Transcript No Slide Title

4th ST Workshop
Chamonix, 30 January - 2 February 2001
Control System Implementation and Follow-up
within the CV Contracts for the LHC
Y. Body, H. Jena, M. C. Morodo
ST-CV
Summary
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CV control systems: an introduction
Implementation within industrial contracts
Detailed design and approval procedures
On-site installation and acceptance procedures
Conclusions
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
CV Control Systems
The requirements for the LHC era:
To integrate our existing heterogeneous
environment --->
Openness
To cope with the geographical dispersion of our
processes --->
Networking
To provide the operation and maintenance teams
with well-adapted tools --->
Powerful local
supervision
The strategy:
A fully industrial standard control system architecture is taken as a reference
Industrial approach
Development and implementation of the particular solutions in collaboration
with the industry ---> Contracts
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Industrial Approach
Trouble Diagnosis
Post-mortem analysis
Web-access
Layer 4: Data handling and web supervision
Layer 3: TCR remote supervision
Process control and
supervision
Standardization of
interfaces
Flexibility
Process-customized
solutions
Reference Data Base
(for TCR data remote configuration)
Technical Data Server
Windows NT Workstations
SCADA: Wizcon
Layer 2: Local supervision
Reliability
Process regulation
Layer 1: Acquisition and regulation
4th ST Workshop
Availability
Ethernet TCP/IP
CERN technical data
monitoring
Data coherence
Archiving station
PLC: Schneider / Siemens
Profibus DP
Data archiving and
web-based
supervisory tools
Maintainability
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Project and Contract Phases
The Feasibility and Specification stages:
Feasibility study
Engineering Design Review
Market Survey
Technical Specification
Call for Tenders
Contract Negotiation
Contract is signed
The Detailed Design, Implementation and Validation stages:
Development
Implementation
Testing and validation
Provisional acceptance
Operational system
Refining and adjustments
Guarantee period
Final acceptance
Contract disengagement
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Collaboration with the Industry
Partnership CERN-Industry: the win-win relation
CERN project resources
Technical
Specification
Contract
follow-up
Contract
External Contractor project resources
The basis: Having a firm understanding of our own needs
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Collaboration with the Industry
Partnership CERN-Industry: the win-win relation
Planning and
resources
allocation
Technical
Specification
Technical
CERN project resources
CERN
CERN privileged
responsibilities
spokesperson
solution
Requirements
to be fulfilled
Contract
follow-up
External
External
Contractor
Contractor
privileged
External Contractor responsibilities
project resources
spokesperson
CERNContractor
Contract
collaboration
strategy
Work and
resources
organization
The basis: Having a firm understanding of our own needs
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Contract Follow-up
The Contract follow-up assures the Conformity with the Requirements
Technical aspects
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Emphasis in validation tests and
acceptance procedures
Project Documentation
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Work procedures
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State- of-the-art of control engineering
Safety issues, all over design and
implementation
Operational tools
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International Standards
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Flexible and well adapted to the CV
processes operation, user-friendly
Complete, clear, concise
In-house knowledge basis
Future system maintainability and
evolution
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IEC 1131-3 PLC programming method
IEC 61506 Industrial-process control doc
IEC 61508 Functional safety
--> Building control systems to be operational for 10-15 years!!!
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Detailed Design and Approval Process
Specification
Contractor’s
Critical points :
Proposal
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 Meetings
 Discussions
 Search for
Feasibility
Availability
Costs
Time
yes
Approval
Implementation
common
solutions
no
CERN’s
Proposal
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Detailed Design and Approval Process:
Example
Specification
Implementation
 Handling
 Availability
 Costs
Control
system with
redundant
architecture
4th ST Workshop
Siemens S7
S7- 400 H
 Further improvement
Schneider
TSX 57
Premium
Backup
Y. Body, H. Jena, M.C. Morodo
Schneider
Premium
with
redundant
Power
supply and
network
CERN ST-CV
Design and Implementation Phases:
Document Handling
CERN
Contractor
Process description
Functional Analysis
Modifications - Approval
Electrical schemas and Layouts
Modifications - Approval
Factory Tests Document
Factory Tests
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Document Handling: Contract Roles
Contractor
A
Wiring diagram
Project Leader
UIAOxxx
ghg
hjhjh
Subcontractor
1
A
Project Leader
Wiring diagram
UIAOxxx
ghg
CERN
A
Works
Responsible
Wiring diagram
Project Leader
UIAOxxx
ghg
hjhjh
Control
A
Approval Team
Wiring diagram
UIAOxxx
hjhjh
ghg
ST-CV
hjhjh
Subcontractor 2
Project Leader
Non-ST
Groups
4th ST Workshop
ST Groups
Y. Body, H. Jena, M.C. Morodo
Client
CERN ST-CV
Control cubicle wiring diagram
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Control cubicle wiring diagram
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Control cubicle wiring diagram
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Document Handling: Contract Roles
Contractor
A
Wiring diagram
Project Leader
UIAOxxx
ghg
hjhjh
Subcontractor
1
A
Project Leader
Wiring diagram
UIAOxxx
ghg
CERN
A
Works
Responsible
Wiring diagram
Project Leader
UIAOxxx
ghg
hjhjh
Control
A
Approval Team
Wiring diagram
UIAOxxx
hjhjh
ghg
ST-CV
hjhjh
Subcontractor 2
Project Leader
Non-ST
Groups
4th ST Workshop
ST Groups
Y. Body, H. Jena, M.C. Morodo
Client
CERN ST-CV
Control cubicle wiring diagram
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Control cubicle wiring diagram
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Factory Tests
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
On-site Installation and Acceptance
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV
Conclusions
Working within large-scale industrial Contracts demands of us:
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Making the Contractor fully understand our own needs
Best fit the contributions of every participant
Work procedures follow-up (emphasis to safety and quality)
Accurate validation and acceptance procedures
And last but not the least, always consider that...
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Efforts investment in Project Documentation is worthwhile
Thank you
4th ST Workshop
Y. Body, H. Jena, M.C. Morodo
CERN ST-CV