PCaPAC 2000Desy, Hamburg, Germany

A Control System Solution for CERN CV Facilities in the LHC Era

D. Blanc, M. C. Morodo, CERN, Geneva, Switzerland

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Summary

Introduction A fully industrial SCADA-based solution The local supervisory station Operability and maintainability In practice: The SPS cooling control system Conclusions and future perspectives

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Background and Requirements

The classic scheme: Specific solutions to optimize the

control of each individual process Heterogeneity: very difficult operation,

maintenance and evolution of the global control environment

Now, the aim is: To optimize the control of the individual

processes but keeping a global and homogeneous control system solution

CV Control System Requirements: Openness, for our heterogeneous

environment Networking, for the high geographical

dispersion of the processes Powerful local supervisory tools, core of

the control system architecture Well-adapted operation and maintenance

tools, to improve the process control reliability

Integration in the TCR monitoring system, by means of standard interfaces

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Keys towards homogeneity

Standard industrial process control architectures Flexibility: scalable and modular architectures Reference Models: coherence and homogeneity Integration of the Reference Models for particular solutions Ease the follow-up of the technical evolution: up-to-date control systems

with a lower maintenance effort Reuse of well-proven solutions: robustness

Complex processes Complex processes complicated process control systemscomplicated process control systems

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Architecture

Layer 1: Acquisition and regulation

Layer 2: Local supervision

Layer 3: TCR remote supervision

Layer 4: Data handling and web supervision

PLC: Schneider / Siemens

Fieldbus: Profibus DPWorldFIP, CAN

Cellbus: Ethernet TCP/IP

SCADA: WizconWindows NT Workstations

Process regulation

Process control and supervision

CERN technical data monitoring

Data archiving and web-based

supervisory tools

Archiving stationWeb-access to layer 2

Reference Data Base

Technical Data Server

(for remote data configuration)

Trouble Diagnosis

Post-mortem analysis

Data coherence

Standardization of interfaces

Flexibility

Process-customized solutions

Reliability

Availability

Maintainability

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Wizcon HCI

Wizcon for Internet, WizSQL,...

WizPLC

WizDCS

SCA

DA

EC

Driv

er

Drivers: PLC

, OPC

, DD

E,...

Layer 3:

TCR Remote Supervision

Layer 1:

Acquisition TCP/IP TCP/IP

The local supervisory station

WizPro

Event-driven

Rea

l-tim

e kernelWindows NT

Wizcon station

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Operability and maintainability

Operation-oriented tools (alarms, HCI,…) designed and built by cross-disciplinary teams

Emphasis in validation tests and acceptance procedures Strong effort in project documentation to keep the in-house knowledge for

enabling maintenance and evolution Software configuration management tools: operational software library and

traceability of the upgrades International standards: IEC 1131-3, IEC 61508, IEC 61506, ...

Building control systems to be operational for 10-15 years!!!Building control systems to be operational for 10-15 years!!!

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

The case: SPS Cooling Control System

Scope: 11 demineralised water cooling

stations The primary raw water circuit

(BA6 cooling towers) Objectives:

Design & implement the CS by introducing the new client-server architecture

Integrate the existing equipment for acquisition and Regulation into the new architecture

To provide the required reliability and precision

The SPS cooling system is responsible for supplying raw water to the heat exchangers

inside the BAs and demineralised water for the cooling of the

magnets and machine components

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

The case: SPS Cooling Control System

Layer 2: SPS auxiliary buildings

SCADA: WizconWindows NT Workstations

DCS: For high performance regulation algorithms, specific calculation and continuous control

HCI: Operation interface tools displaying real-time and archived process dataScheduler: For tasks only depending on date-time conditions

Layer 3: TCR remote supervision

Technical Control Room EC: Software module to integrate the layer 2 in the

TCR remote monitoring system

Operational data and tools: Definition of the data and tools to serve the TCR operational purposes

Layer 4: Data handling and web supervision

Web access to layer 2

Archiving station

Web access: Only for trouble diagnosis. No remote actions will be allowed!!Central archiving: Local supervisory stations send the data periodically

Ethe

rnet

TC

P/IP

Layer 1: SPS cooling stations

PLC: Schneider / SiemensFieldbus: Profibus DP, FIPIO

Logic programs: For sequential running of the plants

Regulation: Single-variable and multi-variable control loops, IMC predictive controller and Smith predictor, Fuzzy Logic

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

The case: SPS Cooling Control System

The studies phase: SPS BA6 prototype Defining the Problems Determining the Plant Operating Conditions Defining the Control Objectives and Strategy

The design phase: Functional and dysfunctional analysis Detailed design and simulation

The implementation phase: Organization:

Project management: CERN ST-CV Group CERN cross-disciplinary team + Industrial Contractor

Feasibility study

Engineering Data Review

Technical Specification

Acceptance tests

Call for tenders

Contract follow-up

Operational systemOperational system

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Conclusions

The control of the CV processes can be achieved without considering specific solutions and by using a fully Industrial SCADA-based control architecture

The retained solution provides with a high process control precision A global vision of the CV facilities allows to achieve the required levels of

flexibility, coherence and homogeneity in order to assure the follow-up of the technical evolution

The reusability of well-proven solutions results in safer control systems: better reliability (robustness) and availability (maintainability)

PCaPAC 2000, Desy D. Blanc, M. C. Morodo, CERN ST-CV

Thank you

CERN ST - CV - Design Unit - Controls

Didier.Blanc@cern.ch CV Control Systems Leader

Carmen.Morodo.Testa@cern.ch CV Control Systems Projects Follow-up