1. 11/03/2003LHC GCS - JCOP ER1 LHC GCS Renaud Barillère – CERN IT-CO

2. 11/03/2003LHC GCS - JCOP ER2 Outline Motivations and Objectives Problem description Status Planning and Resources Issues

3. 11/03/2003 LHC GCS - JCOP ER 3 Motivations The LEP gas systemsThe LEP gas systems A lot of independently built systemsA lot of independently built systems No common control systemNo common control system Several operation modelsSeveral operation models Several technologiesSeveral technologies LHC: a favourable contextLHC: a favourable context Recommended industrial control technologiesRecommended industrial control technologies FieldbusFieldbus PLCsPLCs SCADASCADA

4. 11/03/2003 LHC GCS - JCOP ER 4 The Gas Working Group Mandate of EP-TA1-GS: Produce gas systems for all four LHC experiments.Mandate of EP-TA1-GS: Produce gas systems for all four LHC experiments. Coherent design:Coherent design: Common solution for HW and SWCommon solution for HW and SW Scope:Scope: All components for gas, except gas storage.All components for gas, except gas storage. OperationOperation Gas Maintenance GroupGas Maintenance Group Gas PiquetsGas Piquets

5. 11/03/2003 LHC GCS - JCOP ER 5 Deliverables and Objectives End-User applicationsEnd-User applications For the four LHC experiments gas systemsFor the four LHC experiments gas systems Complete control applicationsComplete control applications Supervision and Process Control layersSupervision and Process Control layers Integrated in LHC experiment DCSIntegrated in LHC experiment DCS Reduce efforts and costReduce efforts and cost DevelopmentDevelopment MaintenanceMaintenance OperationOperation

6. 11/03/2003 LHC GCS - JCOP ER 6 Problem description 23 gas systems in 4 experiments Commonality Modular architecture: Mixer, Distribution, Pump, Exhaust, Purifier, Analysis; Recovery, CO2 Absorber, CO2 Removal, CO2 Envelop. Standard devices Valves, Flow Meters, Mass Flow Controllers, Pressure transmitters,etc. Diversity Optional modules Options in modules

7. 11/03/2003 LHC GCS - JCOP ER 7 Strategy Industrial technologies SCADA, PLC, Fieldbuses Use the industrial way Frameworks For process control and supervision Based on the GWG gas modules Instances Ideal case: Automatic code production Worst case: Systematic copy-paste procedures Real case…

8. 11/03/2003 LHC GCS - JCOP ER 8 Architecture principles Layered applications Supervision Display, Logging, Archiving, Recipes, Access Control Unique look and feel across the 23 applications Abstraction for operators and central team members Process control Automatic behaviors: I/O, STDs, Interlocks Can run without supervision Hierarchical architecture Keep the modular view of GWG experts Low level access for commissioning and debugging

9. 11/03/2003 LHC GCS - JCOP ER 9 Milestones Analysis Understand requirements for a typical gas system Quantify the diversity/commonality Feasibility studies Selection of technologies Selection of re-usable components Design Choice of generic solutions Alice TPC Validation of the design GCS Framework production Production of re-usable high level components Instances production

10. 11/03/2003 LHC GCS - JCOP ER 10 Analysis Completed for the standard modules Evolving with the production of the experiments PRR User Requirement Document Description of the Gas Racks Automatic behavior (STD, Alarms and Interlocks, Events) Commands Use Cases For complexes module operation HMI mock ups To get feed back from Users and Product Leader Gas system descriptions An overview of the commonality

11. 11/03/2003 LHC GCS - JCOP ER 11 Mock-Up #1 Gas Plant

12. 11/03/2003 LHC GCS - JCOP ER 12 Mock-Up #2 Alice TPC

13. 11/03/2003 LHC GCS - JCOP ER 13 Mock-Up #3 Mixer module

14. 11/03/2003 LHC GCS - JCOP ER 14 Mixer modules

15. 11/03/2003 LHC GCS - JCOP ER 15 Distribution modules

16. 11/03/2003 LHC GCS - JCOP ER 16 Pump modules

17. 11/03/2003 LHC GCS - JCOP ER 17 Analysis: To be done… Gas analysis module Late HW design Non standard modules CO2 Envelop, CO2 Removal, Recovery They are not expected to require complex control Detailed top module Delayed to identify UR from experience with ALICE TPC Handling of problems not related to process Communication problems. Power failures The selected SW components should offer natural solutions

18. 11/03/2003 LHC GCS - JCOP ER 18 Feasibility study Technology survey and evaluations Fieldbus devices Analog valve, Mass Flow Controller, Pump, Bus coupler PLCs Siemens, Schneider, Wago UNICOS A Beta version of the PLC layer available in 2001 Prototypes & small gas systems CMS MSGC B1 & B2, ATLAS TRT, NA60.

19. 11/03/2003 LHC GCS - JCOP ER 19 Why UNICOS? Need of a PLC library PLC oriented control PLC software can be complex Need of a common approach for industrial controls UNICOS assets An application framework Covers most of the I/O level Open for specific behavior Open operation model (access for operators and experts)

20. 11/03/2003 LHC GCS - JCOP ER 20 UNICOS PLC Object Object Manual Requests SCADA Auto. Requests Control Logic Parameters Programmer via Engineering WS or to Status Information to other devices operator via SCADA Process Inputs Process variables or Object status Process output or Devices Auto Requests Orders

21. 11/03/2003 LHC GCS - JCOP ER 21 UNICOS Object Model SCADA part SCADA Object Parameters SCADA Configuration tool Requests Information Screen Operators Keyboard PLC objects statusManual Requests PLC

22. 11/03/2003 LHC GCS - JCOP ER 22 I/O Devices Object standard logic Operator via OWS Control LogicProgrammer via EWS Process outputInformations to other objects or to operator via OWS Manual RequestsAuto. RequestsParameters OrdersStatus Process variables Operator via OWS Programmer via EWS Object standard logic Informations to other objects or to operator via OWS Process InputsManual RequestsParameters Status Output device Input device Generic for device of same type - Mode management - Orders setting - Status setting

23. 11/03/2003 LHC GCS - JCOP ER 23 Field device Process InputsManual RequestsAuto. Requests OrdersStatus Parameters Input devices Status or other field devices status Operator via OWS Control LogicProgrammer via EWS Output device auto requests AO/DO Information to other devices or to operator via Scada Interlock logic Device standard logic (black box) Device logic Generic for device of same type - Mode management - Order setting - Status setting - Interlock action Specific to each device - Interlock analyse - Setting Generic interlock to standard logic For a valve Utility Compressed air Ok Power supply Ok Safety DP over the valve<safety limit

24. 11/03/2003 LHC GCS - JCOP ER 24 Process Control object SI/TS/FS Process InputsManual RequestsAuto. RequestsParameters Operator via Scada Control LogicProgrammer via EWS Global control logic Dependent Device 1 control logic Dependent Device n control logic Device standard logic black box Device logic Informations to other devices or to operator via scada Status Field device or Process device AutoRequests Orders other device status Configuration logic Specific Process device logic Orders..... FBon FBoff Interlock logic Field device or Process device AutoRequests Generic for all process device - Mode management - Status setting - Set generic Order to specific process device logic -Run order -active option -... Specific to each device Set Generic interlock to Device standard logic - Full stop - Temp stop - Start interlock Specific to each device Set the feedback on and feedback off of the process control device Specific to process device -Contains the process control logic to start/stop and coord- inates all dependant devices according to generic orders from standard logic & process inputs

25. 11/03/2003 LHC GCS - JCOP ER 25 Object hierarchy MotorSlide ValveOil valveOil Pump Digital Output Compressor 1 Compressor nCompressor 2 Compressor SetCold box WCS_CTCCB_CT 1.8K Cryoplant C CCS_CT I/O Devices Field Devices Process Control Devices For each object type an adapted user interface is created & implemented in the supervision to allow monitoring & control

26. 11/03/2003 LHC GCS - JCOP ER 26 SCADA PLC Object across layers Simple: Analog/Digital input/output local, On/Off, Analog Alarm Complex : Controller Process control SCADA and PLC implementation Defined interface Can be linked Manual request Auto request parameters Process inputs orders status Object logic Object status hardware output Object Auto Request information request parameter Manual request status Object logic hardware variable Object status screen Keyboard mouse EWS Developer Operator configuration Object order

27. 11/03/2003 LHC GCS - JCOP ER 27 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 UNICOS implementation in NA60 gas control layer

28. 11/03/2003 LHC GCS - JCOP ER 28 NA60 Gas System 1

29. 11/03/2003 LHC GCS - JCOP ER 29 NA60 Gas system 2

30. 11/03/2003 LHC GCS - JCOP ER 30 NA60 Gas System 3

31. 11/03/2003 LHC GCS - JCOP ER 31 Design Software architecture One PVSS system One experiment gas plant One UNICOS PCU One sub-detector gas system Preliminary HW architecture Design patterns Process control I/Os, STDs, Alarms, Interlocks, Recipes, Commands Supervision (not completed) Design of GCS extensions to UNICOS UNICOS PLC objects Faceplates and Widgets

32. 11/03/2003 LHC GCS - JCOP ER 32 HW Architecture UX US Surface bldg. Control room Main PLC Ethernet ProfiBUS CPU I/O modul ADC DAC DI/O PBusADC DAC DI/O PBus Device ProfiBUS coupler ProfiBUS Ethernet CAN-bus ProfiBUS CPU I/O modul ADC DAC DI/O PBusADC DAC DI/O PBus Device PLC ProfiBUS P CAN-bus CERN / Experiment Ethernet Operator workstations ELMB FFFF nW

33. 11/03/2003 LHC GCS - JCOP ER 33 Integration in DCS Experiment Control System EV UIM driver Sub -Detector Control System EV UIM driver GAS Control System EV UIM driver Shifter Sub detector expert Shifter, Gas expert, etc Status ATLAS ALICE LHCb Gas Piquet

34. 11/03/2003 LHC GCS - JCOP ER 34 ALICE TPC Design Design of individual module process control Completed: Mixer, Pump, Distribution, Exhaust In progress: Purifier/CO2 Absorber Options are incorporated Design of modules supervision In progress UNICOS PVSS package in Beta version Development Required GCS extensions developed Process control for the designed modules is developed Mixer supervision in development Engineering tools

35. 11/03/2003 LHC GCS - JCOP ER 35 Planning Alice TPC Modules: 2002Q4 -> 2003Q2 System Tests: 2002Q3 -> 2003Q4 Analysis: -> 2003Q3 Non standard modules Top module New requirements… GCS Framework Design: 2003Q2 -> 2003Q3 Implementation: 2003Q3 -> 2004Q1 Instances Implementation and commissioning: 2004-2006.

36. 11/03/2003 LHC GCS - JCOP ER 36 Who is doing what? Detector experts Gas requirements EP-TA1-GS Gas Racks Electrical boxes with fieldbus connections Tests of the above First line maintenance Operation IT-CO User Requirements GCS framework (PVSS and PLC) 23 End user applications Tests of the above Second line maintenance All together Commissioning

37. 11/03/2003 LHC GCS - JCOP ER 37 Resources Numbers Stability A large fraction of temporary manpower. The learning phases and transition are costly.

38. 11/03/2003 LHC GCS - JCOP ER 38 Risks Planning Some delays with Alice TPC Planning the implementation and commissioning of instances Implementations of systems before the GCS framework Time between two systems commissioning Technology Evolution of Schneider for the finalization of HW architecture Integration of the FlowScan (ELMB) in the control system Protocol Embedded software DB infrastructure

39. 11/03/2003 LHC GCS - JCOP ER 39 Conclusions A wide scope 23 end-users applications Complete vertical slices Homogeneity is the key PRR confirmed commonality GCS Framework for 23 instances Tools and technologies are identified Design patterns are being validated Current resource level should be maintained Assumption: Planning stable, systems produced in series. Stability to produce the GCS framework would be appreciated.