1. IBL CO 2 UNICOS CPC6 based control system Lukasz Zwalinski – PH/DT/PO

2. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO Presentation overview I/O requirements Standardization System architecture Selected hardware control components Rack construction and USA15 available place Software principals Software development User interface Access control Software user tools Planning

3. I/O number evaluation per plant IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO I/O Type MARCO I/O Number IBL I/O Number for 1 unit DI32x30x + 18xSpares = 48x DO32x AI 4-20mA: 20x RTD: 14x 4-20mA: 20x + manifolds 10x + 5xSpares = 35x RTD: 14x + 4xSpares + Detector and manifolds 7x + 6xSpares = 31x AO8x4x + 4xSpares = 8x

4. Standardization approach EN-ICE PH-DT-PO PH-DT-DI EN-CV-DC CO 2 HARDWARE Industrial electrical components Control hardware equipment Nomenclature conforming ISA/ANSI standard HARDWARE Industrial electrical components Control hardware equipment Schneider PLC standard SOFTWARE Software components Experience of CO2 plants at CERN CORA & SR1 Electrical diagnostic tools FRAMEWORK UNICOS PVSS IEC61512-1 standard IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

5. System architecture IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO IBL OWS DIP ? Premium CPU + PROFIBUS card IBL plant A CCC Local MODBUS TCP/IP Pneumatic lines PROFIBUS FESTO WAGO I/Os Premium CPU + PROFIBUS card IBL plant B Local MODBUS TCP/IP Pneumatic lines PROFIBUS FESTO WAGO I/Os Hardwired interlocking EN/CV Terminal server Detector Control System ATLAS DSS

6. System architecture IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO Hardware control system components agreed with: ( PH/DT/PO + PH/DT/DI + EN/CV/DC ) Schneider Premium PLC (very well known by EN/CV/DC) WAGO I/O modules - very high packing density and good economy compared to PLC native I/O 24V DC Power Supplies: Industrial, redundant, hot swappable, chassis mounted Circuit protection: Electronic Circuit Breakers specific to protecting 24VDC instrument type electronics Pilot Valves: FESTO PROFIBUS modular valve islands (based on experience on gas systems and detector cooling systems)

7. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO Control rack construction and place IBL plant A IBL plant B MARCO integrated control cabinet design To be discussed and verified in coming weeks: -Can we fit in with new components selected inside control cabinet already integrated in MARCO frame -Shall we/can we construct standard cabinet for ATLAS and CMS CO2 cooling systems -Do we have a space for external control rack if needed Cable trays integrated in MARCO frame Chiller detached from frame + 2x? EN/CV/DC has confirmed that they can do the control rack assembly and testing

8. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO Control rack layout Prepared by Steven Pavis PH/DT/DI for CMS CO 2 cooling station

9. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO UNICOS CPC - framework UNICOS ‐ CPC  UNified Industrial COntrol System  Continuous Process Control UNICOS framework supports 3 control system layers:  supervision (SCADA: PVSS)  control (PLC: Siemens S7 and Schneider)  field layer The package of programming tools includes:  baseline library (with modular PID algorithm)  code generator  skeleton templates and example of objects list Object definitions provided by UNICOS are split into:  I/O Objects (Digital Input, Digital Output, Analog Input)  Field Objects (OnOff, Analog, AnaDig, Controller, etc.)  Process Control Objects (PCO) Offers homogenous user interface http://j2eeps.cern.ch/wikis/display/EN/UNICOS http://www.esrf.eu/icalepcs2011/papers/wepks033.pdf http://www.esrf.eu/icalepcs2011/posters/wepks033_poster.pdf http://indico.cern.ch/getFile.py/access?resId=0&materialId=slides&confId=162565 SCADA Servers Ethernet Network & TCPIP communication services PLC Process Control PLC Process Control & Field interface Operator Consoles Fieldbus Networks control system connection to the process directly or through field- buses Industrial Field layer Industrial Supervision Layer Interface to operators (Monitoring & Command emission) Real time DB & Archiving Control Logic Actions Industrial Control layer

10. Some of the UNICOS Projects LHC Tunnel Cryogenic Control System: - 18 x S7 400PLC + 2 x S7 300PLC, - 15’000 distributed sensors and actuators, - 5’500 interlocks & alarms, - 3’600 PID Control Loops Detector Gas Systems - 24 PLCs Schneider Premium, - 10’000 I/O, - 3’000 alarms, about half of these cause an interlock, - About 200 PID Control Loops CO2 UNICOS system operational at CERN: CORA CO2 cooling system SR1 CO2 cooling system Others: NA48 Experiment - ECN3 HALL - Control Room in Bld. 918 CMS tracker thermal screen Dpt: PH/CMX - Project description: CMS tracker thermal screen: control of the thermal screen to keep it at ambient temperature. - Other data: 250 Inputs/outputs ; 60 actuators; 60 Controllers ECAL detector cooling control system LHC collimator temperatures ATLAS BigWheels ALICE SSD Cooling Interlock ALICE SDD Cooling Interlock ALICE Cooling water valves control IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

11. UNICOS project creation SCADA Server in CCC Logic Generator Instance Generator Specification XML Schneider PLC All generated files should be kept in Subversion Version Control (SVN) service. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

12. Supervision layout  Header  fixed area (toolbar)  Process area  Synoptic  Footer  Contextual area  Historic IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

13. PVSS access 1)Right click on the Current user name or click on the key 2)Click Login as 3)Enter an authorized NICE user / password Main Access Groups:  Monitor  Operator  Expert  Admin Only NICE authorized users (defined previously) are allowed to be log in the PVSS. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

14. Supervision layout: Process Area Static info Text Drawings Animated Widgets Sensors Actuators Controller Process unit Alarms Process unit Sensor Actuator Static info Widget interactions IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

15. PLC actions representation on PVSS panels Electrical diagnosticStepper Accumulator Auto SP calculation Accumulator limiters IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

16. PVSS tools Event listAlarm list IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

17. Recipes and user defined trends Recipe component User defined trends Recipe: Massive parameterization (optional)  Alarm thresholds  Set Points  PID parameters Trends:  Trend tree  Individual trends via object face plate  Dynamic trends IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

18. PCO Alarms with SMS or email notification Digital and Analog Alarms Types: Full Stop interlock (FS): Stop the unit/actuator (all dependent units/actuators are set to their fail-safe position) and wait manual acknowledgement before restarting. Temporary Stop Interlock (TS): Stop the unit/actuator (all dependent units/actuators are set to their fail-safe position) and restart automatically when the interlock disappears. Start Interlock (SI): Prevent the unit from starting (all dependent units/actuators stay in their fail-safe position). IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO

19. Preliminary planning IBL CO2 cooling Person involvedApr-12May-12Jun-12Jul-12Aug-12Sep-12Oct-12Nov-12Dec-12Jan-13Feb-13Mar-13Apr-13May-13Jun-13Jul-13Aug-13Sep-13Oct-13Nov-13Dec-13 Functional analysisWriting EDMS document m-Lukasz h-Maciej Control Components selection m-Lukasz h-Steven, h-Maciej Ordering m-Lukasz h-Steven, h-Maciej Electrical Rack wiring schemem-Lukasz h-Steven h-Maciej Side cabling schemem-Lukasz h-Steven h-Maciej Power distributionm-Lukasz h-Steven h-Maciej Axiculary diagramm-Lukasz h-Steven h-Maciej Power in cavern/labo request to EN-EL m-Lukasz h-Steven Components selection m-Lukasz h-Steven, h-Maciej Rack assembly 3D modelstudent Procurement of long term delivery components m-Lukasz h-Steven, h-Maciej Procurement of short term delivery components m-Lukasz h-Steven, h-Maciej Rack assembly m-EN/CV/DC h-Maciej Testing m-EN/CV/DC h-Maciej Cabling in cavern/fieldm-EN/CV/DC Software PLC programming m-Lukasz h-Steven, h-Maciej PVSS panels&scripts m-Maciej h-Steven PVSS in CCC agree with EN-ICEm-Lukasz X Communication with DCS docm-Lukasz Communication with DCS and DSS m-Lukasz h-Steven, h-Maciej Wiring to DSS (we supply 5in/out I/Os)m-ATLAS Sergey's tech Touch screens m-Lukasz h-Steven, h-Maciej Functional logic testing m-Lukasz h-Steven, h-Maciej Ethernet networkNetops request + outlet position m-Lukasz h-Steven Commissioning m-Lukasz h-Steven, h-Maciej Schedule has to be reviewed according to EN/CV/DC work load

20. Thank You for Your attention. IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO UNICOS framework - more details can be found: http://j2eeps.cern.ch/wikis/download/attachments/23334182/UCPC6_Operator_Training.pdf

21. UNICOS Data flow Object status Human Requests SCADA Object HMI Parameters Manual Requests Operator Information display Programmer SCADA Auto. Requests PLC Object logic Orders PLC Object status Manual Requests Parameters Programmer Process Input I/O Board or Fieldbus PROCESS Process Output Communication Middleware More information on PVSS data flow with code example can be found in following document: http://j2eeps.cern.ch/wikis/download/attachments/19040447/unicos-pvss-unCore-data-flow.pdf?version=1&modificationDate=1309450713000 IBL Review 15 th May 2011 L.Zwalinski – PH/DT/PO