UNICOS Framework METHODS

1
UNICOS Framework METHODS TOOLS

• Philippe Gayet AB-CO-IS

2
CERN Accelerator Control Architecture
3
Industrial Control Architecture
Link to other accelerator control system And
services (alarms, logging,)
Accelerator Presentation Tier
Accelerator Middle Tier
Accelerator Resource Tier
4
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

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
6
Process control Analysis
IEC 61512-1 Physical model
7
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
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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

9
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
10
Development step 1 Objects Specification
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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
12
Introducing Process Logic
13
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
14
Development step 4 Logic Skeleton Generation
Supervision
UNICOS FW
UNICOS comm. interface
UNICOS baseline
PLC
15
Development step 5 Process Logic HMI
Production
Supervision
UNICOS FW
Device instantiation
UNICOS time stamped Middleware
Device instantiation
UNICOS baseline
PLC
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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

17
Accelerator Cryogenics StatusRefrigerators.

• 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
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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
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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
PMA
PA
PA
PLC Safety
AT-ACR
Modbus

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

Point 4
Point 2
Point 1.8
Point 6
Point 8
Central
HP
storage
HP
HP
HP
HP
HP
storage
storage
storage
storage
storage
QSC
QSC
QSC
QSCC
QSC
QSC
QSC
QSC
QSC
QSC
QSCB
QSCC
QSCA
QSCC
QSCA
QSCB
QSCC
QSCA
QSCC
QSCC
QSCB
QSCC
QSCA
QSCB
QSCC
Surface
LN
LN
LN
LN
LN
(buildingsareas)
AB-CO-IS
2
2
2
2
2
QSRB
QSRA
QSRB
QSRB
QSRB
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
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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

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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 ?

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Application software status

• First time (new controls)
• SM18 cryo infra and 6 kW Linde ABB -gt 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 ?
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PVSS server for Cryo
18k
sector
18k
sector
45kb
45ka
common
QSV
LHCB
LHCA
LHCCA
LHCCB
LSS-1
LSS
QSCCA
QSCCB
QSDN
QSCA
QSCB
ARC
ARC
P4,P6,P8
QURCA1
QURCB1
QSAA
QSAB
LSS
LSS1
QUI
QSRB
QSKA
QURCB2
QURCA2
QSRA
QxDS1
QxDS2
QxDS3
QURA
18k
sector
45kb
common
QSV
LHCB
LHCCB
LSS-1
QSCCB
QSDN
QSCB
ARC
P18
QURCB1
QSAB
LSS
QUI
QSRB
QURCB2
Q18DS2
Q18DS3
18k
sector
45ka
common
QSV
LHCA
LHCCA
LSS
QSCCA
QSDN
QSCA
ARC
P2
QURCA1
QSAA
LSS1
QUI
QSKA
QURCA2
QSRA
Q2DS1
Q2DS2
QURA
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Application status

Point 4
Point 2
Point 1.8
Point 6
Point 8
Central
HP
storage
HP
HP
HP
HP
HP
storage
storage
storage
storage
storage
QSC
QSC
QSC
QSCC
QSC
QSC
QSC
QSC
QSC
QSC
QSCB
QSCC
QSCA
QSCC
QSCA
QSCB
QSCC
QSCA
QSCC
QSCC
QSCB
QSCC
QSCA
QSCB
QSCC
Surface
LN
LN
LN
LN
LN
(buildingsareas)
AB-CO-IS
2
2
2
2
2
QSRB
QSRA
QSRB
QSRB
QSRB
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
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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