundant, hot swappable, chassis mounted

• Circuit protection: Electronic Circuit Breakers specific to protecting 24VDC instrument type

electronics

• Pilot Valves: FESTO PROFIBUS modular valve islands

(based on experience on gas systems and detector cooling systems)

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Control rack construction and place

IBL plant A

IBL plant B

MARCO integrated control cabinet design

To be discussed and verified in coming weeks:

- Can we fit in with new components selected

inside control cabinet already integrated in

MARCO frame

- Shall we/can we construct standard cabinet for

ATLAS and CMS CO2 cooling systems

- Do we have a space for external control rack if

needed

Cable trays integrated in MARCO frame

Chiller detached from frame + 2x?

EN/CV/DC has confirmed that they can do the control rack assembly

and testing

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Control rack layout

Prepared by Steven Pavis PH/DT/DI for CMS CO2 cooling station

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

UNICOS CPC - framework

UNICOS‐CPC UNified Industrial COntrol System Continuous Process Control

UNICOS framework supports 3 control system layers: supervision (SCADA: PVSS) control (PLC: Siemens S7 and Schneider) field layer

The package of programming tools includes: baseline library (with modular PID algorithm) code generator skeleton templates and example of objects list

Object definitions provided by UNICOS are split into: I/O Objects (Digital Input, Digital Output, Analog Input) Field Objects (OnOff, Analog, AnaDig, Controller, etc.) Process Control Objects (PCO)

Offers homogenous user interface

http://j2eeps.cern.ch/wikis/display/EN/UNICOShttp://www.esrf.eu/icalepcs2011/papers/wepks033.pdfhttp://www.esrf.eu/icalepcs2011/posters/wepks033_poster.pdfhttp://indico.cern.ch/getFile.py/access?resId=0&materialId=slides&confId=162565

SCADA Servers

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et N

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ork

&

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CP

IP c

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icat

ion

ser

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PLC Process Control

PLC Process Control & Field interface

Operator Consoles

Fieldbus Networks

control system connection to the process directly or through field-

buses

Industrial Field layer

Industrial Supervision Layer

Interface to operators

(Monitoring & Command emission)

Real time DB & Archiving

Control Logic Actions

Industrial Control layer

Some of the UNICOS Projects

LHC Tunnel Cryogenic Control System:- 18 x S7 400PLC + 2 x S7 300PLC,- 15’000 distributed sensors and actuators, - 5’500 interlocks & alarms, - 3’600 PID Control Loops

Detector Gas Systems- 24 PLCs Schneider Premium,- 10’000 I/O,- 3’000 alarms, about half of these cause an interlock,- About 200 PID Control Loops

CO2 UNICOS system operational at CERN:• CORA CO2 cooling system • SR1 CO2 cooling system

Others:• NA48 Experiment - ECN3 HALL - Control Room in Bld. 918• CMS tracker thermal screen

Dpt: PH/CMX- Project description: CMS tracker thermal screen: control of the thermal screen to keep it at ambient temperature. - Other data: 250 Inputs/outputs ; 60 actuators; 60 Controllers

• ECAL detector cooling control system• LHC collimator temperatures• ATLAS BigWheels• ALICE SSD Cooling Interlock• ALICE SDD Cooling Interlock• ALICE Cooling water valves control

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

UNICOS project creation

SCADA Server in CCC

Logic Generator

Instance Generator

Specification XML

Schneider PLC

All generated files should be kept in Subversion Version Control (SVN) service.

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Supervision layout

Headerfixed area

(toolbar)

Process areaSynoptic

FooterContextual areaHistoricIBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

PVSS access

1) Right click on the Current user name

or click on the key

2) Click Login as

3) Enter an authorized NICE user /

password

Main Access Groups:

Monitor

Operator

Expert

Admin

Only NICE authorized users (defined previously)

are allowed to be log in the PVSS.

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Supervision layout: Process Area

Static info Text Drawings

Animated Widgets Sensors Actuators Controller Process unit Alarms

Process unit

SensorActuatorStatic info

Widget interactions

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

PLC actions representation on PVSS panels

Electrical diagnostic Stepper

Accumulator Auto SP calculation

Accumulator limiters

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

PVSS tools

Event list Alarm list

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Recipes and user defined trends

Recipe component User defined trends

Recipe: Massive parameterization (optional) Alarm thresholds Set Points PID parameters

Trends: Trend tree Individual trends via object face plate Dynamic trends

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

PCO Alarms with SMS or email notification

Digital and Analog Alarms

Types:

•Full Stop interlock (FS): Stop the unit/actuator (all dependent

units/actuators are set to their fail-safe position) and wait

manual acknowledgement before restarting.

•Temporary Stop Interlock (TS): Stop the unit/actuator (all

dependent units/actuators are set to their fail-safe position) and

restart automatically when the interlock disappears.

•Start Interlock (SI): Prevent the unit from starting (all

dependent units/actuators stay in their fail-safe position).

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

Preliminary planning

IBL CO2

cooling

IBL CO2 cooling Person involved Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13

Functional analysis Writing EDMS documentm-Lukasz

h-Maciej

Control

Components selectionm-Lukasz

h-Steven, h-Maciej

Orderingm-Lukasz

h-Steven, h-Maciej

Electrical

Rack wiring scheme m-Lukasz h-Steven h-Maciej

Side cabling scheme m-Lukasz h-Steven h-Maciej

Power distribution m-Lukasz h-Steven h-Maciej

Axiculary diagram m-Lukasz h-Steven h-Maciej

Power in cavern/labo request to EN-ELm-Lukasz

h-Steven

Components selectionm-Lukasz

h-Steven, h-Maciej

Rack assembly 3D model student

Procurement of long term delivery components

m-Lukasz

h-Steven, h-Maciej

Procurement of short term delivery components

m-Lukasz

h-Steven, h-Maciej

Rack assemblym-EN/CV/DC

h-Maciej

Testingm-EN/CV/DC

h-Maciej

Cabling in cavern/field m-EN/CV/DC

Software

PLC programmingm-Lukasz

h-Steven, h-Maciej

PVSS panels&scriptsm-Maciej

h-Steven

PVSS in CCC agree with EN-ICE m-Lukasz X

Communication with DCS doc m-Lukasz

Communication with DCS and DSSm-Lukasz

h-Steven, h-Maciej

Wiring to DSS (we supply 5in/out I/Os) m-ATLAS Sergey's tech

Touch screensm-Lukasz

h-Steven, h-Maciej

Functional logic testingm-Lukasz

h-Steven, h-Maciej

Ethernet network Netops request + outlet positionm-Lukasz

h-Steven

Commissioning

m-Lukasz

h-Steven, h-Maciej

Schedule has to be reviewed according to EN/CV/DC work load

Thank You for Your attention.

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO

UNICOS framework - more details can be found:http://j2eeps.cern.ch/wikis/download/attachments/23334182/UCPC6_Operator_Training.pdf

UNICOS Data flow

Object status

Human Requests

SCADA Object HMIParameters

Manual Requests

Operator

Information display

Programmer

SCADA

Auto. Requests

PLC Object logic

Orders

PLCObject status

Manual Requests

Parameters

Programmer

Process Input

I/O Board or Fieldbus

PROCESS

Process Output

Communication Middleware

More information on PVSS data flow with code example can be found in following document:http://j2eeps.cern.ch/wikis/download/attachments/19040447/unicos-pvss-unCore-data-flow.pdf?version=1&modificationDate=1309450713000

IBL Review 15th May 2011 L.Zwalinski – PH/DT/PO