Cryogenics Instrumentation _amp; Controls Commissioning for the LHC

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Cryogenics Instrumentation _amp; Controls Commissioning for the LHC Powered By Docstoc
					                 UNICOS Framework
                 METHODS & TOOLS




Philippe Gayet       AB-CO-IS
CERN Accelerator Control Architecture




      AB-CO TC, 2/2/06   Philippe Gayet
                          Industrial Control Architecture
                          Link to other accelerator control system
                             And services (alarms, logging,…)
  Industrial Supervision Layer                                                                                                                     Accelerator Presentation Tier
                                                                                                                 Operator Consoles




                                               Ethernet Network & TCPIP communication services
          Interface to operators
    (Monitoring & Command emission)


                                                                                                                            <5 Years
                                                                                                                  SCADA Servers                        Accelerator Middle Tier
        Real time DB & Archiving



Industrial Control layer                                                                         PLC Process Control                                 Accelerator Resource Tier
                                                                                                                                    One Communication protocol per supplier
                                                                                                                                          PLC are not compatible with CMW
          Control Logic Actions                                                                                            Life time Control
                                                                                                                            PLC Process
                                                                                                                              & Field interface         COTS from different supplier




Industrial Field layer                                                                               PLC Field interface
                                                                                                                           >10 Years
   control system connection to the process
        directly or through field-buses

                                                                                                                                        Fieldbus Networks




                                   AB-CO TC, 2/2/06                                                                    Philippe Gayet
                      Industrial System Objectives

 Integrates industrial control layers together respecting
  interlayer independence
 Integrates the Industrial Control to the accelerator control
  infrastructure and services (alarms, Logging,..)
 Offers a methodology to produce functional analysis
  directly
 Control project programmable by application development teams
                                                       LHC Startup
    Start up           First
                                              Tools available for
 Supplies Application Development Cryogenic Startup
             Cryogenic commissioning

  various development teams (CERN, Experiment
  collaboration, Outsourcing)        Workload

 Allows long term maintenance by reduced CERN teams
 Offers homogenous and efficient user interface for
  operation crew from equipment commissioning2007 long-
    2000              2001                        2006
                                                             to
  term operation Late Specifications


              AB-CO TC, 2/2/06    Philippe Gayet
                   LHC Cryogenic System

                                             - 4.5K refrigerators
                                             - 1.8K refrigerators
                                             - Helium Storage
                                             - Interconnection box


                                        3600 I/O per Sector




                                             - Magnets & DFBs


                                       2500 I/O per Sector




AB-CO TC, 2/2/06      Philippe Gayet
                   Process control Analysis

                                         Unit




                                          Equipment Modules
                                           Equipment Modules
                                            Equipment Modules
                                             Equipment Modules



                                           Equipment Modules
                                            Equipment Modules
                                             Equipment Modules




                                            Control Modules
                                            Control Modules
                                             Control Modules
                                              Control Modules
                                               Control Modules



                                                 IEC 61512-1
                                                Physical model




AB-CO TC, 2/2/06        Philippe Gayet
                                                                                                             UNICOS Break Down

                                                                                                                                                 IN UNICOS
                 AI
               M value                            PID
                                                                                                                                       -Each control module or




                                                            Process control Object
               An Input
               position
                               Control
                                Valve                                                                                                  equipment module is a device
               An Output
                position

                 DI
                                                                                                                                       -Each device type is an Object
              End switch        On-Off
                                Valve                                                                                                  Class




                                                                                                              Process control Object
                                                                                     Proces control Object
                DO
I/O Boards




              position

                                                                                                                                       -Each device is instantiated in
                 AI
               M value                            PID                                                                                  the control layer as PLC Object
                 AI
                                                         Process control Object



                               Control
               position         Valve

                 AO
                                                                                                                                       -Equipment modules and Units
               position
                                                                                                                                       are embedded in a unique
                  DI
               End switch       On-Off                                                                                                 object class : Process Control
                                Valve
                 DO
                                                                                                                                       Object
               position

                                      Field devices            Control devices
               I/O devices
             Control Modules         Control Modules    Equipment modules                                    UNITS                     -All PLC Object classes are
                                                                                                                                       based on the same model

                                         AB-CO TC, 2/2/06                                                     Philippe Gayet
             UNICOS Operation Principles

                         All control loops and automation duties
Operator
                         are performed within the Control layer
                         in the PLCs. But ....



                         -Operation team must be able to act on
                         each device


                         -In degraded operation conditions
                         operation crew can overcome process
                         logic requests




      AB-CO TC, 2/2/06      Philippe Gayet
           Application Basic Components

  Supervision
                                 - Graphical components (Widgets / Faceplaces)
                                 - Navigation tools
                                 - Objects explorer
 UNICOS FW                       - Trends and alarms handling
                                 - Access control
                                 - Interconnection to accelerator services
UNICOS SCADA
comm. interface             -SCADA Comm. Interface (time stamped data from sources)
                                 - Modbus (Schneider)
                                 - S7 (Siemens)
 UNICOS PLC                      - CMW
 comm. interface
                            -PLC comm. interface & Objects libraries available :
                                  - Premium PL7 (Obsolete not supported anymore)
                                  - Quantum Concept (Will not supported after mid 2006)
                                  - PREMIUM UNITY PLC
UNICOS object                     - QUANTUM UNITY PLC
   library                        - S7 (400 & 300 series)


    PLC




         AB-CO TC, 2/2/06                 Philippe Gayet
Development step 1: Objects Specification




                                         I/O devices
                                             Field devices
                                           PCO devices
     AB-CO TC, 2/2/06   Philippe Gayet
                 Development step 2: Device instance Generation

                                                                                         Supervision
                           device type         Instantiation generation
                           templates

                                                         Supervision                     UNICOS FW
Devices Specification                                      device
                                                          instance
                         devices                                                               Device
                          DB
                                         Instance                              Scripts
                                                                                             instantiation
                                         Generator
                                                       PLC device
                                                       instance


                                                                               UNICOS comm. interface



                                                                                            Device
                                                                                          instantiation
-Instance generators are presently based on ACCES and VB and available for
       - Premium PL7 (Obsolete not supported anymore)
       - Quantum Concept (Will be obsolete & not supported after mid 2006)
       - Premium/Quantum UNITY PLC                                                   UNICOS library
       - S7 (400 & 300 series)
                                                                                               PLC
- Next step will be to port the DB to ORACLE




                            AB-CO TC, 2/2/06                  Philippe Gayet
              Introducing Process Logic




                                       Device instantiation


                                     Place holders for process
                                     Dependent logics




AB-CO TC, 2/2/06    Philippe Gayet
 Development step 3 : PCO Placeholder Specification

  For Each PCO the process engineers from Equipment groups supply the logic associated to each PCO
  in a template document
                                        Interlock Logic




                                                  Configuration logic

Logic Placeholders
                                                                        Global logic
     Interlock Logic
   Configuration logic


     Global logic
   Dependent Object
     control logic
   Dependent Object
     control logic
                                                                                       Dependent Object
                                                                                         control logic
   Dependent Object
     control logic




                         AB-CO TC, 2/2/06                           Philippe Gayet
                  Development step 4 : Logic Skeleton Generation

                                                                                                      Supervision
                            device type                   Instantiation generation
                            templates

                                                                    Supervision                       UNICOS FW
Devices Specification                                                 device
                                                                     instance
                          devices                                                                           Device
                           DB
                                                Instance                                    Scripts
                                                                                                          instantiation
                                                Generator
                                                                  PLC device
                                                                  instance


                                                                                            UNICOS comm. interface


                                                        Basic Logic generation
                                                                                                         Device
                                                                                                       instantiation
                          Logic              Logic                 Logic
                           DB               Generator              Files                              Logic skeleton
                                Logic
                                templates
                                                                                                UNICOS baseline
            Placeholder
             Skeletons
                                                                                                            PLC




                             AB-CO TC, 2/2/06                              Philippe Gayet
Development step 5 : Process Logic & HMI Production

     Synoptic Specification                              Supervision
                                  Manual             Synoptic views, …
                                  production
                                                        UNICOS FW
                                                          Device
                                                        instantiation


                                                     UNICOS time stamped
                                                         Middleware


            Logic Specification                            Device
                                                         instantiation
                                                        Control Logic
                                     Manual
                                     production



                                                      UNICOS baseline

                                                              PLC
          AB-CO TC, 2/2/06          Philippe Gayet
                                                        Conclusion

   We use efficient and proven Concepts :
       Process breakdown
       Included in IEC 61512-1
       Operation and Diagnostics oriented
   Methods & tools
       From process analysis to code production
       Common language for process experts and developers
       Versatile suite of tools open to extension
   Documentation,Tutorials, distribution to be improved
   Integration to AB-CO DB standard to be completed with the
    help of DM



                  AB-CO TC, 2/2/06     Philippe Gayet
             Accelerator Cryogenics Status:
                     Refrigerators.




Philippe Gayet         AB-CO-IS
                   LHC Cryogenic System

                                             - 4.5K refrigerators
                                             - 1.8K refrigerators
                                             - Helium Storage
                                             - Interconnection box


                                        3600 I/O per Sector




                                             - Magnets & DFBs


                                       2500 I/O per Sector




AB-CO TC, 2/2/06      Philippe Gayet
                                                              HW Architecture 1

              Central                                 Central
             Data server                            control room

                                                                       OWS
                                              Local Control
                                                 room


 Quantum                                                                     Premium   EWS

    PCU                                                                        PCU

                                                   Profibus network

   Premium                                           Premium
 Field interface                                   Field interface




    Profibus network                             Profibus network

Accelerator Premium Quantum Solution              Accelerator Full Premium Solution

                           AB-CO TC, 2/2/06               Philippe Gayet
                           Hardware resp. Sharing for cryo
AB-CO Quantum                                               Central       Central & local control
                                                           Data server            room
                                                                            Operator consoles




                                               Ethernet IT-CS
     Premium
                                       BUS X

                                      AT-ACR
                Telefast

                            Phoenix




                                               DP
AT-ACR                                PMA           P P     PLC
                                               PA
                             Modbus                 A A     Safety
               Digital Analog



                           AB-CO TC, 2/2/06              Philippe Gayet
                                   REAL LHC Cryo “Production” control HW structure

                                                     Control room SHC8                                                                  EW1
 CCC                                                                                               OS1                 OS3
                                                                                                   OS2                 OS4              EW2
                  SCADA
            DS1    data
                  servers                                           1.8K          4.5K                       4.5K      1.8K
                                                                                                                                 Ethernet local connection
                                                                                                                                            UTP
                                                               LHCCA        LHCA                   LHCB             LHCCB                        Bat 2851

                                     Ethernet backbone (IT-CS)

SH8                                     SHM8                                              SD8                           SDH8                        SHBB8



QSCA                        QSDN      QSCCA        QSCCB       QSCB        QSAB                   QSRA                 QSKA     QSRB                   QSAA
                  QSV                                                                                                                                  Main Dryer
Comp 4.5K
                        LN2 Buffer    Comp 1.8K Comp 1.8K      Comp 4.5K Main Dryer               UCB 4.5K                     Cold Box 4.5K


                                                                QURA              QUI     Connection       US IP8
                                                      LCB                                 Box
                                                      4.5K                                 5200
                                             3em        US85                               UX85


                                                   QURCA                                               QURCB
                                                                                                                8200
                                            2em
                                                     CB 1.8K                                     CB 1.8K




                                     AB-CO TC, 2/2/06                                    Philippe Gayet
                                                                                                                                                                                                                                                                                                 Hardware status
           Point 1.8          Point 2                          Point 4                                                                                                                                                                                                                           Point 6                          Point 8
            Central
              HP
            storage


             HP                  HP                                   HP                                                                                                                                                                                                                             HP                                HP
           storage             storage                              storage                                                                                                                                                                                                                        storage                           storage




                                                                                                                                                                                                                                                                                                                                                                                Surface
                                                                                                                                                                                                                                                                                                                                                            (buildings+areas)
AB-CO-IS




                          QSC
                     QSCB QSCC       QSCA QSCC         QSC QSC
                                                       QSCC QSCA                   QSC
                                                                              QSCB QSCC                                                                                                                                                                                                  QSC
                                                                                                                                                                                                                                                                                         QSCC QSCB       QSC
                                                                                                                                                                                                                                                                                                         QSCA QSCC        QSC QSC
                                                                                                                                                                                                                                                                                                                          QSCC QSCA                 QSC
                                                                                                                                                                                                                                                                                                                                               QSCB QSCC

                       LN 2               LN 2                    LN 2                                                                                                                                                                                                                           LN 2                               LN 2



                 QSRB                QSRA                   QSRA         QSRB                                                                                                                                                                                                                 QSRB           QSRA              QSRA        QSRB




                                                                                                                                                                                                                                                                                                                                                             Shaft
                                                                                           Point 1.8         Point 2              Point 3           Point 4             Point 5            Point 6             Point 7             Point 8

                                                                                            QSV                 QSV                  QSV                 QSV                 QSV                QSV                QSV                QSV


                                                                                                       QSC
                                                                                                  QSCB QSCC QSCA QSCC                      QSC QSC        QSC
                                                                                                                                           QSCC QSCA QSCB QSCC                     QSC       QSC
                                                                                                                                                                                   QSCC QSCB QSCA QSCC                   QSC QSC
                                                                                                                                                                                                                         QSCC QSCA                QSC
                                                                                                                                                                                                                                             QSCB QSCC




                                                                                                                                                                                                                                                           (buildings+areas)
                                                                                                                                                                                                                                                                               Surface
                                                                                                    QSD                 QSD                          QSD                                    QSD                                     QSD


                                                                                               QSRB                   QSRA                        QSRA         QSRB                     QSRB          QSRA                     QSRA QSRB




                                                                                                                                                                                                                                                               Shaft
                                                                                                                      QURA                        QURA                                            QURA                         QURA


                                                                                              QUI                 QUI                                   QUI                                     QUI                                   QUI




                                                                                                                                                                                                                                                           Cavern
                                                                                                  QURC                QURC                        QURC         QURC                    QURC           QURC                   QURC         QURC
                                                                                                    QRL                  QRL                 QRL                  QRL                QRL                QRL                QRL                 QRL




                                                                                                                                                                                                                                                            Tunnel
                                                                                                  Sector 1-2           Sector 2-3          Sector 3-4           Sector 4-5         Sector 5-6         Sector 6-7         Sector 7-8          Sector 8-1
                                                                                                                                                                   LHC machine cryostat
                                                                                           QSCA : Compressor set for existing 4.5K refrigerator
                                                                                           QSRA : Upper cold box for existing 4.5K refrigerator
                                                                                                                                                    QSCB : Compressor set for new 4.5K refrigerator          QSCC : Compressor set for new 1.8K refrigerator
                                                                                           QURA : Lower cold box for existing 4.5K refrigerator
                                                                                                                                                    QSRB : Cold box for new 4.5K refrigerator                QURC : Cold box for new 1.8K refrigerator


                                                                                                                                                    QUI : Interconnection cold box
                                                                                                                                                                                                             QRL : Main ring transfer Line
                                                                                                                                                    QSV : Gaseous Helium Storage
                                                                                                                                                    QSD : Liquid Nitrogen Storage




                                     QURA                   QURA                                                                                                                                                                                                                                         QURA                  QURA




                                                                                                                                                                                                                                                                                                                                                            Cavern
               QUI                 QUI                             QUI                                                                                                                                                                                                                             QUI                               QUI


                QURC                QURC                   QURC          QURC                                                                                                                                                                                                               QURC        QURC                 QURC          QURC
AT-ACR




                       QRL                QRL            QRL                    QRL                                                                                                                                                                                                        QRL                 QRL          QRL                  QRL




                                                                                                                                                                                                                                                                                                                                                            Tunnel
                      Sector 1-2         Sector 2-3    Sector 3-4             Sector 4-5                                                                                                                                                                                                 Sector 5-6          Sector 6-7   Sector 7-8           Sector 8-1




                                                                     Installed

                                                                      To be specified ,developed & deployed by ACR


                                                 AB-CO TC, 2/2/06                                                                                                                                                                                                                           Philippe Gayet
                                     HW Status & Maintenance

   HP Proliant for Scada (16)
   Schneider PLC (85) 
   We have to Buy & Install Siemens Gateway (24) (P8 OK)

   All equipements for ACR are or will be referenced in :
       ABCAM for asset management
       LHC Layout db for intervention
   AB-CO will monitor the HW evolution and propose
    preventive maintenance
   AB-CO will provide a central spare parts repository
   Servers will be in CCC with the same service as the other
    critical server for LHC Operation
   On site intervention will have to be organized by AB-CO

                 AB-CO TC, 2/2/06    Philippe Gayet
                                                Basic software Issues

   Migration from XP OWS/DS to Proliant Linux DS with UNICOS/PVSS
    V3
     Servers configuration & monitoring (IN) 
     Migration to proliant Linux servers instead of present Windows ongoing


   Migration Of Schneider PLC to UNITY OS
     Application migrated for FI and small PCU 
     Still some Pb with large PCU
           Availability of reliable Online programming capacity on Unity Quantum
                 New release of Schneider development tool in April 
                 New version of object (20% of memory liberated) validated 
           Consolidation of PLC communication
                 CERN Application 
                 Firmware PB contact with Schneider on hardware bug correction no result yet
           Regular firmware update to implement (6 month)
                 Necessity of local intervention for update 




                      AB-CO TC, 2/2/06                Philippe Gayet
                                       Application software status
   First time (new controls):
       SM18 cryo infra and 6 kW Linde ABB -> UNICOS - 1st semester 07
            NOT in present roadmap nor in budget 
       Ex-LEP refrigerator upgrade to UNICOS (pt. 4 and 6) – early 06
            limited AB-CO resources available to establish specification 
            Resources OK for programming 


   The other applications have already been developed in
    other LHC points (duplication)
   All systems are working as if they are not coupled together.
       The HC period will be used by cryogenics Engineers to integrate
        the complete process.
       Need of available programming resources for PLC and supervision


                                                                       OK program ready 
                    AB-CO TC, 2/2/06         Philippe Gayet
                                                      PVSS server for Cryo
             sector       18k            45kb   common     45ka          18k     sector

           LSS-1       LHCCB        LHCB        QSV      LHCA          LHCCA    LSS
           ARC         QSCCB        QSCB        QSDN     QSCA          QSCCA    ARC
P4,P6,P8   LSS        QURCB1        QSAB        QUI      QSAA          QURCA1   LSS+1
                      QURCB2        QSRB                 QSKA          QURCA2
                                                         QSRA
           QxDS3                    QxDS2                QURA          QxDS1
             sector       18k            45kb   common

           LSS-1       LHCCB        LHCB        QSV
           ARC         QSCCB        QSCB        QSDN
P18        LSS        QURCB1        QSAB        QUI
                      QURCB2        QSRB

           Q18DS3                   Q18DS2
                                                common     45ka          18k     sector

                                                QSV      LHCA          LHCCA    LSS
                                                QSDN     QSCA          QSCCA    ARC
 P2                                             QUI      QSAA          QURCA1   LSS+1
                                                         QSKA          QURCA2
                                                         QSRA
                                    Q2DS2                QURA          Q2DS1
                      AB-CO TC, 2/2/06                Philippe Gayet
                                                                                                                                                                                                                                                                                           Application status
           Point 1.8          Point 2                          Point 4                                                                                                                                                                                                                           Point 6                          Point 8
            Central
              HP
            storage


             HP                  HP                                   HP                                                                                                                                                                                                                             HP                                HP
           storage             storage                              storage                                                                                                                                                                                                                        storage                           storage




                                                                                                                                                                                                                                                                                                                                                                                Surface
                                                                                                                                                                                                                                                                                                                                                            (buildings+areas)
AB-CO-IS




                          QSC
                     QSCB QSCC       QSCA QSCC         QSC QSC
                                                       QSCC QSCA                   QSC
                                                                              QSCB QSCC                                                                                                                                                                                                  QSC
                                                                                                                                                                                                                                                                                         QSCC QSCB       QSC
                                                                                                                                                                                                                                                                                                         QSCA QSCC        QSC QSC
                                                                                                                                                                                                                                                                                                                          QSCC QSCA                 QSC
                                                                                                                                                                                                                                                                                                                                               QSCB QSCC

                       LN 2               LN 2                    LN 2                                                                                                                                                                                                                           LN 2                               LN 2



                 QSRB                QSRA                   QSRA         QSRB                                                                                                                                                                                                                 QSRB           QSRA              QSRA        QSRB




                                                                                                                                                                                                                                                                                                                                                             Shaft
                                                                                           Point 1.8         Point 2              Point 3           Point 4             Point 5            Point 6             Point 7             Point 8

                                                                                            QSV                 QSV                  QSV                 QSV                 QSV                QSV                QSV                QSV


                                                                                                       QSC
                                                                                                  QSCB QSCC QSCA QSCC                      QSC QSC        QSC
                                                                                                                                           QSCC QSCA QSCB QSCC                     QSC       QSC
                                                                                                                                                                                   QSCC QSCB QSCA QSCC                   QSC QSC
                                                                                                                                                                                                                         QSCC QSCA                QSC
                                                                                                                                                                                                                                             QSCB QSCC




                                                                                                                                                                                                                                                           (buildings+areas)
                                                                                                                                                                                                                                                                               Surface
                                                                                                    QSD                 QSD                          QSD                                    QSD                                     QSD


                                                                                               QSRB                   QSRA                        QSRA         QSRB                     QSRB          QSRA                     QSRA QSRB




                                                                                                                                                                                                                                                               Shaft
                                                                                                                      QURA                        QURA                                            QURA                         QURA


                                                                                              QUI                 QUI                                   QUI                                     QUI                                   QUI




                                                                                                                                                                                                                                                           Cavern
                                                                                                  QURC                QURC                        QURC         QURC                    QURC           QURC                   QURC         QURC
                                                                                                    QRL                  QRL                 QRL                  QRL                QRL                QRL                QRL                 QRL




                                                                                                                                                                                                                                                            Tunnel
                                                                                                  Sector 1-2           Sector 2-3          Sector 3-4           Sector 4-5         Sector 5-6         Sector 6-7         Sector 7-8          Sector 8-1
                                                                                                                                                                   LHC machine cryostat
                                                                                           QSCA : Compressor set for existing 4.5K refrigerator
                                                                                           QSRA : Upper cold box for existing 4.5K refrigerator
                                                                                                                                                    QSCB : Compressor set for new 4.5K refrigerator          QSCC : Compressor set for new 1.8K refrigerator
                                                                                           QURA : Lower cold box for existing 4.5K refrigerator
                                                                                                                                                    QSRB : Cold box for new 4.5K refrigerator                QURC : Cold box for new 1.8K refrigerator


                                                                                                                                                    QUI : Interconnection cold box
                                                                                                                                                                                                             QRL : Main ring transfer Line
                                                                                                                                                    QSV : Gaseous Helium Storage
                                                                                                                                                    QSD : Liquid Nitrogen Storage




                                     QURA                   QURA                                                                                                                                                                                                                                         QURA                  QURA




                                                                                                                                                                                                                                                                                                                                                            Cavern
               QUI                 QUI                             QUI                                                                                                                                                                                                                             QUI                               QUI


                QURC                QURC                   QURC          QURC                                                                                                                                                                                                               QURC        QURC                 QURC          QURC
AT-ACR




                       QRL                QRL            QRL                    QRL                                                                                                                                                                                                        QRL                 QRL          QRL                  QRL




                                                                                                                                                                                                                                                                                                                                                            Tunnel
                      Sector 1-2         Sector 2-3    Sector 3-4             Sector 4-5                                                                                                                                                                                                 Sector 5-6          Sector 6-7   Sector 7-8           Sector 8-1


                                                                     Ready in Unity V2 PVSS, upgrade on request of ACR
                                                                    To Copy from existing version in Unity V2
                                                                     To port from concept to Unity V2 PVSS
                                                                     To be specified by ACR & Developed by CO

                                                                      To be specified ,developed & deployed by ACR

                                                 AB-CO TC, 2/2/06                                                                                                                                                                                                                           Philippe Gayet
                                                   Conclusions

   HW & SW deployment almost completed but
    during the HC a large amount of SW
    consolidation work will have to be done
   No major technical issues but
       Communication weakness must be solve before JUNE
       The PLC Firmware evolution will imply a careful
        planning and resources




               AB-CO TC, 2/2/06   Philippe Gayet

				
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