1. MAUVE CO2 cooling review - 2017
MAUVE control system
L. Zwalinski, L. Davoine – CERN EP/DT/FS
November 1st, 2017
European Organization for Nuclear Research (CERN), CH-1211 Geneva 23, Switzerland
MAUVE CO2 cooling review

2. Control system architecture
Data Server ready in CCC
cs-ccr-dclhcb
4 cabinets Architecture:
3 cabinets: 1800x1200x400
1 cabinet: 1800x600x500
MAUVE CO2 cooling review

3. DIP communication with DCS
Released the CPC-COMM Wizard with RP and WinCC OA CPC Component by BE-ICS supporting:
Additional protocols: SNMP and DIP (in addition to existing BACnet, OPC UA, CMW, S7 polling and Modbus polling).
Alarms on WordStatus and AnalogStatus objects.
Value (message) conversion for AnalogInput and AnalogStatus objects.
We can subscribe to DIP in UNICOS cooling application to display and archive detector temperatures in one common SCADA system. New tool creates data points in our SCADA application. PLC does not see this values. It can be used for monitoring and manual operation purposes.
Further development has been requested by EP-DT to BE-ICS to allow for bridge DIP values received from DCS to cooling PLC.
MAUVE CO2 cooling review

4. Control cabinets design
Master - cabinet 1
UT - cabinet 2
Velo - cabinet 3
VFD - cabinet 4
Master control
CO2 plant + backup chiller
CO2 plant + backup chiller
2x CO2 pumps
Each cabinet will be equipped with its own local EMS button.
MAUVE CO2 cooling review

5. Control cabinets design
Master - cabinet 1
UT - cabinet 2
Velo - cabinet 3
Power distribution and redundant hot swappable 24V DC PS
PLC and distributed I/Os
Power handling
(heaters, compressor, etc.)
Signal handling and analog valve drivers equipped with battery pack for safety position
FESTO pneumatics distribution and valve islands
MAUVE CO2 cooling review

6. Control cabinet design Power Distribution
Discussed & agreed 6 months ago
To be validated by EN/EL
EBD
EXD
General Power
Experiment Power
ESD
Backup by a Diesel if EBD lost
Transfer switch Automatic
UPS
Master - cabinet 1
UT - cabinet 2
Velo - cabinet 3
VFD - Cabinet 4
MAUVE CO2 cooling review

7. MAUVE CO2 cooling review - 2017
Electrical design
AutoCAD electrical design is on going. It is very much advanced. So far we have 57 pages for VELO & UT control/electrical cabinet.
MAUVE CO2 cooling review

8. MAUVE CO2 cooling review - 2017
Cable schedules
Cable schedules both for internal plant cabling and JB & DB are ready with internal naming convention.
The LHCb cable DB scheme is under preparation. We have well received template from Laurent.
MAUVE CO2 cooling review

9. Process break-down and operation modes
Control software follows CERN UNICOS CPC6 framework standard as all the other CO2 cooling systems at CERN.
Operation
System has been demanded to run in nominal conditions = operation option mode:
UT system is demanded to start in Operation Option Mode
Velo system is demanded to start in Operation Option Mode
Interconnection valves stay close
UT active, Velo passive
System has been demanded to run in back-up scenario with UT plant providing CO2 for both detectors:
UT system is demanded to start in Active Option Mode
Velo system is demanded to start in Passive Option Mode
Interconnection valves will open
UT passive, Velo active
System has been demanded to run in back-up scenario with Velo plant providing CO2 for both detectors:
UT system is demanded to start in Passive Option Mode
Velo system is demanded to start in Active Option Mode
MAUVE CO2 cooling review

10. MAUVE CO2 cooling review - 2017
Normal Operation
MAUVE CO2 cooling review

11. MAUVE CO2 cooling review - 2017
UT Active, Velo Passive
MAUVE CO2 cooling review

12. Normal Operation with Backup Chiller requested
If primary chiller DI is OFF (positive logic) then backup chiller will be ON.
DSS signal to be discussed with Olivier when BackUp Chiller is ON.
MAUVE CO2 cooling review

13. Allowance table for CO2 PCO
The CO2 system can change it’s operation mode only when system is stopped.
In case of need to operate in active/passive scheme system shall be stopped and restarted in desired option mode.
Option Mode
Operation
UT act Velo pas
UT pas Velo act x
MAUVE CO2 cooling review

14. MAUVE CO2 cooling review - 2017
User Interface panels
Work on interface panels has started
MAUVE CO2 cooling review

15. MAUVE CO2 cooling review - 2017
Alarms philosophy
Damper electrical heater:
Alarm level I – Temporary Stop Interlock - heater interlocked if T > 120 °C, restarted when T < 120 °C
Alarm level II – Full Stop Interlock - heater interlocked if T > 140 °C, waiting for acknowledge * & T < 120 °C
Alarm level III – Hardware Interlock (thermal switch) – all heaters interlocked (mechanically), waiting for acknowledge * & T < 120 °C & thermal switch OK
Alarm levels:
Alarm level I Warning Group
Alarm level II Full Stop Group
Membrane CO2 liquid pump:
Alarm level I – Temporary Stop Interlock - pump interlocked if membrane P > 5.0 bar, restarted when P < 5 bar
Alarm level II – Full Stop Interlock – pump interlocked if membrane P > 10 bar, waiting for acknowledge* & P < 5 bar
MAUVE CO2 cooling review

16. MAUVE CO2 cooling review - 2017
Alarms philosophy
UT Alarm groups
Velo Alarm groups
Main CO2 Alarm groups
DSS interlock
MAUVE CO2 cooling review

17. CO2 main plant – alarm groups
Plant Full Stop Interlock:
occurs if any of the Process Alarms triggered
Main PCO is interlocked
no automatic restart
alarm indication (mail or/and SMS)
Plant Warning:
occurs if any of the Process Alarms triggered
alarm indication only (mail or/and SMS)
MAUVE CO2 cooling review

18. MAUVE CO2 cooling review - 2017
UT plant – alarm groups
ALARM GROUPS:
Plant
Communication
Pump
Electrical heater
Pressure
Valve
Temperature
Sensors
Filters
Manifold
MAUVE CO2 cooling review

19. MAUVE CO2 cooling review - 2017
UT plant – alarm groups
UT Warning:
occurs if any of the Process Alarms triggered
alarm indication only (mail or/and SMS)
UT Full Stop Interlock:
occurs if any of the Process Alarms triggered
Bpix PCO is interlocked
no automatic restart
alarm indication (mail or/and SMS)
MAUVE CO2 cooling review

20. MAUVE CO2 cooling review - 2017
Conclusions
Control cabinets 3D CATIA design completed.
The electrical design is well progressing.
Electrical components mostly selected.
Material procurement starts now.
FA under preparation.
CCC SCADA server ready.
SCADA UIs under construction.
MAUVE CO2 cooling review