Cryogenics Instrumentation _ Controls Commissioning for the LHC

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Cryogenics Instrumentation _ Controls Commissioning for the LHC Powered By Docstoc
					                                            CRYO Control
                     Sector78 cooldown experience




                                    Enrique Blanco
                                          AB/CO IS


TC AB/CO 1/Feb/07   E. Blanco AB/CO IS                1
                                                      Outline

1.   Architecture
     1. General Cryogenics Architecture: Sector78 layout
     2. Total integration: Control system & CIET
     3. Scalability and Magnitude : Devices , archiving
2.   Responsibilities and Planning
3.   Production methodology
     1.   Automatic generation : PLCs, FEC, SCADA, CIET, VFT
     2.   Generation and deployment timings
4.   Communications
     1.   IEPLC (automatic mapping), PLC (Siemens-Schneider)
5.   Surveillance: UNICOS PVSS tools
     1.   Support 24h
6.   Commissioning: experience and problems
     1. FECs: FESA, CMW
     2. PLCs
     3. Experience gained: Reorganization PVSS DS: Tunnel
        isolated


          TC AB/CO 1/Feb/07   E. Blanco AB/CO IS               2
                                                                           1.- Architecture
                                                                            1.1.- Sector78 Layout

                           WorldFip Copper cable
TT      858
                           WorldFip Fiber
CV      300                Profibus Fiber
                                                             TUNNEL
PV/QV   85                 Profibus DP Copper cable
PT      105                Ethernet UTP

LT      59

EH      292

all     1700




                                                                             SURFACE

                                                                            TN



               TC AB/CO 1/Feb/07                      E. Blanco AB/CO IS                        3
                                                                                              1.- Architecture
                                                       1.2.- Total Integration: Control System & CIET

                                                                            CRYO Instrumentation           Local Cryogenic
                                  CCR                                   PVSS DS        expert tool
                                         PVSS DS Sector78                                                   control room

                               OWS                                                                                  OWS [1..x]
                               [1..x]
Ethernet

                                                   Return                PLC
                                                   Module               QUIC
                                                                       Schneider

                                                                                                                       PLC
  FECs
                                                                                                                     S7-400
  (FESA)                                                                                                             Siemens
                                                      RM sector 81
                                                                                                                   UNICOS
                                                   RM sector 78      RM sector 78

                                       WFIP                                          PROFIBUS DP
                                    Networks (7)                                       networks


                                                                                         PROFIBUS PA networks
           RadTol
           electronics




                         TT, PT, LT, DI, EH                                         CV

                                  TC AB/CO 1/Feb/07                    E. Blanco AB/CO IS                                      4
                                                                 1.- Architecture
                                              1.3.- Scalability & magnitudes

   Instruments                                     Instrument    Number   Archiving   Archiving
                                                                           CRYO        CIET
                                                    TT            858      858         6864
   Archiving
        Deadbands initially defined                CV            300      300         0
         reduced communications load
                                                    PV/QV         85       0           0

   PVSS scalability: adding sectors
    to the existing DS                              PT            105      105         840

      Online adding of new systems is
                                                    LT            59       59          472
       done theoretically smoothly but
       in practice we’ve found that
       special care must be applied                 EH            292      292         2920
       (i.e.: alarms inundation from the            all           1700     1399        11096
       sector 78 instrumentation
       readout provoked a slow down in
       cryo operation for the whole
       point 8)
      New factor to be taken into                    Sector: (LOGGING)
       account: Commissioning phase!                          SCADA 1      change/minute
                                                              CIET   2.41 changes/minute
       where minimum interactions are
       desired between sector and
       production of helium equipments.


                TC AB/CO 1/Feb/07      E. Blanco AB/CO IS                                          5
                                                                           1.- Architecture
                                                                                          1.4.- Scalability

  4.5KA   common       4.5KB     Initial                   Final          4.5k A            4.5k B
 LHCA QSV  LHCB
 QSCA QSDN QSCB                                                           LHCA              LHCB
 QSAA QUI  QSAB                                                           QSAA              QSCB
 QSKA      QSRB                                                           QSKA              QSAB
                                                                          QSRA              QSRB
 QSRA
                                                                          QURA
 QURA     Q8DS2                                                                        Q8DS2

1.8KA                 1.8KB                          Secto          1.8k A         Common    1.8k B
                                                                                                              Secto
LHCCA              LHCCB                               r                                                        r
QSCCA              QSCCB                                            QSCCA          QSV       QSCCB
QURCA1             QURCB1                             S81           QURCA1         QSDN      QURCB1
                                                                                                              S78
QURCA2             QURCB2                                           QURCA2         QUI       QURCB2

Q8DS1              Q8DS3                          Q8DS1                             Q8DS3              Q8DS5
                                                                              ds5                      ds1*
    ds3                                ds1*                                   26%                      26%
                                              Factors initially taken:
    33%                                33%
                                              - Load distribution
                                              Factors finally taken:
                                              - Load / Functionality at       ds3
                                                                                                      ds2
                     ds2                      commissioning time              21%
                                                                                                      27%
                     34%

                   TC AB/CO 1/Feb/07                 E. Blanco AB/CO IS                                        6
                                              2.- Responsibilities, Planning
                                                                                     2.1.- Responsibilities

                         CCR                                                                    Local Cryogenic
                                                        CIET PVSS DS P8
                               PVSS DS Sector78                                                  control room

      OWS
      [1..x]                                                                                             OWS [1..x]

Ethernet

                                         Return               PLC
                                         Module               QUIC
                                                              Schneider

                                                                                                            PLC
  FECs
                                                                                                          S7-400
  (FESA)                                                                                                  Siemens
                                             RM sector 81
                                                                                                        UNICOS
                                         RM sector 78       RM sector 78

                             WFIP                                           PROFIBUS DP
                          Networks (7)                                        networks


                                                                              PROFIBUS PA networks
           RadTol
           electronics




                         TC AB/CO 1/Feb/07                    E. Blanco AB/CO IS                                    7
                                  2.- Responsibilities, Planning
                                                            2.2.- AB/CO IS duties


   PLC
      We provide: - S7-UNICOS generator
                    - General Support
      We do:       - VFT: Virtual flow meters
                    - Communications (IEPLC, PLC-PLC)
   SCADA
      We provide: - PVSS UNICOS
                   - General support: configuration & integration
   FEC
      We do: - FEC application development & maintenance
   CIET
      We do: - Expert Tool development & maintenance



          In general participating, as members of the CFAWG,
         in the control system design

              TC AB/CO 1/Feb/07        E. Blanco AB/CO IS                      8
                                       2.- Responsibilities, Planning
                                                                                 2.3.- Planning 2007


         Concurrent commissioning of the LHC sectors
                                                                                                              Flushing

                S45              S45                                                                          Cooldown
                                                                                                              Controls
                         S81             S81                                                                  ready

                           S34               S34

                                       S56                 S56

                                                    S23                  S23

                                                          S67                  S67

                                                                                     S12                  S12




Feb       Mar   April      May         Jun          Jul            Aug               Sep            Oct                Nov

                                                                                           Based on P. Gomes planning v22




                   TC AB/CO 1/Feb/07               E. Blanco AB/CO IS                                                  9
                                           3.- Production methodology
                                                                                                   3.1.- Specs

                                                                                                        AT/ACR IN
                                                         Specs                                          AB/CO IS
LHC controls                                          Generator
 Database



                                                        Specs File


                                                                                AT/ACR IN Addins

                         FEC/CIET                         VFT                     S7-UNICOS
                         Generator                    Generator                    Generator




                  CIET                   FEC                        PLC                   SCADA
               Configuration          Configuration               application           Configuration




                       TC AB/CO 1/Feb/07                 E. Blanco AB/CO IS                                  10
                                               3.- Production methodology
                                                                                   3.2.- Deployment time

                                                                                                                        AT/ACR IN
                                                           Specs                                                        AB/CO IS
LHC controls                                            Generator
 Database
                                                          Gen: 5 min


                                                          Specs File


                                                                                   AT/ACR IN Addins

                         FEC/CIET                           VFT                       S7-UNICOS
                         Generator                      Generator                      Generator

                                                                                                  Gen: 30 min
        Gen: 10 min                                         Gen: 5 min


                                                                 OffLine: 1 h
                               OffLine: 30 m
                                                                 Stop: 0 m        OffLine: 3 h           OffLine: 0 h
    OffLine: 0 m               Stop: 1 m       OffLine: 5 m
                                                                                  Stop: 5 m              Stop: 2 h
    Stop: 2 hours              (reboot)        Stop: 0 m

                  CIET                     FEC                        PLC                          SCADA
               Configuration            Configuration               application                  Configuration




                       TC AB/CO 1/Feb/07                   E. Blanco AB/CO IS                                                 11
                                 AT ACR/IN Difficulties


   Fault and missing part of the specs detected on the
    level:
       UNICOS S7 Generator
       PLC compilation
       PVSS importation
   Specs for process logic growing up rapidly and change
    very often
   Unexpected behaviour of the UNICOS S7 Generator




             TC AB/CO 1/Feb/07    E. Blanco AB/CO IS                               12
                                                       Czeslaw Fluder AT/ACR/IN 22.01.2007
                      AT ACR/IN Generation timing

   Expected
       Generation of the software for 1 sector (2 PLCs & PVSS) – 2
        days
   Real
       Last generation for ARC78 – 1 week
       Last generation for LSS78 – 2 weeks (including the night)
       Total time for production the PLC and PVSS software for
        Sector 78 – more then 3 month (including study and
        development of the templates)
   Time detalis
       50% cleaning the specs
       40% developing logic templates
       10% genereting the software




              TC AB/CO 1/Feb/07   E. Blanco AB/CO IS                               13
                                                       Czeslaw Fluder AT/ACR/IN 22.01.2007
                                                                         4.- Communications
                              4.1.- AB/CO IS realization and initial responsibility


PIC                                 CRYO (QUI)                                     VACUUM
             cfp-(…)-CIP(…)                                                                      PLCVAC(…)
                cfp-(…)-CIP(…)                  cfp-UX85-QUIC




                                          Modbus
CRYO                                      Siemens-Schneider

                                                                       IEPLC
                        *made by AT/ACR

                                                                                     cfc-sh8-ql8ce

  cfp-shc8-LSS78              cfp-shc8-ARC78                                               cfc-sh8-qr7ab

             IEPLC

                                   Power                                           PIC
                                                        UDP
                                   Converters

cfc-sh8-ql8df
      cfc-sh8-qr7uz
                                                  cfc-(…)                                cfp-(…)-CIP(…)
                                                                                            cfp-(…)-CIP(…)

                         TC AB/CO 1/Feb/07                    E. Blanco AB/CO IS                             14
                                             4.- Communications
                                                        4.2.- Detailed view


   IEPLC Automatic procedure
       PLC communication configuration
       DB mapping
   Modbus Siemens
       Exchange data to/from an Schneider PLC
       Full experienced in QRL cooldown
   PIC
       Procedure established
   Power converters
       Two options: CMW (SCADA level) or UDP (PLC level). The
        last is retained if we want to include current information to a
        feed-forward temperature control loop.



               TC AB/CO 1/Feb/07   E. Blanco AB/CO IS                     15
                                                         5.- Surveillance
                                                         5.1.- User Diagnostics

   CIET: Cryogenics Instrumentation Expert Tool
       This tool has been extensively used not only to diagnose the
        cryogenics instrumentation (TT,PT,LT, EH) but also to diagnose WFip
        agents and also the WFIP segment status




               TC AB/CO 1/Feb/07    E. Blanco AB/CO IS                       16
                                                     5.- Surveillance
                                                5.2.- UNICOS PVSS tools


   UNICOS PVSS system Integrity tools
   Automatic e-mailing in case of problems with:
       PLC communications: DS-PLC, DS-FEC, PLC-PLC,
        PLC-FEC
       Local archiving
       LHC services: Logging




            TC AB/CO 1/Feb/07   E. Blanco AB/CO IS                   17
    6.- Commissioning experience and Problems
                   6.1.- Problems in production machines/applications

     SCADA: PVSS S7 driver frozen
         Bug introduced in a PVSS release by ETM (third-party library)
     FEC
         Difficult landing for the application commissioning
         Any change in FESA class design implies retrofit in database affecting all
          devices deployed: enormous time consuming. [sector ~ 4 hours]
         CMW:
                     High load revealed CMW server reconnection problems (subscription)
                     Fail in a patch rollback CMW on all platforms prevented connections
                     Deployment in FESA 2.8 a new librery (Corba) aslo made the same effect
         NFS server change
                     SharedServer task dead -> FEC reboot
     PLC
     1.   Large applications revealed problems with Siemens Step7 tools
          1.   Importation
          2.   Compilation
          3.   Symbolic ceiling reached in arc78
     Our next problem will be facing change in the name of the FECs for P8
      due to the late requirement of the RM separation from the tunnel to the
      refrigeration controls (new FECs introduction in P8,P6,P4,P2)



                   TC AB/CO 1/Feb/07              E. Blanco AB/CO IS                           18
    6.- Commissioning experience and Problems
                                                                                         6.2.- Actions taken

     Sector 78
           We did adapt as much as possible to the AT/ACR needs
           Not enough time for getting proper specifications
     Actions taken
           Specs versioning mechanism allowed us to skip several “sub-versions”
            to optimize our resources
                                                                               Current           Foreseen
                      Preparation, flushing                     300 K          Status    80 K    week6

    PLC
    SCADA


    FEC
    CIET
                                                                                                  Time
              V1.0     V1.1      V2.0         V2.x V3.0                 V3.4             V4.0


           Adapt our UNICOS framework to their particular needs by means of
            creating new features or just new devices whenever needed at SCADA
            and PLC levels
           Return experience allowed as to better tune our tools to provide
            maximum flexibility during generation
                     TC AB/CO 1/Feb/07                    E. Blanco AB/CO IS                                19
    6.- Commissioning experience and Problems
                                6.3.- Goals for next sectors commissioning

    SCADA
      Provide enough knowledge to ACR/IN to allow interact tunnel DS with
       the refrigerators DS without fear.
      Provide an environment to ensure smooth integration of the tunnel
       applications
      Optimize maintenance being homogeneous with the rest of
       applications
    PLC
        Provide the Polish/Greek team (AT/ACR IN) with documented
         standard procedures and tools to arrive to self-sufficiency:
              IEPLC
              VFT
              PLC COMMUNICATIONS
        Discharge all responsibility in their PLC applications
    FEC
        By the time being the application will remain in AB/CO IS as it is not
         completely finished and more features are constantly coming notably
         to avoid instrumentation problems.



                 TC AB/CO 1/Feb/07       E. Blanco AB/CO IS                  20
    6.- Commissioning experience and Problems
                                                          6.4.- Lessons

    Sector78 has been our test bench to fine tune our applications

    Development environment: Only updates sufficiently tested must
     be applied within this period to avoid collateral effects
    Discharging responsibilities at PLC level will allow as to
     concentrate in concurrent sector commissioning optimally
    Managing versions was highly helpful in view of the number of
     specs changes that could be produced during the cooldown
       Sector 78 specs have been and will be changed/adapted even during
        the cooldown period
       Initially until 3 times per week !
    Infrastructure: PVSS DS in Technical Network become exposed
     machines because AT/ACR IN developers needs. Current WTS
     not enough (PLC tools, performance,…)

             The most important factor: ADAPTABILITY

                TC AB/CO 1/Feb/07   E. Blanco AB/CO IS                 21
                                                                 Thanks to …

   Still not the time of celebrating but confidence is high,
    therefore thanks to:
       All the people involved in the project
            Database team: XML FESA generation, Logging
            FESA team
                   Not for passing us the responsibility of the FEC cryo application at
                    the very last moment…
                   … but for the highly valuable support provided since then.
            WorldFip: providing us the test FEC gratefully
            And to our section, specially my “sporting” colleagues:




                   TC AB/CO 1/Feb/07        E. Blanco AB/CO IS                             22

				
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