JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez1 A Project for the GAS control System At NA60

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez2 One requirement. Rebuild the NA60 gas control 3 Opportunities: 1.Use industrial products Access to all components via electrical signals 24 V digital Profibus Schneider Premium PLC 2.Follow a standardized design Check the validity of the URD defined by the LHC gas control group 3. Implement an automatic control process Evaluate the UNICOS approach applied to the Gas controls.

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez3 NA60 Gas System

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez4 Several Electro-valves piloted via 24 Volt signals Some interlock signals 4 Mass Flow Controllers (0-10V analog signals) Gas Flow Regulators with their own PID control loop  Setpoint gas flow  Read the gas fow Nothing new about those products 32 Low cost Gas Flowmeter (pt100 principle) System based on an intelligent Profibus slave unit Complete new prototype Industrial Products

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez5 In 1995 a Working group was set up for the requirement of the LHC detectors for the gas systems. The aim is to develop scalable standard designs. The control of the NA60 is built around a subset of the URD specification of the LHC GCS  For the MIXER  For the DISTRIBUTION This did not put too severe constraints Use a standardized design

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez6 The idea to use the UNICOS came from an encounter at ICALEPS 1999 UNified Industrial COntrol System It is an implementation approach of industrial control products Based on the expertise gained by LHC groups LHC IAS/ACR/ECR This concept will be used for the control of LHC Cryogenics systems (4.5K and 1.8K ) ATLAS cryogenic part of the detector CMS cryogenic part of the detector Implement an industry-like process control

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez7 UNICOS is based on modular “Objects” The UNICOS Architecture define everything The structure of the program in the PLC unit The communication mechanism The data base The HMI (scada) implementation. Implicitly: UNICOS defines your hardware Architecture (the modularity of your project)

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez8 Db Scada Data server PLC I/o channels PLC plc I/o channels Control layer Field layer Summary

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez9 The integration of a complete UNICOS framework was not possible. UNICOS implementation just released (april 2001) UNICOS based on Quantum PLC Too expensive for a project like NA60 Manpower resources limited. Our goal was to get expertise with UNICOS and to analyze mainly the “control and the field layers” For that we made several choices …

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez10 We have merged the control layer and the field layer In a single Premium PLC. Premium and Quantum use the same language. Some worries about the different architecture. CPU power capacity similar Memory capacity of the Premium extendable PLC I/o channels plc I/o channels Control layer Field layer Control and Field layers

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez11 PLC Device Manual Requests Operator via SCADA Auto. Requests Control Logic Parameters Programmer via Engineering WS Status Information to other devices or to operator via SCADA Process Inputs Process variables or device status Process output or Devices Auto Requests Orders General interface for UNICOS library objects From Ph. GAYET – LHC/IAS

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez12 UNICOS implementation in NA60 gas control layer (1/2) Example of the MIXER Ar Flow reading Input object Mixer Process Control object PLC cycle iC4H10 Flow reading Input object Freon Flow reading Input object alcohol Flow reading Input object Ar Flow sp. Analog object iC4H10 Flow sp. Analog object Freon Flow sp. Analog object alcohol Flow sp. Analog object Ar valve cmd. On/off object iC4H10 valve cmd. On/off object Freon valve cmd. Analog object alcohol valve cmd. On/off object Ar Flow sp. Output object Ar valve cmd. Output object iC4H10 Flow sp. Output object iC4H10 valve cmd. Output object Freon Flow sp. Output object Freon valve cmd. Output object alcohol Flow sp. Output object alcohol valve cmd. Output object

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez13 UNICOS implementation in NA60 gas control layer (2/2) memory assignment and data access Both PLC and Data server (OPC server) can be configured through memory mapping: Object interface definition (1 Excel sheet/object class) Object declaration (1 Excel sheet) VB memory mapping app. Check consistency Assign memory cells Parameters PLC programming environmentData server configurator

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez14 The NA60 Gas Control layer contains about 80 objects. We decided to limit the amount of object data defined when configuring the server and to use a special access protocol: The user asks the PLC to send data concerning a selected object The PLC fills a buffer with the data of the selected object The buffer is read in by the SCADA according to the type of the selected object Access to object input/output parameters

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez15 Communication protocol of UNICOS is based on a customized PLC-data server event-based protocol The communication mechanism between SCADA and PLC was replaced by the following: Data server is an OPC server Data from PLC polled by OPC server through Modbus TCP protocol Db SCADA PLC DataBase

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez16 Scada Currently, the scada design for the UNICOS architecture as provided by LHC-IAS is based on Arc-Informatic/Pcvue32 We did not use this product. The use of this scada implementation requires the database. The implementation under PVSS was a task too complex The knowledge of PVSS was limited. Scada

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez17 It was decided: To use BridgeView (Lv 6i) to test the PLC development in the laboratory. To give to NA60 the development with PVSS of the operator console needed during the RUN. The goal was “if possible” to develop the expert console under the PVSS scada.

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez18 At the end: The use of BView was simple The array implementation of all variables in the PLC did provide a simple way to manage all objects.  We have a full control of all “object” input/output parameters. The development of the expert console was done in BView.  One prototype done by IT/CO  The final one done by the GAS team. The operator console is available with BView and a subset is integrated in the NA60-PVSS scada.

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JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez22 Web access of the operator console click hereclick here

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez23 Web Access of the Operator Console Click HereClick Here

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez24 NA60 PVSS setup

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez25 Muon spectrometer panel

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez26 Chamber 1 gas flow

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez27 March Study of UNICOS. Study of the Mixer April Porting of UNICOS into Premium Study and implementation of the distributor, May Porting of UNICOS into Premium Development of the uPLC access Development of the Bview panel for all Object. June Implementation of the distributor. Debugging in the lab Development of the expert panel and others. July Firsts Week integration and final test. Mid July, the GAS system was operational. Timescale.

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez28 Goals achievement: 1.Use industrial products Done. Also for the microPLC – FLOWMETER. 2.Use a standardized design The validity of the GWG -URD has been shown Its modularity is suitable with UNICOS Improvement of the URD. 3. Implement an automatic control process The UNICOS approach applied to the Gas Controls is possible.

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez29 Once they work, Industrial products are very stable. UNICOS approach is a complete solution for a large project (“clef en main”). Control layer and Field layer of Unicos are well designed and they are a solid base for every PLC development. Small projects should use these layers concepts even if they do not exploit all resources (like for NA60).  Finalize a Premium library of objects.  Create a Siemens library of objects.  Advantage : similar code in all systems What we learned:

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez30 Perspectives Unicos stable release in use in SM18 Unicos and PVSS –Unicos JCOP Graphical objects Communication Schneider Unity Same development environment for Quantum and Premium

JCOP - 17 October 2001NA60_GAZ - E. Mazel J. Rochez31 This is the end