Cryogenics Instrumentation & Controls Commissioning for
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Transcript Cryogenics Instrumentation & Controls Commissioning for
UNICOS A FRAMEWORK TO BUILD
INDUSTRY LIKE CONTROL SYSTEMS
PRINCIPLES & METHODOLOGY
Renaud Barillère
CERN IT-CO
Philippe Gayet
CERN AB-CO
Outline
Industrial Control in CERN Accelerator Control
Industrial Control Framework Objectives
Process Control Analysis
UNICOS Model
Process Control Specification
Application Production
Conclusion
ICALEPCS, 12/10/05
Philippe Gayet CERN
CERN Accelerator Control Architecture
ICALEPCS, 12/10/05
Philippe Gayet CERN
Industrial Control Architecture
Link to other accelerator control system
Industrial Supervision LayerAnd services (alarms, logging,…)
Accelerator Presentation Tier
Interface to operators
(Monitoring & Command emission)
Real time DB & Archiving
Industrial Control layer
Control Logic Actions
Industrial Field layer
Ethernet Network & TCPIP communication services
Operator Consoles
<5 Years
SCADA Servers
PLC Process Control
Accelerator Middle Tier
Accelerator
Resource
Tier
One Communication
protocol
per supplier
Life
PLC time
Process Control
& Field interface
PLC Field interface
>10 Years
control system connection to the process
directly or through field-buses
Fieldbus Networks
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COTS from different supplier
Industrial Control Framework Objectives
Integrates industrial control layers together respecting
interlayer independence
Integrates the Industrial Control to the accelerator control
infrastructure and services (alarms, Logging,..)
Offers a methodology to produce functional analysis
directly
teams
Control
project programmable by application development
LHC Startup
First
Start up
Cryogenic available
Startup
Cryogenic
commissioning Development Tools
Supplies Application
for
various development teams (CERN, Experiment
collaboration, Outsourcing)
Workload
Allows long term maintenance by reduced CERN teams
Offers homogenous and efficient user interface for
operation
crew
from equipment commissioning
to long
2000
2001
2007
2006
term operation Late Specifications
ICALEPCS, 12/10/05
Philippe Gayet CERN
Process control Analysis
Unit
Equipment
Modules
Equipment
Modules
Equipment
EquipmentModules
Modules
Equipment
Modules
Equipment
EquipmentModules
Modules
Control Modules
Control Modules
Control Modules
Control Modules
Control Modules
IEC 61512-1
Physical model
ICALEPCS, 12/10/05
Philippe Gayet CERN
UNICOS Break Down
IN UNICOS
AI
M value
Control
Valve
AI
M value
AI
position
PID
Control
Valve
AO
position
DI
End switch
UNIT
DO
position
-Each device type is an Object
Class
Equipment module
I/O Boards
On-Off
Valve
Equipment module
An Output
position
DI
End switch
-Each control module or
equipment module is a device
Equipment module
An Input
position
PID
On-Off
Valve
-Equipment modules and Units
are embedded in a unique
object class : Process Control
Object
DO
position
I/O devices
Field devices
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-Each device is instantiated in
the control layer as PLC Object
Process Control Objects
-All PLC Object classes are
based on the same model
Philippe Gayet CERN
Object Model (Control Part)
Objects status
Operator
Parent Object
Process inputs
Manual Requests
Auto. Requests
PLC internal Object Logic
Parameters
PLC Object
Orders
Process output
or
Child Auto Requests
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Status
Information to
other object
or to
operator
Philippe Gayet CERN
Programmer
PLC Objects Interactions
Field
Object
Process Inputs
Object status
Manual Requ.
Parameters
Object logic
Auto. Requests
Orders
Output
Object
Process Inputs
Object status
Input
Object
Manual Requ.
Object logic
Process Inputs
Parameters
Object status
Manual Requ.
Object logic
Auto. Requests
Auto. Requests
Orders
Orders
I/O Board or
Fieldbus
Output Channel
Input Channel
PROCESS
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Parameters
Philippe Gayet CERN
UNICOS Operation Principles
Operator
-Operation team must be able to act on
each device
-In degraded operation conditions
operation crew can overcome process
logic requests
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Layers Integration
In the Supervision layer a proxy is associated to each object
This proxy will present the relevant object info to the operator
And allow manual command emission
Industrial Supervision Layer
SCADA
Proxy
Human
Requests
SCADA Object
Information
display
Manual Request
HMI
Parameters
Object status
Industrial Control Layer
PLC Object
Process Inputs
Object status
Manual Requ.
Object logic
Parameters
Auto. Requests
Orders
Process
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Auto Manual Requests Conflicts
Auto Manual Requests Arbiter
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Application Basic Components
Supervision
UNICOS FW
- Graphical components (Widgets / Faceplaces)
- Navigation tools
- Objects explorer
- Trends and alarms handling
- Access control
- Interconnection to accelerator services
UNICOS SCADA
Middleware
UNICOS PLC
Middleware
UNICOS object
library
PLC
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PCO devices
Field devices
I/O devices
Objects Specification
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Philippe Gayet CERN
Application Generation
Supervision
device type
templates
Instantiation generation
Devices Specification
devices
DB
Instance
Generator
Supervision
device
instance
UNICOS FW
Scripts
Device
instantiation
PLC device
instance
UNICOS time stamped
Middleware
Device
instantiation
UNICOS library
PLC
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Introducing Process Logic
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UNICOS Process Control Object Model
Input objectsStatus
Or other objects status
Operator
Parent PCO
Control Logic
Manual Requests
Auto Requests
Process Inputs
PCO Process dependant part
Interlock
Logic
Configuration
Logic
PCO predefined inputs
PCO standard logic
Parameters
PCO predefined outputs
PCO Standard part
Global control logic
Dependent Object
control logic
Order
..
Order
Programmer
Status
Dependent Device
control logic
Information to other
objects or to
operator via SCADA
Order
Device instantiation
Child Process Control Objects
and Child Field Objects
Auto Request
ICALEPCS, 12/10/05
Place holders for process
Dependent logics
Philippe Gayet CERN
PCO Placeholder Specification
For Each PCO the process engineers supply the logic associated to each PCO in a template document
Interlock Logic
Configuration logic
Logic Placeholders
Global logic
Interlock Logic
Configuration logic
Global logic
Dependent Object
control logic
Dependent Object
control logic
Dependent Object
control logic
Dependent Object
control logic
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Logic Skeleton Generation
Supervision
device type
templates
Instantiation generation
Devices Specification
devices
DB
Instance
Generator
Supervision
device
instance
UNICOS FW
Scripts
Device
instantiation
PLC device
instance
UNICOS time stamped
Middleware
Basic Logic generation
Device
instantiation
Logic
DB
Logic
Generator
Logic
Files
Logic
templates
Logic skeleton
UNICOS baseline
Placeholder
Skeletons
PLC
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Process Logic & HMI Production
Supervision
Synoptic Specification
Manual
production
Synoptic views, …
UNICOS FW
Device
instantiation
UNICOS time stamped
Middleware
Logic Specification
Device
instantiation
Control Logic
Manual
production
UNICOS baseline
PLC
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Advanced Application Production
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Model based Generation
Supervision
device type
templates
META-MODEL
Meta-Model
devices
DB
Instantiation generation
Instance
Generator
Supervision
device
instance
UNICOS FW
Scripts
Device
instantiation
PLC device
instance
Meta-Model
Generator
UNICOS time stamped
Middleware
Logic generation
Device
instantiation
Logic
DB
Replace generic skeleton
By
Actual logic model
Logic
Generator
Logic
Files
Logic
templates
Complete Logic code
UNICOS baseline
PLC
ICALEPCS, 12/10/05
Philippe Gayet CERN
Conclusion
Concepts:
Methods
From process analysis to code production
Tools
Process breakdown
CLOSE to IEC 61512-1
Operation and Diagnostics oriented
Common language for process experts and developers
Versatile suite of tools open to extension
UNICOS based application
LHC GCS, experiment magnets
LHC accelerator and experiment cryogenic
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Generator Principle
Specification DB
PROGRAM $Application$_AI_$PLC Nb$_Status
VAR
$Application$_AI_$PLC Nb$_Status_Crono : CRONO;
$Application$_AI_$PLC Nb$_Status_WTB : WORD_TO_BIT;
$Application$_AI_$PLC Nb$_Status: SECT_CTRL;
_TimeRef : DINT;
$Equipment$_$Location$_$Name$_StsReg01 AT %QW$StsReg01$
: WORD;
$Equipment$_$Location$_$Name$_HFSt AT %QD$HFSt$ : REAL;
$Equipment$_$Location$_$Name$_PosSt AT %QD$PosSt$ : REAL;
$Equipment$_$Location$_$Name$_AuMoSt : BOOL;
$Equipment$_$Location$_$Name$_FoMoSt : BOOL;
$Equipment$_$Location$_$Name$_IoErrorW : BOOL;
$Equipment$_$Location$_$Name$_IoSimuW : BOOL;
$Equipment$_$Location$_$Name$_FoDiPro : BOOL;
END_VAR
PLC code or SCADA DB Template
ICALEPCS, 12/10/05
Produced code or DB
Philippe Gayet CERN
Control project
First
Start up
Cryogenic commissioning
LHC Startup
Cryogenic Startup
Workload
2000
2001
Late Specifications
ICALEPCS, 12/10/05
Philippe Gayet CERN
2006
2007