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					                         A Project for the

                    GAS control System

                           At NA60



JCOP - 17 October 2001     NA60_GAZ - E. Mazel J. Rochez   1
One requirement. Rebuild the NA60 gas control
  3 Opportunities:

    1. Use industrial products
       • Access to all components via electrical signals
              • 24 V digital
              • Profibus
              • Schneider Premium PLC

    2. Follow a standardized design
       • Check the validity of the URD defined by the
          LHC gas control group

    3. Implement an automatic control process
       • Evaluate the UNICOS approach applied to the
         Gas controls.
 JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    2
                         NA60 Gas System




JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   3
Industrial Products

   • Several Electro-valves piloted via 24 Volt signals

   • Some interlock signals

   • 4 Mass Flow Controllers (0-10V analog signals)
        •Gas Flow Regulators with their own PID control loop
               Setpoint gas flow
               Read the gas fow
        Nothing new about those products

   •32 Low cost Gas Flowmeter (pt100 principle)
         •System based on an intelligent Profibus slave unit
         Complete new prototype

     JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    4
Use a standardized design



  In 1995 a Working group was set up for the requirement of
  the LHC detectors for the gas systems.
  The aim is to develop scalable standard designs.

      •The control of the NA60 is built around a subset of the
       URD specification of the LHC GCS

                 For the MIXER
                 For the DISTRIBUTION

           This did not put too severe constraints


     JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez      5
Implement an industry-like process control

 The idea to use the UNICOS came from an encounter
 at ICALEPS 1999

                    UNified Industrial COntrol System

 It is an implementation approach of industrial control products
 Based on the expertise gained by LHC groups
                             LHC IAS/ACR/ECR

 This concept will be used for the control of
    • LHC Cryogenics systems (4.5K and 1.8K )
    • ATLAS cryogenic part of the detector
    • CMS cryogenic part of the detector

   JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   6
•UNICOS is based on modular “Objects”

•The UNICOS Architecture define everything

            • The structure of the program in the PLC unit
            • The communication mechanism
            • The data base
            • The HMI (scada) implementation.

      Implicitly:
         • UNICOS defines your hardware Architecture
         (the modularity of your project)



JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez       7
                                                                                Summary
                                             Scada



                  Db      Data server



 Control layer

                               PLC                                            PLC

Field layer



      plc                plc                plc                   plc                  plc
   I/o channels        I/o channels      I/o channels          I/o channels         I/o channels


     JCOP - 17 October 2001           NA60_GAZ - E. Mazel J. Rochez                          8
The integration of a complete UNICOS framework
was not possible.

          • UNICOS implementation just released (april 2001)
          • UNICOS based on Quantum PLC
                • Too expensive for a project like NA60
          • Manpower resources limited.

Our goal was to get expertise with UNICOS and to analyze
mainly the “control and the field layers”


          For that we made several choices …

JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    9
Control and Field layers


    Control layer                           PLC



        Field layer
                            plc                                 plc
                                            plc
                      I/o channels                                   I/o channels
                                              I/o channels


     We have merged the control layer and the field layer
     In a single Premium PLC.
     • Premium and Quantum use the same language.
     • Some worries about the different architecture.
     • CPU power capacity similar
     • Memory capacity of the Premium extendable
   JCOP - 17 October 2001            NA60_GAZ - E. Mazel J. Rochez                  10
General interface for UNICOS library objects


                Process variables
                       or               Operator via               Control Logic    Programmer via
                  device status           SCADA                                     Engineering WS


                 Process Inputs        Manual Requests             Auto. Requests     Parameters




                                                     PLC Device




                                            Orders                Status


                                       Process output         Information to
                                             or                other devices
                                    Devices Auto Requests          or to
                                                                operator via
                                                                   SCADA




                                                                                    From Ph. GAYET – LHC/IAS



 JCOP - 17 October 2001                 NA60_GAZ - E. Mazel J. Rochez                                     11
                    UNICOS implementation in NA60 gas control layer (1/2)
                            Example of the MIXER


             Ar Flow reading       iC4H10 Flow reading          Freon Flow reading         alcohol Flow reading
                 Input object            Input object                 Input object              Input object



                                                              Mixer
                                                        Process Control object
PLC cycle




            Ar Flow sp.             iC4H10 Flow sp.                 Freon Flow sp.             alcohol Flow sp.
            Analog object               Analog object                 Analog object               Analog object

                  Ar valve cmd.          iC4H10 valve cmd.             Freon valve cmd.           alcohol valve cmd.
                   On/off object             On/off object                Analog object               On/off object


            Ar Flow sp.             iC4H10 Flow sp.                 Freon Flow sp.             alcohol Flow sp.
            Output object               Output object                 Output object              Output object

                  Ar valve cmd.          iC4H10 valve cmd.             Freon valve cmd.          alcohol valve cmd.
                   Output object             Output object                 Output object             Output object

               JCOP - 17 October 2001           NA60_GAZ - E. Mazel J. Rochez                                  12
    UNICOS implementation in NA60 gas control layer (2/2)
         memory assignment and data access

 Both PLC and Data server (OPC server) can be
 configured through memory mapping:
        Object interface definition                                     Object declaration
        (1 Excel sheet/object class)                                    (1 Excel sheet)




                                VB memory mapping app.
    Parameters                          • Check consistency
                                        • Assign memory cells



PLC programming environment                                     Data server configurator


   JCOP - 17 October 2001              NA60_GAZ - E. Mazel J. Rochez                         13
     Access to object input/output parameters


The NA60 Gas Control layer contains about 80 objects.

We decided to limit the amount of object data defined when
configuring the server and to use a special access protocol:

 • The user asks the PLC to send data concerning a
     selected object

 • The PLC fills a buffer with the data of the selected object

 • The buffer is read in by the SCADA according to the type of
     the selected object

 JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez     14
DataBase                                        SCADA


                           Db

                                                  PLC

     Communication protocol of UNICOS is based on a
     customized PLC-data server event-based protocol

       The communication mechanism between SCADA
       and PLC was replaced by the following:
       •           Data server is an OPC server
       •           Data from PLC polled by OPC server
                   through Modbus TCP protocol
  JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   15
Scada


                                  Scada

 Currently, the scada design for the UNICOS architecture as
 provided by LHC-IAS is based on Arc-Informatic/Pcvue32

 We did not use this product.

 • The use of this scada implementation requires the database.

 • The implementation under PVSS was a task too complex

 • The knowledge of PVSS was limited.


   JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   16
It was decided:

   • To use BridgeView (Lv 6i) to test the PLC development
     in the laboratory.

   • To give to NA60 the development with PVSS of the
     operator console needed during the RUN.

   • The goal was “if possible” to develop the expert console
     under the PVSS scada.




 JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    17
At the end:

   • The use of BView was simple
   • The array implementation of all variables in the PLC
     did provide a simple way to manage all objects.
            We have a full control of all “object” input/output
              parameters.

   • The development of the expert console was done in BView.
           One prototype done by IT/CO
           The final one done by the GAS team.

   • The operator console is available with BView and
     a subset is integrated in the NA60-PVSS scada.


    JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    18
JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   19
JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   20
JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   21
          Web access of the operator console click here




JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez    22
       Web Access of the Operator Console Click Here




JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   23
                         NA60 PVSS setup




JCOP - 17 October 2001    NA60_GAZ - E. Mazel J. Rochez   24
                     Muon spectrometer panel




JCOP - 17 October 2001    NA60_GAZ - E. Mazel J. Rochez   25
                         Chamber 1 gas flow




JCOP - 17 October 2001     NA60_GAZ - E. Mazel J. Rochez   26
                             Timescale.

March Study of UNICOS.
               Study of the Mixer
April          Porting of UNICOS into Premium
               Study and implementation of the distributor,
May            Porting of UNICOS into Premium
               Development of the uPLC access
               Development of the Bview panel for all Object.
June           Implementation of the distributor.
               Debugging in the lab
               Development of the expert panel and others.
July           Firsts Week integration and final test.
               Mid July, the GAS system was operational.

JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez          27
                           Goals achievement:

1. Use industrial products
      • Done.
      • Also for the microPLC – FLOWMETER.

2. Use a standardized design
      • The validity of the GWG -URD has been shown
      • Its modularity is suitable with UNICOS
      • Improvement of the URD.

3. Implement an automatic control process
     • The UNICOS approach applied to the Gas Controls
        is possible.


  JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   28
                          What we learned:

• Once they work, Industrial products are very stable.

• UNICOS approach is a complete solution for a large
   project (“clef en main”).

• Control layer and Field layer of Unicos are well designed
   and they are a solid base for every PLC development.

• Small projects should use these layers concepts even if
  they do not exploit all resources (like for NA60).
           Finalize a Premium library of objects.
           Create a Siemens library of objects.

                Advantage : similar code in all systems

 JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez       29
                         Perspectives
• Unicos stable release in use in SM18
• Unicos and PVSS
    – Unicos JCOP
          • Graphical objects
          • Communication
• Schneider Unity
          • Same development environment for Quantum and
            Premium



JCOP - 17 October 2001    NA60_GAZ - E. Mazel J. Rochez    30
                         This is the end




JCOP - 17 October 2001   NA60_GAZ - E. Mazel J. Rochez   31

				
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