1. UNICOS: UNified Industrial COntrol System CPC (Continuous Process Control) Basic course SESSION 0: INTRODUCTION
UCPC 6 UNICOS-Continuous Process Control
CERN, UNICOS Team

2. Outline Objectives, Instructors, Contents and Material
CERN, March/2017
Objectives, Instructors, Contents and Material
Process Automation at CERN
Introduction to Process Control
Automation Architecture and Hardware
Session 0: Introduction

3. Objectives
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.
CERN, March/2017
Session 0: Introduction

4. Real Installation: QSDN
Cryogenics Surface Dewar Nitrogen 
CERN, March/2017
Session 0: Introduction

5. Prerequisites
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 languages, specially SFC (sequential function charts) and ST (structured text)
Programming PLCs
CERN, March/2017
Session 0: Introduction

6. Instructors
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
Marcin Bes (BE-ICS-PCS)
Course coordination:
William Booth (BE-ICS-PCS)
CERN, March/2017
Session 0: Introduction

7. Contents Day 1 From 09:00 to 12:00 SESSION 0: General Introduction  
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
CERN, March/2017
Session 0: Introduction

8. Contents Day 1 From 13:30 to 17:30 Day 2 From 9:00 to 12:00
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
CERN, March/2017
Session 0: Introduction

9. Contents
Day 2
From 13:30 to 17:30
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
CERN, March/2017
* Depending on schedule
Session 0: Introduction

10. Contents
Day 3
From 09:00 to 17:30
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
CERN, March/2017
Session 0: Introduction

11. Contents
Day 4
From 09:00 to 16:00
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
CERN, March/2017
Session 0: Introduction

12. Contents Day 4 From 16:00 to 17:00 CLOSING SESSION: Q & A
CLOSING SESSION: Q & A
CERN, March/2017
Session 0: Introduction

13. Material 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…)
CERN, March/2017
Instructor
Students 2 3 9 … 4 1 1 2 3 4 5 6
Session 0: Introduction

14. Outline Objectives, Instructors, Contents and Material
CERN, March/2017
Objectives, Instructors, Contents and Material
Process Automation at CERN
Introduction to Process Control
Automation Architecture and Hardware
Session 0: Introduction

15. CERN structure in a few words…
Partial view of the 2016 structure
CERN, March/2017
Sectors
Accelerator & technology
Beams
Engineering
Technology
Directorate Office
Research & Computing
Exp. physics
Theoretical physics
Information Technology
Projects
Scientific Information Service
Finance & HR
Finance & Administration
Industry, Procurement & KT
Human Resources
Site Management and Buildings
International Relations
Session 0: Introduction

16. Controls @ CERN BEAMS Department Structure 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
CERN, March/2017
BEAMS Department Structure
Session 0: Introduction

17. Industrial Controls & Safety Systems
BE-ICS group
Industrial Controls & Safety Systems Structure
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
Session 0: Introduction
CERN, March/2017

18. Our AUTOMATION Solution
CERN
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
CERN, March/2017
PLCs
Industrial
Communications
SCADA
Our AUTOMATION Solution
Information
Technology
Advanced
Control
Regulation
Session 0: Introduction

19. Automation General Architecture
process control strategy: P&ID.
electrical and cabling of instrument and control systems
Instrumentation
Control logic (PLCs)
Supervisory systems (SCADA)
commissioning, start-up, operation and support
plant optimization
Communications Network
Industrial Fieldbus
SUPERVISION
CONTROL
FIELD
CERN, March/2017
Session 0: Introduction

20. Outline Objectives, Instructors, Contents and Material
CERN, March/2017
Objectives, Instructors, Contents and Material
Process Automation at CERN
Introduction to Process Control
Automation Architecture and Hardware
Session 0: Introduction

21. Process
CERN, March/2017
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.
Session 0: Introduction

22. process control
CERN, March/2017
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
Session 0: Introduction

23. Process classification
CERN, March/2017
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. It is an on/off or start/stop process. Discrete processes can be found in many manufacturing, motion and packaging applications.
e.g. fitting rear mirrors in a car by robots
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.
e.g. maintaining the temperature in a room.
Batch process
Characterized by a prescribed processing of materials for a finite duration (step wise fashion)
e.g. food production
Session 0: Introduction

24. Instrumentation
CERN, March/2017
Three tasks are involved: measurement, comparison, adjustment
Measurements
Flow
Level
Pressure
Temperature
Comparison
Open loop
Close loop
Actuation
Valves
Heaters
Motors,...
Session 0: Introduction

25. Designing Process Control systems
CERN, March/2017
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.
Session 0: Introduction

26. Some process Examples Cooling Cryogenics VAC CERN, March/2017
Session 0: Introduction

27. Outline Objectives, Instructors, Contents and Material
CERN, March/2017
Objectives, Instructors, Contents and Material
Process Automation at CERN
Introduction to Process Control
Automation Architecture and Hardware
Session 0: Introduction

28. Architecture Ethernet Corporate Ethernet Technical Fieldbus O C O P C
WTS P C
CERN, March/2017
Ethernet Corporate P C
Enterprise computers
Ethernet Technical
WTS O
CERN Control Room(s)
OWS
EWS C O
Local OWS
Touch panel
SCADA Server(s) C P O
Operator
Control
Process
PLC(s)
Fieldbus
I&O and devices
Session 0: Introduction

29. UNICOS Hardware Components
CERN, March/2017
Supervision Layer
WinCC OA SCADA
*Labview (for labo-sized projects)
Control Layer
Siemens S7-300, S7-400, S7-1500
Schnedier Premium, Quantum, M340, M580
Codesys (Somachine, TwinCat3)
Local operation
Simatic HMI (WinCC flexible, TIA portal)
Schneider Magelis
Industrial communications
Profibus, Profinet, Ethernet/IP
Modbus TCP
* In preparation
Session 0: Introduction

30. Questions (Introduction)
CERN, March/2017
Session 0: Introduction