Enrique Blanco, CERN

Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department

IINDUSTRIALNDUSTRIAL CCONTROLONTROL EENGINEERINGNGINEERINGCERNCERN

EELECTRICALLECTRICAL EENGINEERINGNGINEERING EEVENTVENT

MMEETEET THETHE BUYERBUYER

LLONDONONDON, 27, 27‐‐SSEPEP‐‐20112011

London, 27 September, 2011 Enrique Blanco

on behalf of the CERN EN/ICE group


OUTLINE

Process Automation at CERN

27/09/2011

Some reference projects

CERN Standards: UNICOS

Opportunities to work with CERN

Enrique Blanco, CERN EN/ICE 2

Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering DepartmentCERN STRUCTURE IN A FEW

WORDS…27/09/2011



AUTOMATION@ CERN: ENGINEERING DEPARTMENT

The Industrial Control Engineering Group in the Engineering Department PLC

27/09/20Engineering Department develops solutions and provides support in the domain of large and medium scale industrial

l ll

PLCs

Industrial SCADA

011

control systems as well as laboratory control systems and promotes their use.

IndustrialCommunications SCADA

Our AUTOMATION

Mandate key points:‐ Identifying commercial solutions‐Adopted solutions support D i & D l i h

AdvancedControlInformation

AUTOMATION Solution

‐Design & Develop in‐house frameworks and components‐Design, implement and support control systems.

ControlTechnology

Regulationy



AUTOMATIONGENERALARCHITECTURE

SUPERVISIONSUPERVISION

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Communications Network

CONTROLCONTROL

011

1 process control strategy: P&ID

Industrial Fieldbus

FIELDFIELD

1. process control strategy: P&ID.2. electrical and cabling of instrument and control systems3. Instrumentation 4. Control logic (PLCs)5. Supervisory systems (SCADA)6. commissioning, start‐up, operation and supportg p p pp7. plant optimization



OUTLINE


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LHC CRYOGENICS

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18 kW @ 4.5 Refrigerators LHC Superconducting magnetsStorageCompressor station



LHC CRYOGENICS CONTROL

‐ 27 km of decentralized instrumentation and control‐50.000 I/O, 11.000 actuators, ~100 PLCs, ~40 FECs‐26 SCADA servers : ½ million Tags

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WinCCOA HMI in the CCC

Tunnel Instrumentation

g 011

WinCCOA HMI in the CCC

electro‐pneumatic positioner, SIPART PS2



DETECTOR SAFETY SYSTEM

The DSS saves from harm a Particle Detector by executing protective actions in response to th d t ti f d fi d

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the detection of user‐defined Alarm Conditions.

S A t t Al

011

Sensors, Actuators or Alarm Conditions can be added or re‐parameterized at any time by the User without stopping the the User, without stopping the system



OTHER PROJECTS …

l

Homogenized solutions based on an CERN de facto standard (UNICOS)

‐Cryogenics Instrumentation Expert Tool‐ 9 SCADA Data servers with more than 1 million Tags, 12 GB archived data

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‐ Low‐beta LHC magnet Alignment

‐ ISOLDE Vacuum controls‐ Discrete process application‐WinCCOA + S7‐300 PLCs

SPS Power converters controls

‐ WinCCOA + Industrial PCs

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Low beta LHC magnet Alignment‐GEODE Data Base integration‐WinCCOA + Industrial PCs

‐ SPS Power converters controls‐Re‐engineering based on UNICOS‐WinCCOA+ S7‐300 PLCs

‐ LHC collimatorsLHC collimators‐ LHC Interlock system‐WinCCOA + S7‐300 PLCs

SURVEY ISOLDE VACUUMCISCollimatorsCIET



OUTLINE


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UNICOS FRAMEWORK

• [1998] UNICOS (UNified Industrial Control System) was born at CERN as a need to develop the LHC cryogenics control system. The goalwas to create an industrial control system covering the three layers of the typical automation

27/09/20y g y yppyramid.

011

• [2002] UNICOS replace the PcVue SCADA and adopt ETM’s PVSS under the CERN recommendation (nowadays called “WinCCOA” by SIEMENS). • [2004] UNICOS offered the choice of creating applications based on SIEMENS S7 PLCs S7 PLCs • [2009]UNICOS turned into de facto standard framework to develop industrial control applications at CERN:

Cryogenics, Cooling, HVAC, Vacuum, Interlocks,…

• [2010]The UNICOS framework has been extended to other kinds of applications (i.e.: supervisory, monitoring, …)



UNICOS BASICS I

UNICOS establishes:

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A well defined set of standard objects (devices), both in the control and supervision layers, modeling most of the equipment and needs of continuous processes

The relationships between them

A formalized way of :Define the process units of a process (ISA‐88 standard: Batch

)processes)

Programming the specific process logic for those units



UNICOS BASICS II Not only a bunch of devices!

DEVELOPMENT: Provides the developer with tools to produce rapid control

27/09/2011p p papplications . Automatic generation of code

COMMISSIONING: Allows early plant commissioning, reducing check tasks to the instruments and electrical level (cabling). Access to devices without SCADA d ldevelopment.

OPERATION: Provides the operator a way to interact all the objects (as long as their privileges allow it access control)allow it: access control)

Navigation capabilities between panels and trends: WWW browser‐like, contextual buttons, pop‐up navigation

Process Alarm and Event list Process Alarm and Event list MAINTENACE: Allows optimized code evolution and maintenance by a reduced

development team DIAGNOSTICS: Tools to diagnose problems (process alarms, Infrastructure: DIAGNOSTICS: Tools to diagnose problems (process alarms, Infrastructure:

control components,…)



PROCESS VS. CONTROL ARCHITECTUREOperation

Point 4 Cryogenic System PCO

Standard

Operation in multiple scenarios

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LHC 1.8KCryoplants

PCOAutomatic

Generation of the PCO objects (From FI

S ifi ti )

Standard Unicos

Programming and Process

Logic

Generation of

the

objects and I/O

Devices

Field DevicesI/O

Boards‐Fieldbus‐Other

PLCs

AI

AO

DI

DO

Analog

InputAnalog

Output

Digital

InputDigital O

utputobjects and connections betw

een objects

(From

I/O

& FI

Specifications)I/O

Boards‐Fieldbus‐Other

PLCs

Specifications)E

nrique Blanco, C

ER

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N/IC

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UNICOS: USER INTERFACE

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UNICOS METHODOLOGY

Specifications creationI d d b filli EXCEL (XML) k h

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Instances: data captured by filling EXCEL (XML) worksheets Eventually these specifications may be created also automatically (e.g. DB oriented)

Functional Analysis + Logic specification: Word templates

A i i (UAB UNICOS A li i B ild ) Automatic generation (UAB: UNICOS Application Builder) Instance generator Standard Logic generation

M l i i Manual intervention Process logic coded by the control engineer in an standardized way. Some

applications may create automatically the logic based on templates. Process synoptics: drag & drop

Support Documentation Tutorials



UNICOS SPECIFICATIONS

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UNICOS CPC Specs



UNICOS MANUAL PROCEDURES

The goal is to reduce the human intervention: Process logic can be either:

d d b h l i i d d

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coded by the control engineer in an standard way. Some applications may create automatically the logic based on

templates. HMI P i d & d f UNICOS CPC HMI Process synoptics: drag & drop from a UNICOS-CPC catalog

Synoptics design

Logic Placeholders



OUTLINE


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OPPORTUNITIES TO WORK WITH CERN

Cooling & Ventilation Process Automation Following our CERN standards: UNICOS

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Following our CERN standards: UNICOS

P4 Cooling towers STP18 Cooling towersEnrique Blanco, CERN EN/ICE 23


OPPORTUNITIES TO WORK WITH CERN

Projects maintenance Identify and/or improve specialized tools to get

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Identify and/or improve specialized tools to get better diagnostics of specific components of the control system (e.g. industrial fieldbuses, plant-wide engineering) and allow us to reduce the downtimeengineering) and allow us to reduce the downtime.

Perform the preventive and corrective maintenance as well as upgrades or our installations.

Project Engineering and quality assurance Automatic testing procedures to validate our g p

frameworks code Project Engineering integration mechanisms and

tools tools



OPPORTUNITIES TO WORK WITH CERN Other possibilities in different fields

Access Control Handling

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Handling Monitoring systems Real-Time Communications …



OPPORTUNITIES TO WORK WITH CERN27/09/2011

Outsourcing YES !!!

but

under CERN Standards.


Enrique Blanco, CERN

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