1. LHC Cryogenics Control: INTEGRATION OF THE INDUSTRIAL CONTROLS (UNICOS) AND FRONT-END SOFTWARE ARCHITECTURE (FESA) APPLICATIONS
Enrique BLANCO
Controls Group: Industrial Systems
AB Department, CERN
Geneva, Switzerland
Enrique Blanco AB/CO IS

2. Outline UNICOS + FESA INDUSTRIAL CONTROL 1.- Cryogenics Introduction
2.- Control system
3.- Frameworks (Automatic generator tools)
4.- Conclusions
INDUSTRIAL CONTROL
Enrique Blanco AB/CO IS

3. 1.- LHC Cryogenics Architecture
Cryogenic point
3.3 km
LHC cryogenics overview
Cryogenic plant
LHC tunnel (27 km)
(Transfer line)
Long Straight Section
CRYO:
Based in the use of Superfluid helium to cool down to 1.9 K
Refrigeration power is distributed along 27 km
8 Large cryogenic plants: each one feeds a 3.3 km sector (LSS + ARC)
Standard Cell: 100m # 32 #
Keywords:
RADIATION
DISTRIBUTED
Enrique Blanco AB/CO IS

4. 2.- Cryogenics Control System Instrumentation
Large number of sensors and actuators.
Tunnel instrumentation exposed to radiation (custom development to withstand the hostile environment)
LHC cryogenics
standard cell PI&D
(~100 meters)
Instruments
Range
Total
TT (temperature) K
9500
PT (pressure)
0-20 bar
2200
LT (level)
Various
540
EH (heaters)
2500
CV (Control Valves) %
3800
PV/QV (On Off Valves) --
2000
- Large number
Radiation environtment
Industrial sensors but in-house radtol signal acquisition
Intelligent positioners (split)
RadTol Signal Conditioners
Profibus PA
8 wires
Enrique Blanco AB/CO IS

5. 2.- Cryogenics Control System Tunnel Architecture
Local & Central
Control Rooms
SCADA Data Servers
UNICOS
PLCs
Ethernet (TN) DP
Profibus DP
FESA
FECs
WorldFIP TT CV
TT, PT, LT, EH, DI
Ehsp, LTen
shaft (~100 m)
Protected areas PA PA PA PA
Architecture: from botton to top
FIELD LAYER:
- Instrumentation (radiation areas): TT, PT, LT, DI, EH
- Signal conditioning (radiation areas)
- SPLIT intelligent positioners
- WorldFip and Profibus PA – DP
CONTROL LAYER:
- FECs (Industrial PCs Linux SLC4 ; FESA application interfacing WorldFip data)
- PLCs (S7-400 interfacing Profibus)
- FEC & PLC exchange information
SUPERVISION LAYER:
- Dedicated Technical Ethernet
- SCADA data servers (HP prolient machines, Linux SLC4)
- Windows clients in control rooms: local and central control rooms
EXAMPLE CLOSING A CONTROL LOOP: TT -> Wfip -> FEC -> PLC -> Profibus -> Valve.
Alcoves
Radiation areas
LSS
RadTol electronics
Tunnel
LSS
ARC
LHC Tunnel (3.3 Km)
Enrique Blanco AB/CO IS

6. 2.- Cryogenics Control System Industrial Communications
Sector 78 TUNNEL
WorldFip Copper cable
WorldFip Fiber
Profibus DP Copper cable
Tunnel
Profibus Fiber
Ethernet UTP
Alcoves
shaft (~100 m)
- Fieldbuses: WorldFip & Profibus (PA & DP)
- Ethernet as a control network (included in the close-control loops)
Example: Sector 78
- Distributed  Fiber optics
Ethernet: Protected technical network
SURFACE
Enrique Blanco AB/CO IS

7. 3.- Frameworks FESA Cryogenics application processes
Front-End Software Architecture*
CERN accelerator real-time software model
Deployed to Front-End computers (FECs) running Linux/LynxOS
Cryogenics application processes
WorldFip: Read/Write Worldfip agents
Real-Time action
Device: Calculates devices data (Minimize electronics cards calculations)
Segment: Groups devices and communicates to the PLC
Server: CMW Exchange data
FESA Application Process Execution
* Ref: “Frond-End Software Architecture”, M. Arruat, et all. (ICALEPCS 07)
CERN Real-time object-oriented framework to design equipment software.
Deployed to (Front-End machines) FECs running Linux (SLC4) / LynxOS
FESA generates the framework (a generic solution tailored by the user)
Users do:
Design the devices (encoded as a XML schema)
Implement their custom code & relationships
CMW interface : subscription mechanism
Enrique Blanco AB/CO IS

8. UNified Industrial COntrol System
3.- Frameworks UNICOS
UNified Industrial COntrol System P
Logic
Process Control Objects (Compressors, feedbox, …)
I/O Channels
Field Objects (Valves, Heaters, …)
Instances C
UNICOS
Specifications
PLC and SCADA Baseline
Generates PLC and SCADA Devices
Placeholders where the control engineer must write the process logic C
Simplified HMI tool to create process synoptics (drag & drop) O
Diagnostics tools
CMW interface
Long-Term archiving
LHC alarm system
- Industrial framework to provide Industrial Control Applications
- Starting from the Specifications file (I/O channels + Field objects (Analog, Controller, Alarms, …)
- Process Engineer Process decomposition + specific LOGIC
- Current implementation targets: PLCs (Siemens + Schneider) + SCADA (PVSS II)
- Based in the use of Generators O
Operators P
Process Engineer C
Control Engineer
Enrique Blanco AB/CO IS

9. 3.- Frameworks UNICOS Objects design breakdown
Sector Cryogenics Process Control Objects
2 elementary cryogenics cells*
i =1..8
j =1..18
Process Decomposition exercise (e.g.: Tunnel) :
Control a basic tunnel equipment (bi-cell)
Reduce the amount of logic to create by using a few templates which will be parameterized and generated automatically (e.g.: Controllers)
UNICOS design: objects breakdown DECOMPOSITION RESULT
- I/O: Input and Output channels AI, DI, AO, DO
- Field objects: physical devices: Analog (Valves, Heaters), AnaDig, OnOff (Valves), Local, … Alarms
- Process Control Objects: (PCO) allow equipment control (Compressor, Coldbox) but it could be a physical decomposition.
Dependent logic hangs of every PCO.
Decomposition allows a much lower number of objects and in view of the nature of the machine will be repeated many times. A few templates are requires which will be parameter-dependant and generated automatically.
I/O objects + Controller (field objects)
Objects
Tunnel
Analog Inputs
12136
Analog Outputs
4856
Digital Inputs
4536
Digital Outputs
1568
Close Loop Controllers
3680
Process Decomposition: Controllers example
LHC
Sector
Arc
Bi-cell
3680
500
250 20
Enrique Blanco AB/CO IS

10. 3.- Automatic generation Tools UNICOS & FESA integration
Minimize hand code activities and focus on specific control logic
Versioning mechanism to trace all the instances and allow different generation speeds
Generation time of a complete LHC sector : ~ 1 day C
Specifications
Control Engineer
LHC controls (Poster RPPA03)
Database
Generator
Generators
Devices
PLC comms
Devices
Code
FEC comms
SCADA comms
Devices
Synoptics (Tunnel Panels)
Generation Time < 1 day for a whole LHC Sector :
Analog Inputs: ~1500
Analog Outputs: ~600
Digital Inputs: ~ 500
Digital Outputs: ~ 200
Analog (Valves, Heaters, ….): ~500
Close Loop Controllers: ~450
Optimize Time, ensures coherence and allows multiple generation
Device Design
Custom code
- device calculations
WorldFip comms.
Deployment: C
FESA
Baseline Baseline
Deployment: C
UNICOS
FECs
FECs
PLCs
SCADA
Enrique Blanco AB/CO IS

11. 3.- Frameworks UNICOS SCADA Structure
Instrumentation
CIET
Instrumentation Engineers I
Sector R
Sector L O
Cryogenics
Operators
Ethernet
Cryogenics
LHC cryogenic point
CIET: Cryogenics Instrumentation Expert Tool
4.5 K
Distributed architecture: central machine (panels & synoptics)
LHC services: Logging, Alarms and CMW interface
Based in the same framework (UNICOS) we provide 2 different applications giving Alternative views: Instrumentation and Operation O
Operators
Sector L
1.8 K
Sector R I
Instrumentation Engineer
Enrique Blanco AB/CO IS

12. 4.- Conclusions Successful integration of UNICOS and FESA frameworksP C
Successful integration of UNICOS and FESA frameworks
Industrial approach
CERN accelerator software model
Generation tools
Avoid synchronization tasks and concentrate on the specific control logic
Rapid prototyping & optimal regeneration mechanisms
Cryogenics control system fully commissioned (LHC Sector) [1/8 machine]
Highly distributed and radiation environment
Heterogeneous control equipments
Scalability and openness (LHC services)
Currently in production giving entire satisfaction to cryogenics and hardware commissioning operators
Enrique Blanco AB/CO IS

13. World's largest superconducting installation cooled by helium !
C | F
AB Controls Group (Industrial Systems Section)
UNICOS
FESA
Cryogenics CERN
LHC commissioning
Thanks to all people involved in the project: CERN: AB/CO, AT/ACR