AB-CO review Support for Cryogenics

Philippe Gayet AB/CO IS CERN, 20/09/05 Outline Scope Hardware Type, Responsibility sharing, Status Basic software Issues UNICOS Framework status ACR HW and SW production answers On site commissioning Support Software Quality Answers for PVSS Conclusion

Philippe Gayet AB/CO IS CERN, 20/09/05 Scope of Support for Unicos team AT-ACR for accelerator cryogenics AT-ECR for experimental cryogenics PH-TA3 for magnets Not in scope of this talk but done by the same team AT-VAC for PVSS AT-ACR for cryo expert application(Enrique’s Talk) PIC for PVSS QPS (Herve’s talk)

Philippe Gayet AB/CO IS CERN, 20/09/05 Hardware for ACR Quantum Premium AB-CO AT-ACR EthernetIT-CS Telefast Digital Phoenix Analog PMA Modbus DP PA PAPA PAPA PLC Safety BUS X AT-ACR Gateway WFIP Gateway Siemens ET 200 Boards WFIP Networks WFIP agents Central Data server Central & local control room Operator consoles

Philippe Gayet AB/CO IS CERN, 20/09/05 Hardware Resp. sharing With ACR ProcurementInstallation SCADAAB/CO QUANTUM/PremiumAB/CO FIP GatewayAB/CO S7 GatewayAB/CO Profibus from protected areas to S7 GatewaysAB/CO S7 Profibus RIO in protected areasAB/COAT/ACR S7 RIO QRL specificAT/ACR Fieldbus couplers (optical, DP/PA, etc…)AB/COAB/CO & AT/ACR Intelligent Valve ActuatorsAT/ACR Local Profibus NetworkAT/ACR FIP networkAB/CO LHC RadTol tunnel RIO (FIP Agent)AT/ACR

Philippe Gayet AB/CO IS CERN, 20/09/05 Quantum PCU EWS Hadware for PH-TA3 & ECR Quantum RIO Field interface Schneider Proprietary bus Local Control room Central control room OWS Profibus network Central Data server UNITY PCU Premium Field interface Profibus network AB-CO

Philippe Gayet AB/CO IS CERN, 20/09/05 Hardware Resp. sharing ECR/PH-TA3 ProcurementInstallation SCADAAB/CO PLCAB/COAT/ECR Fieldbus couplers (optical, DP/PA, etc…)AB/COAT/ECR Intelligent Valve ActuatorsAT/ECR Local Profibus NetworkAT/ECR

Philippe Gayet AB/CO IS CERN, 20/09/05 HW Status & Maintenance HP Proliant for Scada ( ) Schneider PLC ( ) Profibus components (waiting for profibus card for Quantum for ECR) We have to Buy & Install Siemens Gateway (24) (P8 OK) All equipements for ACR are or will be referenced in : ABCAM for asset management LHC Layout db for intervention Same service can be extended to ECR, Ph-Ta3 AB-CO will monitor the HW evolution and propose preventive maintenance AB-CO will provide a central spare parts repository Servers will be in CCC with the same service as the other critical server for LHC Operation On site intervention will have to be organized by AB-CO

Philippe Gayet AB/CO IS CERN, 20/09/05 Basic software Issues Migration from XP OWS/DS to Proliant Linux DS with UNICOS/PVSS V3 Servers configuration & monitoring (IN) Use of Proliant Linux servers instead of present Windows gives to CO an additional workload (application configuration)  Migration Of Schneider PLC to UNITY OS Done for FI and small PCU Still some Pb with large PCU Availability of reliable Online programming capacity on Unity Quantum  New release of Schneider development tool   New version of object (20% of memory liberated) ongoing validation  Problem is one of the Schneider priority Consolidation of PLC communication  CERN Application  Firmware PB contact with Schneider on hardware bug correction no result yet 

Philippe Gayet AB/CO IS CERN, 20/09/05 UNICOS Framework status New framework UNICOS/PVSS V3 deployed Faster, interface to Timber, LASER, DIP(GTPM) Communication Schneider/Siemens Migration Of Schneider PLC to UNITY OS Existing methodology and at least 3 systems ready (1 ECR, 2 ACR) Tools for software production Thermometers calibration in Siemens Schneider DB & Field Object part (Concept, UNITY, PVSS) Schneider logic for sectors Concept, Unity to be tested Siemens DB & logic ready for first prototype

Philippe Gayet AB/CO IS CERN, 20/09/05 ACR HW and SW production answers First time (new controls): All tunnel cryogenic system (ACR/IN with AB/CO support) – If only support needed if more  SM 18 cryo infra and 6 kW Linde ABB -> UNICOS - 1st semester 07 NOT in present roadmap nor in budget  Ex-LEP refrigerator upgrade to UNICOS (pt. 4 and 6) – early 06 limited AB-CO resources available to establish specification as usual  Resources OK for programming Already performed in other LHC points (duplication): Precoolers and upgrade (all pts) – 1st semester 06 QUI Pt.1.8 and 6 but need upgrade for all - 1st semester 06 QURC Pt. 1.8, 6 – end 05 Pt kW refr. ABB -> UNICOS – SD Dryers pt 2, 4, 6, 8 - end 2005 – beginning 06 OK program ready

Philippe Gayet AB/CO IS CERN, 20/09/05 AB-CO-IS AT-ACR Application status LN Sector 1-2Sector 2-3Sector 3-4Sector 4-5Sector 5-6Sector 6-7Sector 7-8Sector 8-1 QSRB QURA QUI Point 4 Point 2Point 1.8Point 6Point 8 Surface (buildings+areas) Cavern QURC QSC QSRA QUI QURC QUI Shaft QRL Tunnel HP storage LN 2 2 HP storage HP storage HP storage HP storage QSCB Central HP storage QSC QSCC QURA QSCA QSCC QSRB QSRA QSCCQSCA QSCB QSC QSCC QSC QSCAQSCC QSC QSCCQSCB QSC QSCCQSCAQSCB QSC QSCC To Copy from existing version in Unity V2 To port from concept to Unity V2 PVSS To be specified by ACR & Developed by CO To be Developed & Deployed by ACR/IN Ready in Unity V2 PVSS, upgrade on request of ACR

Philippe Gayet AB/CO IS CERN, 20/09/05 On site commissioning Support Commissioning of individual sub-systems Tunnel cryogenics, ex-LEP refrigerators, QUI, QURC’s, dryers, pre-coolers, SM18 infra and refr. All on critical path for hardware commissioning, Requires presence of AB-CO software specialist at start-up (no on-call support) to shorten, optimize and make safe and reliable tests (first few days only are sufficient) Global system commissioning, upgrades and consolidations Participation of AB-CO to the commissioning activities to optimize collective behavior of sub- systems and optimize general process during the tests at least during first sectors and systems testing. Cryogenics and HC will work on 2x8 shift; any stop will disrupt the HC planning and hold up to 10 persons / day -> it requires fast troubleshooting -> on-call service 24h/24h 3rd operation and consolidation Availability of AB-CO specialist for controls improvement and upgrade during the first years of operation 24 h/ 24h on-call support for installation in operation (ABB installations prior to transfer to UNICOS ?) Resources: No sufficient support from AB-CO to cover the commissioning of more than 1 – 2 subsystems at the time-> 4 sector in parallel -> forget! No on-call support during non-working hours for urgent troubleshootingof controls Mainly “call centre” type technical support (we need AB-CO support in the control room during machines start-up) to improve efficiency, share of responsibility and achievements, better understanding of problems, team work ! 3 Staff PLC +2 staff SCADA + (1 contract staff) available part time for this support 

Philippe Gayet AB/CO IS CERN, 20/09/05 Software Quality SW verification prior to cooldown to minimize on-line modifications during runs No Pb if specification delivered on due time (3 months prior to delivery)  Maintain and ensure SW modification consistency and up- to-date version, QA and logging of SW modifications QA for specification required from ACR side QA is not always compatible with the present way of Cryo system commissioning but an effort is done on our side on the subject. Ensure control system improvement and modification are correctly tracked and updated in default SW version. A central software repository is used with manual tracking we will use CVS for versioning as fast as possible The encountered problems were mainly due to the different upgrade of PLC platform

Philippe Gayet AB/CO IS CERN, 20/09/05 Answers for PVSS Support for GTPM applications necessary for fast restart after major stop Interface ready exchanged information to be define by ACR Support for supervision screens and fixed displays production, maintenance and upgrade First production done in frame of software contract Evolution to be done by ACR operation team (no PVSS knowledge required) training done By AB-CO Slow response and “load” of the control system Mostly due due to low performance Operator consoles and PVSS 2.12 (outdated now) Trends: still progress needs to be made Please elaborate you specs as it is a tools under IT-CO responsibility Data logging: data extraction without formatting and ready to analyse Already available in PVSS, & in Timber. Data logging: continuous change of naming in DB makes difficult the creation of automatic routines for data collection and analysis We are now migrating to production environment no change anymore unless you require them Diagnostics info: not always available or difficult to implement We are nom migrating to production environment PVSSIII: on-line modification not possible ????

Philippe Gayet AB/CO IS CERN, 20/09/05 Conclusion Hardware installation & support & maintenance OK ACR production application under way without major PB BUT Still some dark area of responsibility to clarify Support for ring software Synoptic maintenance Specification elaboration Long term Operation support (different level of responsibility within the same control system) Still some technical PB to address Online modifications Communication reliability Resources not compatible with ACR requests on commissioning support