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Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
IINDUSTRIALNDUSTRIAL CCONTROLONTROL EENGINEERINGNGINEERINGCERNCERN
EELECTRICALLECTRICAL EENGINEERINGNGINEERING EEVENTVENT
MMEETEET THETHE BUYERBUYER
LLONDONONDON, 27, 27‐‐SSEPEP‐‐20112011
London, 27 September, 2011 Enrique Blanco
on behalf of the CERN EN/ICE group
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OUTLINE
Process Automation at CERN
27/09/2011
Some reference projects
CERN Standards: UNICOS
Opportunities to work with CERN
Enrique Blanco, CERN EN/ICE 2
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering DepartmentCERN STRUCTURE IN A FEW
WORDS…27/09/2011
Enrique Blanco, CERN EN/ICE 3
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
AUTOMATION@ CERN: ENGINEERING DEPARTMENT
The Industrial Control Engineering Group in the Engineering Department PLC
27/09/20Engineering Department develops solutions and provides support in the domain of large and medium scale industrial
l ll
PLCs
Industrial SCADA
011
control systems as well as laboratory control systems and promotes their use.
IndustrialCommunications SCADA
Our AUTOMATION
Mandate key points:‐ Identifying commercial solutions‐Adopted solutions support D i & D l i h
AdvancedControlInformation
AUTOMATION Solution
‐Design & Develop in‐house frameworks and components‐Design, implement and support control systems.
ControlTechnology
Regulationy
Enrique Blanco, CERN EN/ICE 4
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
AUTOMATIONGENERALARCHITECTURE
SUPERVISIONSUPERVISION
27/09/20
Communications Network
CONTROLCONTROL
011
1 process control strategy: P&ID
Industrial Fieldbus
FIELDFIELD
1. process control strategy: P&ID.2. electrical and cabling of instrument and control systems3. Instrumentation 4. Control logic (PLCs)5. Supervisory systems (SCADA)6. commissioning, start‐up, operation and supportg p p pp7. plant optimization
Enrique Blanco, CERN EN/ICE 5
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OUTLINE
Process Automation at CERN
27/09/2011
Some reference projects
CERN Standards: UNICOS
Opportunities to work with CERN
Enrique Blanco, CERN EN/ICE 6
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
LHC CRYOGENICS
27/09/20011
18 kW @ 4.5 Refrigerators LHC Superconducting magnetsStorageCompressor station
Enrique Blanco, CERN EN/ICE 8
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
LHC CRYOGENICS CONTROL
‐ 27 km of decentralized instrumentation and control‐50.000 I/O, 11.000 actuators, ~100 PLCs, ~40 FECs‐26 SCADA servers : ½ million Tags
27/09/20
WinCCOA HMI in the CCC
Tunnel Instrumentation
g 011
WinCCOA HMI in the CCC
electro‐pneumatic positioner, SIPART PS2
Enrique Blanco, CERN EN/ICE 9
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
DETECTOR SAFETY SYSTEM
The DSS saves from harm a Particle Detector by executing protective actions in response to th d t ti f d fi d
27/09/20
the detection of user‐defined Alarm Conditions.
S A t t Al
011
Sensors, Actuators or Alarm Conditions can be added or re‐parameterized at any time by the User without stopping the the User, without stopping the system
Enrique Blanco, CERN EN/ICE 10
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OTHER PROJECTS …
l
Homogenized solutions based on an CERN de facto standard (UNICOS)
‐Cryogenics Instrumentation Expert Tool‐ 9 SCADA Data servers with more than 1 million Tags, 12 GB archived data
27/09/20
‐ Low‐beta LHC magnet Alignment
‐ ISOLDE Vacuum controls‐ Discrete process application‐WinCCOA + S7‐300 PLCs
SPS Power converters controls
‐ WinCCOA + Industrial PCs
011
Low beta LHC magnet Alignment‐GEODE Data Base integration‐WinCCOA + Industrial PCs
‐ SPS Power converters controls‐Re‐engineering based on UNICOS‐WinCCOA+ S7‐300 PLCs
‐ LHC collimatorsLHC collimators‐ LHC Interlock system‐WinCCOA + S7‐300 PLCs
SURVEY ISOLDE VACUUMCISCollimatorsCIET
Enrique Blanco, CERN EN/ICE 11
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OUTLINE
Process Automation at CERN
27/09/2011
Some reference projects
CERN Standards: UNICOS
Opportunities to work with CERN
Enrique Blanco, CERN EN/ICE 12
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS FRAMEWORK
• [1998] UNICOS (UNified Industrial Control System) was born at CERN as a need to develop the LHC cryogenics control system. The goalwas to create an industrial control system covering the three layers of the typical automation
27/09/20y g y yppyramid.
011
• [2002] UNICOS replace the PcVue SCADA and adopt ETM’s PVSS under the CERN recommendation (nowadays called “WinCCOA” by SIEMENS). • [2004] UNICOS offered the choice of creating applications based on SIEMENS S7 PLCs S7 PLCs • [2009]UNICOS turned into de facto standard framework to develop industrial control applications at CERN:
Cryogenics, Cooling, HVAC, Vacuum, Interlocks,…
• [2010]The UNICOS framework has been extended to other kinds of applications (i.e.: supervisory, monitoring, …)
Enrique Blanco, CERN EN/ICE 13
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS BASICS I
UNICOS establishes:
27/09/2011
A well defined set of standard objects (devices), both in the control and supervision layers, modeling most of the equipment and needs of continuous processes
The relationships between them
A formalized way of :Define the process units of a process (ISA‐88 standard: Batch
)processes)
Programming the specific process logic for those units
Enrique Blanco, CERN EN/ICE 14
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS BASICS II Not only a bunch of devices!
DEVELOPMENT: Provides the developer with tools to produce rapid control
27/09/2011p p papplications . Automatic generation of code
COMMISSIONING: Allows early plant commissioning, reducing check tasks to the instruments and electrical level (cabling). Access to devices without SCADA d ldevelopment.
OPERATION: Provides the operator a way to interact all the objects (as long as their privileges allow it access control)allow it: access control)
Navigation capabilities between panels and trends: WWW browser‐like, contextual buttons, pop‐up navigation
Process Alarm and Event list Process Alarm and Event list MAINTENACE: Allows optimized code evolution and maintenance by a reduced
development team DIAGNOSTICS: Tools to diagnose problems (process alarms, Infrastructure: DIAGNOSTICS: Tools to diagnose problems (process alarms, Infrastructure:
control components,…)
Enrique Blanco, CERN EN/ICE 15
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
PROCESS VS. CONTROL ARCHITECTUREOperation
Point 4 Cryogenic System PCO
Standard
Operation in multiple scenarios
27/09/2011
LHC 1.8KCryoplants
PCOAutomatic
Generation of the PCO objects (From FI
S ifi ti )
Standard Unicos
Programming and Process
Logic
Generation of
the
objects and I/O
Devices
Field DevicesI/O
Boards‐Fieldbus‐Other
PLCs
AI
AO
DI
DO
Analog
InputAnalog
Output
Digital
InputDigital O
utputobjects and connections betw
een objects
(From
I/O
& FI
Specifications)I/O
Boards‐Fieldbus‐Other
PLCs
Specifications)E
nrique Blanco, C
ER
N E
N/IC
E16
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS: USER INTERFACE
27/09/2011
Enrique Blanco, CERN EN/ICE 18
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS METHODOLOGY
Specifications creationI d d b filli EXCEL (XML) k h
27/09/2011
Instances: data captured by filling EXCEL (XML) worksheets Eventually these specifications may be created also automatically (e.g. DB oriented)
Functional Analysis + Logic specification: Word templates
A i i (UAB UNICOS A li i B ild ) Automatic generation (UAB: UNICOS Application Builder) Instance generator Standard Logic generation
M l i i Manual intervention Process logic coded by the control engineer in an standardized way. Some
applications may create automatically the logic based on templates. Process synoptics: drag & drop
Support Documentation Tutorials
Enrique Blanco, CERN EN/ICE 19
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS SPECIFICATIONS
27/09/2011
UNICOS CPC Specs
Enrique Blanco, CERN EN/ICE 20
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
UNICOS MANUAL PROCEDURES
The goal is to reduce the human intervention: Process logic can be either:
d d b h l i i d d
27/09/2011
coded by the control engineer in an standard way. Some applications may create automatically the logic based on
templates. HMI P i d & d f UNICOS CPC HMI Process synoptics: drag & drop from a UNICOS-CPC catalog
Synoptics design
Logic Placeholders
Enrique Blanco, CERN EN/ICE 21
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OUTLINE
Process Automation at CERN
27/09/2011
Some reference projects
CERN Standards: UNICOS
Opportunities to work with CERN
Enrique Blanco, CERN EN/ICE 22
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OPPORTUNITIES TO WORK WITH CERN
Cooling & Ventilation Process Automation Following our CERN standards: UNICOS
27/09/2011
Following our CERN standards: UNICOS
P4 Cooling towers STP18 Cooling towersEnrique Blanco, CERN EN/ICE 23
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OPPORTUNITIES TO WORK WITH CERN
Projects maintenance Identify and/or improve specialized tools to get
27/09/2011
Identify and/or improve specialized tools to get better diagnostics of specific components of the control system (e.g. industrial fieldbuses, plant-wide engineering) and allow us to reduce the downtimeengineering) and allow us to reduce the downtime.
Perform the preventive and corrective maintenance as well as upgrades or our installations.
Project Engineering and quality assurance Automatic testing procedures to validate our g p
frameworks code Project Engineering integration mechanisms and
tools tools
Enrique Blanco, CERN EN/ICE 24
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OPPORTUNITIES TO WORK WITH CERN Other possibilities in different fields
Access Control Handling
27/09/2011
Handling Monitoring systems Real-Time Communications …
Enrique Blanco, CERN EN/ICE 25
Industrial ControlsIndustrial ControlsEngineering DepartmentEngineering Department
OPPORTUNITIES TO WORK WITH CERN27/09/2011
Outsourcing YES !!!
but
under CERN Standards.
Enrique Blanco, CERN EN/ICE 26