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

11/03/2003 LHC GCS - JCOP ER 1

LHC GCS

Renaud Barillère – CERN IT-CO


Outline

Motivations and ObjectivesProblem descriptionStatusPlanning and ResourcesIssues


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 Recommended industrial control

technologiestechnologies• FieldbusFieldbus• PLCsPLCs• SCADASCADA


The Gas Working Group

• Mandate of EP-TA1-GS:Mandate of EP-TA1-GS:Produce gas systems for all four LHC Produce gas systems for all four LHC experiments.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


Deliverables and Objectives

• End-User applicationsEnd-User applications• For the four LHC experiments gas For the four LHC experiments gas

systemssystems• 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


Problem description

23 gas systems in 4 experimentsCommonality

Modular architecture:Mixer, Distribution, Pump, Exhaust, Purifier, Analysis;Recovery, CO2 Absorber, CO2 Removal, CO2 Envelop.

Standard devicesValves, Flow Meters, Mass Flow Controllers, Pressure

transmitters,etc.

DiversityOptional modulesOptions in modules


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…


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


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

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

11/03/2003 LHC GCS - JCOP ER 13

Mock-Up #3 Mixer module

11/03/2003 LHC GCS - JCOP ER 14

Mixer modulesExperiment Gas system Number

of gasesRatios[%] Double MFC

[5],[8],[9]Comments

TRT Xenon/ CO2 / O2 70 / 27/ 3 yes see 1.)TRT cooling CO2 100 no see 2.)MDT Argon / CO2 / H2O 93 / 7 / 500 ppm yes Std 3 gas mixerCSC Argon / CO2 / CF4 30 / 50 / 20 yes Std 3 gas mixerRPC C2H2F4 / i -C4H10 / (SF6) 97 / 3 / (0) yes Std 2 (or 3) gas mixerTGC CO2 / n-C5H10(liquid) 55 / 45 no Std 2 gas mixerDT Argon / CO2 80 / 20 yes Std 2 gas mixerRPC C2H2F4 / i-C4H10 / (SF6) 96.5 / 3.5 yes Std 2 (or 3) gas mixerCSC Argon / CO2 / CF4 40 / 50 / 10 yes Std 3 gas mixerTotem RPC C2H2F4 / i-C4H10 / (SF6) 96.5 / 3.5 no Std 2 gas mixerTotem CSC Argon / CO2 / CF4 40 / 50 / 10 no Std 3 gas mixerTPC Ne / CO2 90 / 10 yes Std 2 gas mixerTDR Xenon / CO2 80 / 20 yes Std 2 gas mixerTOF C2H2F4 / i-C4H10 / SF6 90 / 5 / 5 yes Std mixerHMPID CH4 / Ar(purge) 100 / 100 no Std 2 gas mixer see 3.)

CPV Ar / CO2 80 / 20 no Std 2 gas mixerPMD Ar / CO2 70 / 30 no Std 2 gas mixeruTracker Ar / CO2 / ? 80 / 20 no Std 2 (or 3) gas mixeruTrigger Ar / C2H2F4 / i-C4H10 / SF6 49 / 40 / 7 / 4 / no Std 4 gas mixersystem 1system 2system 3system 4

1.) 1-2 weeks per year Ar/CO2/CF4 mixture 70/26/4 for cleaning,- vented mode. ~85% standard mixtureThe Run state could be slightly different: the injection of mixture would be driven by 2 pressure events (TBD).2.) one Electro-valve , no MFC --> not standard module3.) this is a mixer. Either 100% Ar or 100% CH4

Reviewed by RB and SHDate: 2003-02-07, without LHCb systems

Atlas

CMS

Alice

LHCb

11/03/2003 LHC GCS - JCOP ER 15

Distribution modules

[I] [III] [IV] a b c d e f g h jTRT A 1 1 80 total y y y y yTRT cooling A 1 6 1 y y y y y yMDT A 1 15 272 total y y y y y yCSC A 1 2 16 or 32 y y y y y y yRPC A 1 5 128 total y y y y y y yTGC A 1 8 128 total y y y y y y yDT A 1 5 50 Y Y Y Y Y y

Barrel D 2 5 240 y y y y y y y y 2.)FW 1+2 D 2 4 24 / Rack y y y y y y y yFW 3 D 2 4 12 / Rack y y y y y y y y

CSC D 2 5 18 or 9 / R. y y y y y yTotem RPC A 1 2 ~20 Y Y Y y Y yTotem CSC A 1 2 ~20 Y Y Y Y Y yTPC A 1 1 0 Y Y Y Y YTDR A 1 18 13 y y y y y y yTOF A 1 2 45 total y y y y y y yHMPID A 1 1 ~20 Y Y Y Y Y Y yCPV A 1 1 5 y y y y y yPMD A 1 1 6 y y y y y yuTracker A 1 1 28 y y y y y yuTrigger A 1 1 16 y y y y y ysystem 1 likely A or Dsystem 2 likely A or Dsystem 3 likely A or Dsystem 4 likely A or D

1.) option -j : channel flow meter present2.) RPC has three dediated areas: Barrel, FW outer + middle layer, and FW inner layer

Reviewed by RB and SHDate: 14/02/2003, without LHCb systems.

Gas system Type Group of Racks

Channels/ rack

Racks Rack options Comment

Atlas

LHCb

Sub-Part

RPC

CMS

Alice

Group optionsExperiment

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

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.

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

11/03/2003 LHC GCS - JCOP ER 32

HW ArchitectureU

XU

SSu

rfac

e bl

dg.

Con

trol

roo

m

Main PLC

Eth

ern

etE

ther

net

Pro

fiB

US

CP

U

I/O

mod

ul

AD

C

DA

C

DI/

O

PB

us

AD

C

DA

C

DI/

O

PB

us

Device

ProfiBUS coupler ProfiBUS

Eth

ern

etC

AN

-bu

s

Pro

fiB

US

CP

U

I/O

mod

ul

AD

C

DA

C

DI/

O

PB

us

AD

C

DA

C

DI/

O

PB

us

Device

PLC

ProfiBUS

P

CAN-bus

CERN / Experiment Ethernet

Operatorworkstations

ELMB ELMB ELMB

F F FF nW

11/03/2003 LHC GCS - JCOP ER 33

Integration in DCS

Experiment Control System

EVUIM

UIM

driver

Sub-Detector Control System

EVUIM

UIM

driver

GAS Control System

EVUIM

UIM

driver

Shifter

Sub detector expert

Shifter,Gas expert,etc

Status

Status

Status

ATLASALICELHCb

Gas Piquet

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

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.

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

11/03/2003 LHC GCS - JCOP ER 37

Resources

• Numbers

• Stability• A large fraction of temporary manpower.• The learning phases and transition are costly.

Tasks Required ActualAnalysis 0.5 FTE

2 Pers.Allocated

Alice TPC 4 FTEs6 Pers.

3.2 FTEs allocated0.8 uncertain

FrameworkDesign & Implementation

4 FTEs6 Pers.

3.2 FTEs allocated0.8 uncertain

InstancesDev., tests, Commissioning

3.5 FTEs(5 Pers.)

1,2 FTEs allocated2 Pers.

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

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.

Documents

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