1. Industrial Controls & Saffety Systems Beams Department CPC (C ONTINUOUS P ROCESS C ONTROL ) B ASIC COURSE SESSION 0 : INTRODUCTION UNICOS: UN IFIED I NDUSTRIAL CO NTROL S YSTEM CPC (C ONTINUOUS P ROCESS C ONTROL ) B ASIC COURSE SESSION 0 : INTRODUCTION CERN, UNICOS Team UCPC 6 UNICOS-Continuous Process Control

2. Industrial Controls & Saffety Systems Beams Department O UTLINE Objectives, Instructors, Contents and Material Process Automation at CERN Introduction to Process Control Automation Architecture and Hardware Session 0: Introduction CERN, March/2016 2

3. Industrial Controls & Saffety Systems Beams Department O BJECTIVES The course introduces the UNICOS-CPC framework and gives to the students the means of building industrial process control applications. It focuses on further hands-on examples of developing process control applications. Students will be better able to optimize the CERN standardization by means of deploying adapted standards and choosing the right best practices. With a real project scenario as a baseline, students will apply themselves all the introduced concepts during all the phases when developing a project. You will be able to: - Analyze an industrial process and design the more adapted control system. - Develop and implement process control applications based on the CERN UNICOS standard. - Help operation staff during their 24/7 needs by the preventive diagnostics of the controls infrastructure. Session 0: Introduction CERN, March/2016 3

4. Industrial Controls & Saffety Systems Beams Department R EAL I NSTALLATION : QSDN CERN, March/2016 4 Session 0: Introduction Cryogenics Surface Dewar Nitrogen

5. Industrial Controls & Saffety Systems Beams Department P REREQUISITES Desirable knowledge of P&IDs, E&ICs and automatic control Interpret flows and piping Understand electrical connections Basic regulatory control skills Basic knowledge of PLC and SCADA architecture Understand the PLC architecture (Siemens) Create and Configure SCADA projects (WinCC OA) Sound knowledge of programming in IEC-61131 languages, specially SFC (sequential function charts) and ST (structured text) Programming PLCs Session 0: Introduction CERN, March/2016 5

6. Industrial Controls & Saffety Systems Beams Department I NSTRUCTORS The course is divided in sessions each having different experts: Session 0: Introduction Enrique Blanco (BE/ICS PCS) Session 1: Project Specifications & Functional analysis Benjamin Bradu (BE/ICS PCS) Session 2: Deployment of the process control application Marc Quilichini (BE/ICS PCS) Session 3: Development of the process control application Jeronimo Ortola Vidal (BE/ICS PCS) Session 4: SCADA: Configuration, Operation and maintenance Alexey Merezhin (BE/ICS PCS) Session 0: Introduction CERN, March/2016 6

7. Industrial Controls & Saffety Systems Beams Department C ONTENTS SESSION 0 : General Introduction Introduction Course contents Process Control Automation Architecture & Hardware components UNICOS Basics CPC package: Devices : TCT Generation tools: UAB From Process to Operation using UNICOS-CPC Objects main functionalities UNICOS – CPC Procedure Support: UNICOS-CPC web page & CERN team Session 0: Introduction Day 1 From 09:00 to 12:00 CERN, March/2016 7

8. Industrial Controls & Saffety Systems Beams Department C ONTENTS SESSION 1 : Project Specifications & Functional Analysis Project specifications Hardware needs IO List (E&IC) P&ID Functional Analysis How to deal with the analysis Alarms & Interlocks Object dependencies Design phase CPC objects description PCOs functionalities Specs creation Session 0: Introduction Day 1 From 13:30 to 17:30 Day 2 From 9:00 to 12:00 CERN, March/2016 8

9. Industrial Controls & Saffety Systems Beams Department C ONTENTS SESSION 2: Deployment of the control application UAB Project creation Automatic Code Generation Instances generation (PLC, WinCC Flex, WinCC OA) Libraries: PLC architecture: baselines WinCC Flexible basics SCADA project structure: packages needed UCPC Project architecture: Siemens Create PLC + PVSS projects (also components) Import Instances for each component Components deployment PLC, SCADA (*and Local panels) deployment Session 0: Introduction Day 2 From 13:30 to 17:30 CERN, March/2016 9 * Depending on schedule

10. Industrial Controls & Saffety Systems Beams Department C ONTENTS SESSION 3 : Development of the control application Siemens PLC basics Step7 project: SCL & Graph UCPC in Siemens (architecture) UAB Logic generation Importation of logic Advanced programming: full automation Basic PLC code for logic Python scripting language in UNICOS Logic Templates Versioning PLC & SCADA versions tags SVN best practices Session 0: Introduction Day 3 From 09:00 to 17:30 CERN, March/2016 10

11. Industrial Controls & Saffety Systems Beams Department C ONTENTS SESSION 4: SCADA: Configuration, Operation and maintenance User interface creation: Panels SCADA features UI navigation and components Widgets Diagnostics: alarms, events, diagnostics, filtering Archiving User rights: Usage of Domains Remote UIs (OWS) Operation: UNICOS principles of operation OWS Diagnostics (TSPP communication) Online modifications Spare channels Session 0: Introduction Day 4 From 09:00 to 16:00 CERN, March/2016 11

12. Industrial Controls & Saffety Systems Beams Department C ONTENTS CLOSING SESSION : Q & A Session 0: Introduction Day 4 From 16:00 to 17:00 CERN, March/2016 12

13. Industrial Controls & Saffety Systems Beams Department M ATERIAL Classroom/Laboratory Exercises: The course consists of multiple application exercises of the whole life cycle of a process control application development (e.g. specs, functional analysis, diagnostics…) Session 0: Introduction CERN, March/2016 13 2 2 3 3 4 4 5 5 2 2 3 3 9 9 … 4 4 1 1 1 1 InstructorStudents

14. Industrial Controls & Saffety Systems Beams Department O UTLINE Objectives, Instructors, Contents and Material Process Automation at CERN Introduction to Process Control Automation Architecture and Hardware Session 0: Introduction CERN, March/2016 14

15. Industrial Controls & Saffety Systems Beams Department CERN STRUCTURE IN A FEW WORDS … CERN, March/2016 15 Session 0: Introduction Accelerator & technology Beams Engineering Technology Research & Computing Exp. physics Theoretical physics Information Technology Finance & HR Finance & Administration Industry, Procurement & KT Human Resources Site Management and Buildings International Relations Partial view of the 2016 structure

16. Industrial Controls & Saffety Systems Beams Department C ONTROLS @ CERN BEAMS Department ABP Accelerator and Beam Physics BI Beam Instrumentation OP Operation RF Radio Frequency CO Controls ICS Industrial Controls & Safety ASR Administration, Safety & Resources BEAMS Department Structure CERN, March/2016 Session 0: Introduction 16

17. Industrial Controls & Saffety Systems Beams Department BE-ICS GROUP Industrial Controls & Safety Systems AC Access Control CSE Critical systems Engineering FGA Fire, Gas & Alarms SDS SCADA & Distributed Systems PCS Process Control Systems CIC Connections & Informatics for control Industrial Controls & Safety Systems Structure CERN, March/2016 17 Session 0: Introduction

18. Industrial Controls & Saffety Systems Beams Department A UTOMATION @ CERN: E NGINEERING D EPARTMENT The Industrial Control & Safety Systems Group in the Beams Department develops solutions and provides support in the domain of large and medium scale industrial control system, fire&gas detection systems as well as the access control of the installations. Mandate key points: - Identifying commercial solutions -Design & Develop in-house frameworks and components -Outsource access control systems -Design, implement and support control systems. - Adopted solutions support PLCs Industrial Communications Advanced Control SCADA Information Technology Regulation Our AUTOMATION Solution Session 0: Introduction CERN, March/2016 18

19. Industrial Controls & Saffety Systems Beams Department A UTOMATION G ENERAL A RCHITECTURE 1. process control strategy: P&ID. 2. electrical and cabling of instrument and control systems 3. Instrumentation 4. Control logic (PLCs) 5. Supervisory systems (SCADA) 6. commissioning, start-up, operation and support 7. plant optimization Communications Network Industrial FieldbusSUPERVISIONCONTROL FIELD Session 0: Introduction CERN, March/2016 19

20. Industrial Controls & Saffety Systems Beams Department O UTLINE Objectives, Instructors, Contents and Material Process Automation at CERN Introduction to Process Control Automation Architecture and Hardware Session 0: Introduction CERN, March/2016 20

21. Industrial Controls & Saffety Systems Beams Department P ROCESS Process, as used in the terms process control and process industry, refers to the methods of changing or refining raw materials to create end products. Process industries include the chemical industry, the oil and gas industry, the food and beverage industry, the pharmaceutical industry, the water treatment industry, and the power industry. CERN, March/2016 21 Session 0: Introduction

22. Industrial Controls & Saffety Systems Beams Department PROCESS CONTROL Process control refers to the methods that are used to control process variables when manufacturing a product. Manufacturers control the production process for several reasons: Reduce variability: increase quality Increase efficiency: increase profits Ensure safety: optimize conditions CERN, March/2016 22 Session 0: Introduction

23. Industrial Controls & Saffety Systems Beams Department P ROCESS CLASSIFICATION Discrete process Handles distinct, separate products. In a discrete industrial process, both inputs and outputs must be discrete data flows and/or discrete data stores. Discrete processes can be found in many manufacturing, motion and packaging applications. Continuous process Characterized by smooth and uninterrupted variables in time, and are defined as continuous processes. In a continuous process control system, the variables associated with any process are monitored and subsequent control actions are implemented to maintain variables within predetermined process constraints. Batch process Characterized by a prescribed processing of materials for a finite duration CERN, March/2016 23 Session 0: Introduction

24. Industrial Controls & Saffety Systems Beams Department I NSTRUMENTATION Three tasks are needed: Measurement, Comparison, Adjustment Measurements Flow Level Pressure Temperature Comparison Open loop Close loop Actuation Valves Heaters Motors,... CERN, March/2016 24 Session 0: Introduction

25. Industrial Controls & Saffety Systems Beams Department D ESIGNING P ROCESS C ONTROL SYSTEMS Understand the process Identify the operating parameters Identify the measurable(s) Identify the points of measurements and actuation Select measurement methods Select control method Select control system (redundancy, fail safe,…) Design and develop the control logic Integrate and test Some of these tasks require a close collaboration with Process Engineers. CERN, March/2016 25 Session 0: Introduction

26. Industrial Controls & Saffety Systems Beams Department S OME PROCESS E XAMPLES Cooling Cryogenics VAC CERN, March/2016 26 Session 0: Introduction

27. Industrial Controls & Saffety Systems Beams Department O UTLINE Objectives, Instructors, Contents and Material Process Automation at CERN Introduction to Process Control Automation Architecture and Hardware Session 0: Introduction CERN, March/2016 27

28. Industrial Controls & Saffety Systems Beams Department A RCHITECTURE CERN, March/2016 28 Session 0: Introduction PLC(s) Fieldbus I&O and devices O Local OWS Touch panel Ethernet Corporate P C Enterprise computers WTS P C SCADA Server (s) Ethernet Technical WTS O CERN Control Room(s) OWS EWS C C P O Operator Control Process

29. Industrial Controls & Saffety Systems Beams Department H ARDWARE C OMPONENTS Supervision Layer WinCC OA SCADA *Labview (for labo-sized projects) Control Layer Siemens S7-300, S7-400, *S7-1x00 Schnedier Premium, Quantum Codesys (Somachine, TwinCat3) Local operation Simatic HMI (WinCC flexible, TIA portal) Schneider Magelis Industrial communications Profibus, Profinet, Ethernet/IP Modbus TCP * In preparation CERN, March/2016 29 Session 0: Introduction

30. Industrial Controls & Saffety Systems Beams Department Q UESTIONS (I NTRODUCTION ) 30 Session 0: Introduction CERN, March/2016