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UNICOS Framework METHODS & TOOLS

UNICOS Framework METHODS & TOOLS. Philippe Gayet AB-CO-IS. CERN Accelerator Control Architecture. Industrial Supervision Layer. Operator Consoles. Interface to operators (Monitoring & Command emission). <5 Years. SCADA Servers. Real time DB & Archiving.

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UNICOS Framework METHODS & TOOLS

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  1. UNICOS Framework METHODS & TOOLS Philippe Gayet AB-CO-IS

  2. CERN Accelerator Control Architecture Philippe Gayet

  3. Industrial Supervision Layer Operator Consoles Interface to operators (Monitoring & Command emission) <5 Years SCADA Servers Real time DB & Archiving Industrial Control layer PLC Process Control Ethernet Network & TCPIP communication services One Communication protocol per supplier PLC are not compatible with CMW Life time Control Logic Actions PLC Process Control & 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 Industrial Control Architecture Link to other accelerator control system And services (alarms, logging,…) Accelerator Presentation Tier Accelerator Middle Tier Accelerator Resource Tier Philippe Gayet

  4. First Cryogenic commissioning Cryogenic Startup Control project Start up LHC Startup 2000 2001 2007 Late Specifications Workload 2006 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 programmable by application development teams • Supplies Application Development Tools available for various development teams (CERN, Experiment collaboration, Outsourcing) • Allows long term maintenance by reduced CERN teams • Offers homogenous and efficient user interface for operation crew from equipment commissioning to long-term operation Philippe Gayet

  5. 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 Philippe Gayet

  6. 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 Process control Analysis IEC 61512-1 Physical model Philippe Gayet

  7. Control Valve AI M value PID An Input position An Output position Process control Object On-Off Valve DI End switch Process control Object Proces control Object I/O Boards DO position AI M value PID Control Valve AI position Process control Object AO position On-Off Valve DI End switch DO position UNICOS Break Down • IN UNICOS • Each control module or equipment module is a device • Each device type is an Object Class • Each device is instantiated in the control layer as PLC Object • Equipment modules and Units are embedded in a unique object class : Process Control Object • All PLC Object classes are based on the same model Control devices Equipment modules UNITS Field devices Control Modules I/O devices Control Modules Philippe Gayet

  8. Operator UNICOS Operation Principles • All control loops and automation duties 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 Philippe Gayet

  9. Graphical components (Widgets / Faceplaces) • Navigation tools • Objects explorer • Trends and alarms handling • Access control • Interconnection to accelerator services Application Basic Components Supervision UNICOS FW UNICOS SCADA comm. interface • SCADA Comm. Interface (time stamped data from sources) • Modbus (Schneider) • S7 (Siemens) • CMW UNICOS PLC 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 • QUANTUM UNITY PLC • S7 (400 & 300 series) UNICOS object library PLC Philippe Gayet

  10. I/O devices Field devices PCO devices Development step 1: Objects Specification Philippe Gayet

  11. Instantiation generation device type templates Supervisiondevice instance Devices Specification Device instantiation devices DB Scripts Instance Generator PLC device instance Device instantiation Development step 2: Device instance Generation Supervision UNICOS FW UNICOS comm. interface • 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 • S7 (400 & 300 series) • Next step will be to port the DB to ORACLE UNICOS library PLC Philippe Gayet

  12. Device instantiation Place holders for process Dependent logics Introducing Process Logic Philippe Gayet

  13. Interlock Logic Configuration logic Global logic Dependent Object control logic 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 Logic Placeholders Interlock Logic Configuration logic Global logic Dependent Object control logic Dependent Object control logic Dependent Object control logic Philippe Gayet

  14. Instantiation generation device type templates Supervisiondevice instance Devices Specification Device instantiation devices DB Scripts Instance Generator PLC device instance Basic Logic generation Device instantiation Logic Generator Logic Files Logic DB Logic skeleton Logic templates Placeholder Skeletons Development step 4 : Logic Skeleton Generation Supervision UNICOS FW UNICOS comm. interface UNICOS baseline PLC Philippe Gayet

  15. Synoptic Specification Synoptic views, … Manual production Logic Specification Control Logic Manual production Development step 5 : Process Logic & HMI Production Supervision UNICOS FW Device instantiation UNICOS time stamped Middleware Device instantiation UNICOS baseline PLC Philippe Gayet

  16. 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 Philippe Gayet

  17. Accelerator Cryogenics Status:Refrigerators. Philippe Gayet AB-CO-IS

  18. 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 Philippe Gayet

  19. HW Architecture 1 Central control room Central Data server OWS Local Control room Quantum PCU Premium PCU EWS Profibus network Premium Field interface Premium Field interface Profibus network Profibus network Accelerator Full Premium Solution Accelerator Premium Quantum Solution Philippe Gayet

  20. Telefast Phoenix Digital Analog Hardware resp. Sharing for cryo AB-CO Quantum Central Data server Central & local control room Operator consoles Ethernet IT-CS Premium BUS X AT-ACR DPPA PA PA PLC Safety PMA AT-ACR Modbus Philippe Gayet

  21. REAL LHC Cryo “Production” control HW structure Control room SHC8 EW1 CCC OS3 OS4 OS1 OS2 EW2 SCADA data servers DS1 4.5K 1.8K 4.5K 1.8K Ethernet local connection UTP Bat 2851 LHCCA LHCA LHCCB LHCB Ethernet backbone (IT-CS) SDH8 SH8 SD8 SHM8 SHBB8 QSDN QSCB QSAB QSCCB QSRB QSCCA QSKA QSCA QSAA QSRA QSV Main Dryer Comp 1.8K LN2 Buffer Comp 1.8K Comp 4.5K Main Dryer Cold Box 4.5K UCB 4.5K Comp 4.5K QURA US IP8 QUI Connection Box LCB 4.5K 5200 3em UX85 US85 QURCB QURCA 8200 2em CB 1.8K CB 1.8K Philippe Gayet

  22. 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 QSC QSC QSC QSC QSC QSC QSC QSC QSC QSCC QSCC QSCA QSCB QSCC QSCA QSCB QSCC QSCC QSCB QSCA QSCC QSCC QSCA QSCB QSCC Surface LN LN LN LN LN (buildings+areas) AB-CO-IS 2 2 2 2 2 QSRB QSRB QSRB QSRB QSRA QSRA QSRA QSRA 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 AT-ACR 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 Philippe Gayet

  23. 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 Philippe Gayet

  24. 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  Philippe Gayet

  25. 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  Philippe Gayet

  26. PVSS server for Cryo sector 18k 45kb common 45ka 18k sector LSS-1 QSV LHCA LSS LHCCB LHCB LHCCA ARC QSCCB QSCB QSDN QSCA QSCCA ARC P4,P6,P8 LSS QURCA1 QURCB1 QSAB QSAA LSS+1 QUI QURCB2 QSRB QSKA QURCA2 QSRA QxDS3 QxDS2 QxDS1 QURA sector 18k 45kb common LSS-1 QSV LHCCB LHCB ARC QSCCB QSCB QSDN P18 LSS QURCB1 QSAB QUI QURCB2 QSRB Q18DS3 Q18DS2 common 45ka 18k sector QSV LHCA LSS LHCCA QSDN QSCA QSCCA ARC P2 QURCA1 QSAA LSS+1 QUI QSKA QURCA2 QSRA Q2DS2 Q2DS1 QURA Philippe Gayet

  27. 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 QSC QSC QSC QSC QSC QSC QSC QSC QSC QSCC QSCC QSCA QSCB QSCC QSCA QSCB QSCC QSCC QSCB QSCA QSCC QSCC QSCA QSCB QSCC Surface LN LN LN LN LN (buildings+areas) AB-CO-IS 2 2 2 2 2 QSRB QSRB QSRB QSRB QSRA QSRA QSRA QSRA 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 AT-ACR 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 Philippe Gayet

  28. 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 Philippe Gayet

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