AB-CO review Support for Cryogenics. Philippe Gayet AB/CO IS CERN, 20/09/05 Outline Scope Hardware...

AB-CO reviewSupport for Cryogenics

Philippe Gayet AB/CO ISCERN, 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


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)


Hardware for ACR

Quantum

Premium

AB-CO

AT-ACR

Ethernet IT-CS

Tele

fast

Digital

Phoeni

x

Analog

PMAModbus

DPPA

PA

PA

PLCSafety

BUS X

AT-ACR

GatewayWFIP

GatewaySiemens

ET 200Boards

WFIP Networks

WFIP agents

CentralData server

Central & local control room

Operator consoles


Hardware Resp. sharing With ACR

Procurement Installation

SCADA AB/CO AB/CO

QUANTUM/Premium AB/CO AB/CO

FIP Gateway AB/CO AB/CO

S7 Gateway AB/CO AB/CO

Profibus from protected areas to S7 Gateways AB/CO AB/CO

S7 Profibus RIO in protected areas AB/CO AT/ACR

S7 RIO QRL specific AT/ACR AT/ACR

Fieldbus couplers (optical, DP/PA, etc…) AB/CO AB/CO & AT/ACR

Intelligent Valve Actuators AT/ACR AT/ACR

Local Profibus Network AT/ACR AT/ACR

FIP network AB/CO AB/CO

LHC RadTol tunnel RIO (FIP Agent) AT/ACR AT/ACR


Quantum

PCU

EWS

Hadware for PH-TA3 & ECR

Quantum RIOField interface

Sch

nei

der

Pro

pri

etar

y b

us

Local Control room

Central control room

OWS

Profibus network

CentralData server

UNITY

PCU

PremiumField interface

Profibus network

Profibus network

AB-CO


Hardware Resp. sharing ECR/PH-TA3

Procurement Installation

SCADA AB/CO AB/CO

PLC AB/CO AT/ECR

Fieldbus couplers (optical, DP/PA, etc…) AB/CO AT/ECR

Intelligent Valve Actuators AT/ECR AT/ECR

Local Profibus Network AT/ECR AT/ECR


HW Status & Maintenance

HP Proliant for Scada (15 + 4 + 2) Schneider PLC (110 + 15 + 5) 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


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


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


ACR HW and SW production answers

First time (new controls): All tunnel cryogenic system (ACR/IN with AB/CO support) – 2006-

07 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. 1.8 18 kW refr. ABB -> UNICOS – SD 06-07 Dryers pt 2, 4, 6, 8 - end 2005 – beginning 06

OK program ready


AB

-CO

-IS

AT

-AC

RApplication status

QSD

Sector 1-2Sector 2-3Sector 3-4Sector 4-5Sector 5-6Sector 6-7Sector 7-8Sector 8-1

QSRBQURAQUIQUI

Point 4Point 3Point 2Point 1.8 Point 5Point 6 Point 7Point 8 Surface(buildings+areas)CavernQURCQURC

QSCQSRAQUIQURCQURC QURCQURC QURCQURCQUI QUI

Shaft

QRL LHC machine cryostatQRLQRLQRLQRLQRL QRLQRLTunnel

QSVQSCBQSC QSCQSCC

QURA QURA QURA

QSCAQSCC QSRB QSRB QSRBQSRA QSRA QSRAQSCCQSCAQSCBQSCQSCC QSCQSCAQSCCQSCQSCCQSCB QSCQSCQSCCQSCAQSCBQSCQSCCQSV QSVQSVQSV QSV QSV QSVQSDQSDQSDQSD

QSCA : Compressor set for existing 4.5K refrigeratorQSRA : Upper cold box for existing 4.5K refrigeratorQURA : Lower cold box for existing 4.5K refrigeratorQSCB : Compressor set for new 4.5K refrigeratorQSRB : Cold box for new 4.5K refrigeratorQUI : Interconnection cold boxQSV : Gaseous Helium StorageQSD : Liquid Nitrogen Storage QSCC : Compressor set for new 1.8K refrigeratorQURC : Cold box for new 1.8K refrigeratorQRL : Main ring transfer Line

QSD

Sector 1-2Sector 2-3Sector 3-4Sector 4-5Sector 5-6Sector 6-7Sector 7-8Sector 8-1

QSRBQURAQUIQUI

Point 4Point 3Point 2Point 1.8 Point 5Point 6 Point 7Point 8 Surface(buildings+areas)CavernQURCQURC

QSCQSRAQUIQURCQURC QURCQURC QURCQURCQUI QUI

Shaft

QRL LHC machine cryostatQRLQRLQRLQRLQRL QRLQRLTunnel

QSVQSCBQSC QSCQSCC

QURA QURA QURA

QSCAQSCC QSRB QSRB QSRBQSRA QSRA QSRAQSCCQSCAQSCBQSCQSCC QSCQSCAQSCCQSCQSCCQSCB QSCQSCQSCCQSCAQSCBQSCQSCCQSV QSVQSVQSV QSV QSV QSVQSDQSDQSDQSD

QSCA : Compressor set for existing 4.5K refrigeratorQSRA : Upper cold box for existing 4.5K refrigeratorQURA : Lower cold box for existing 4.5K refrigeratorQSCB : Compressor set for new 4.5K refrigeratorQSRB : Cold box for new 4.5K refrigeratorQUI : Interconnection cold boxQSV : Gaseous Helium StorageQSD : Liquid Nitrogen Storage QSCC : Compressor set for new 1.8K refrigeratorQURC : Cold box for new 1.8K refrigeratorQRL : Main ring transfer Line

LN2LN2LN2

Sector 1-2 Sector 2-3 Sector 3-4 Sector 4-5 Sector 5-6 Sector 6-7 Sector 7-8 Sector 8-1

QSRB

QURA

QUIQUI

Point 4Point 2Point 1.8 Point 6 Point 8

Su

rface(b

uildin

gs+areas)

Cavern

QURCQURC

QSC

QSRA

QUI

QURC QURC QURC QURC QURC QURC

QUI QUI

Sh

aft

QRL QRL QRL QRL QRL QRL QRL QRL Tu

nn

el

HPstorage

LN2LN2

HPstorage

HPstorage

HPstorage

HPstorage

QSCB

CentralHP

storage

QSC QSCQSCC

QURA QURA QURA

QSCA QSCC

QSRB QSRB QSRBQSRA QSRA QSRA

QSCC QSCAQSCB QSCQSCC QSCQSCA QSCCQSCQSCC QSCB QSCQSCQSCC QSCA QSCB QSCQSCC

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


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 S

CADA + (1 contract staff) available part ti

me for this support


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


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 ????


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

AB-CO review Support for Cryogenics. Philippe Gayet AB/CO IS CERN, 20/09/05 Outline Scope Hardware...

Documents

Transcript of AB-CO review Support for Cryogenics. Philippe Gayet AB/CO IS CERN, 20/09/05 Outline Scope Hardware...