automating the automation cern dr. enrique blanco head of the process control section industrial...

1

Automating the automationCERN

Dr. Enrique BlancoHead of the Process Control sectionIndustrial Controls & Safety Systems Group Beams Department

CERN Enrique Blanco

• Introduction: CERN• Process control standardization• R&D activities

CERN Enrique Blanco 2

Outline

Conseil Européen pour la Recherche Nucléaire

World largest Particle Physics Laboratory (1954)

21 Member CountriesAustria, Belgium, Bulgaria, Check Republic, Denmark, Finland, France, Germany, Greece, Italia, Hungary, Holland, Israel, Norway, Poland, Portugal, Slovakia, Spain, Sweden, Switzerland, UK.

Yearly Budget~1100 MCHF (~ 900 MEUR)

Experiments financed externally.

7 Observers CountriesEC, USA, Russia, India, Japan, Turkey,

UNESCO

Personnel2400 Staff730 Fellows & Associates200 Students

>10000 Users2000 External companies

2 Candidate CountriesRomania and Serbia (pre-stage of

membership)

Enrique Blanco 3CERN

Fundamental researchStudy of the Universe structure: Exploring the Physics laws which govern the fundamental blocks of the matter and the space-time structure

CenturyIV – V

AC

End of centuryXIX

Beginning of centuryXX 1960

Atom 10-10 >>>>>>>>>>>>>>>>>> Quark ~ 10-19

CERN Goal


On 4 July 2012, the ATLAS and CMS experiments at CERN's Large Hadron Collider announced they had each observed a new particle in the mass region around 126 GeV. This particle is consistent with the Higgs boson

Higgs Boson

Enrique Blanco 5

A Higgs boson decays to 4 leptons in this collision recorded by the ATLAS detector on 18 May 2012

Peter Higgs stands on the cavern floor at CMS

CERN

Acce

lera

tor

com

plex

1eV -> 1.602 10-19 J 14 TeV -> 22.4 x 10–7 joules

450 GeV

14 TeV

25 GeV

Accelerator complex


• One of the CERN goals: maximize uptime of the instruments (accelerators, detectors,…) in order to optimize physics data availability

• This objective implies the maximum availability and optimal operation of all the auxiliary/utilities systems (e.g. cryogenics, cooling, HVAC, gas, motion, interlocks,…) -> the correspondent control systems must ensure this.

• What is uncommon at the CERN accelerators control systems?• Environment (radiation areas)• Large systems (highly distributed and/or interconnected)• Complexity (control logic) • Precision (measurements)• Performance (regulation)


Control challenges


27km length100m underground

Thousands of Superconducting magnets (1.8 x 109 km of superconducting filaments)

Coldest place in Universe: -271° C

LHC AcceleratorWorld Largest accelerator

compressorstations

cold boxes

helium storage

liquid nitrogen storage

helium transfer line

liquid helium storage

3.3 km 3.3 km

LHC Cryogenics

CERN Enrique Blanco 9LHC sector: 3.3 km


LHC cryogenics control : facts

Electro-pneumatic positioner, SIPART PS2

WinCC OA HMI in the CCC

Tunnel Instrumentation

- 27 km of decentralized instrumentation and control

- 50k I/O, 11k actuators, ~5k Control loops- Control: ~100 PLCs (Siemens, Schneider),

~40 FECs (industrial PCs)- Supervision: 26 SCADA servers : 1.5 million

TAGS

RadTol in-house electronics for signal conditioning and actuation

• Introduction: CERN• Process control Standardization• Research activities


Outline

CERN Organization


Accelerator & technology

• Beams

• Engineering

• Technology

Research & Computing

• Exp. physics

• Theoretical physics

• Information Technology

Finance & HR

• Finance & Administration

• Industry, Procurement & KT

• Human Resources

• Site Management and Buildings

International Relations

Partial view of the 2016 structure

Controls @ CERN

BEAMSDepartment

ABP Accelerat

or and Beam

Physics

BI Beam

Instrumentation

OPOperatio

n

RF Radio

Frequency

CO Control

s

ICS Industrial Controls & Safety

ASR Administration, Safety & Resources

BEAMS Department Structure

BE-ICS group

Industrial Controls & Safety Systems

ACAccess Control

CSECritical systems

Engineering

FGAFire, Gas & Alarms

SDSSCADA & Distributed Systems

PCSProcess ControlSystems

CICConnectio

ns & Informatic

s for control

Industrial Controls & Safety Systems Structure


• UNICOS (UNified Industrial Control System) was born at CERN as a need to develop the LHC cryogenics control system


Creating standards: UNICOS

• UNICOS benefits- Development (Homogenized applications)- Maintainable code (Original developer is not critical)- Unified operation in control rooms

Facilitate the task of the automation engineer by allowing him/her in focusing only in the automation duty and not in the software production itself: Automatic generation of code.

Field

Control

Supervision SCADAPLC

Field equipment

• Based on industrial standards - ISA-88 / IEC-61512: Batch control - IEC-61499 : Distributed systems

• Framework composed of - Generic set of reusable devices - Analysis and Development method - Programming structure

Not only a bunch of devices• UNICOS CPC provides libraries (control and supervision layers)

• A well defined set of standard device types (objects), modeling most of the equipment and needs of continuous processes and the relationships between them.

•A formalized way of :• Define the control units of a process (ISA-88 standard: Batch processes)• Programming the specific process logic for those units

I/O Objects Digital I/O Analog I/O

Field Objects OnOff Analog AnalogDigital Local AnaDO

Control Objects Controller Alarms Process Control Object

Interface Objects Parameter (Digital, Word, Analog) Status (Word, Analog)


17CERN Enrique Blanco

Process inputs

Objects status

PLC internal Object Logic

Orders

Process outputor

child Auto Request

Status

Information toother object

or toOperator

Auto Requests

Parent Object

PLC Object

Manual Requests

PlantOperato

r

Parameters ControlEnginee

r

UNICOS CPC Object model

Objects & Layers Integration

CERN 18Enrique Blanco

In the Supervision layer the object presents the relevant information to the operator and allow manual commands

Supervision Layer

Control Layer

Object status

Human Requests

SCADA Object HMIParameters

Manual Request

Information display

SCADA

Object

Auto. Requests Object logic

Orders

PLC Object Object status Manual Request

Parameters

Process Inputs

Process

PlantOperato

r

SCADA Server(s)

CERN Control Room(s)

OWS

Field Layer

Enrique Blanco 19

• SUPERVISION, Visualization and programming• SIEMENS WinCC OA (PVSS) SCADA (standard)

• CONTROL• SIEMENS, Schneider (standards)• Industrial PCs: SIEMENS IPC, Codesys

• FIELD LAYER• Industrial instrumentation: Sensors, actuators• Industrial customized actuators: Profibus PA positioners• Virtual instrumentation: VFT (flowmeters)

• COMMUNICATIONS• Fieldbuses: Profibus, WorldFIP, CAN (CERN standards)• Ethernet based: Profinet, Ethernet/IP

CERN

Industrial COTS


UNICOS Engineering life cycle

Decomposition Automatic Code Generation

Logic specifics& Synoptics

Deployment

PLC

Reverse Engineering

Specifications


Methodology: (1) DecompositionUnit

Equipment ModulesEquipment ModulesEquipment ModulesEquipment Modules

Equipment ModulesEquipment ModulesEquipment Modules

Control ModulesControl ModulesControl ModulesControl Modules

Control Modules

IEC 61512-1 Physical model

22

Methodology: (1) Process vs. Control

CERN

I/O Devices

Field Devices

Control Devices

Interface: I/O Boards-Fieldbus-Other PLCs

CompressorQSCCx

LHC 1.8KCryoplants

Point 4 Cryogenic System

Compressor 1

PV Valve

CV Valve

PID

AI AODI DOAnalog

Input

Analog Output

Digital

Input

Digital

Output

Analog

Local OnOff

Controller

PCO

PCO

PCO

PCO

Automatic Generation of the

PCO objects (From

Specifications)

Standard Unicos

Programming and

Process Logic

programs (From

Specification)

Operation in

multiple scenario

s

Automatic Generation of

the objects and

connections between

objects (From Specifications)

- Each control module or equipment module is a device- Equipment modules and Units are embedded in a unique

object class: PCO (Process Control Object)

Enrique Blanco

Methodology: (2) Specifications

CERN 23Enrique Blanco

UNICOS CPC Specs (xls/xml file)

Functional Analysis + Logic specification(Word templates)

PL

C: S

chne

ider

M

340

Schneider

Pan

el: W

inCC

Fl

ex

PLC

: S7

SCA

DA

: Win

CC

OA

UAB

UAB: UNICOS Application Builder


Methodology: (3) Code generation

CPC Wizard

Input

Specifications

Device Instantiation Templates

Process LogicTemplates

Baselines

SCADATouch Panel

PLC

Device Types

AnalogAlarm

PID

Control System Developer

Output

ControlApplication

PLC S7

Methodology: (4) Process control logic

For Each PCO the process engineers supply the logic associated to each PCO in a template document (WORD)

Process logic can be either:- coded by the control engineer in an standard

way. - some applications may create automatically

the logic based on templates.

- These templates are based on Phyton scripting wherePLC logic can be also written in PLC programming language.

Interlock LogicConfiguration logic

Global logic

Interlock LogicConfiguration logic

Sequencer / Transitions (2)Dependent Object

control logicDependent Object

control logic

Dependent Objectcontrol logic

Sequencer

///


Logic Placeholders



Global logic


Methodology: (5) HMI synoptics


• Manual intervention (or automatic if known a priori)

Synoptic design - by drag & drop (manual operation)- Automatically created (xml)

Cryogenics• LHC accelerator & Detectors• Experimental areas• FRESCA2: Nitrogen

Cooling & HVAC • Tunnels and caverns ventilation• Machinery cooling• Control rooms air conditioningInterlocks• LHC Collimator Temperature

InterlocksMotion• ATLAS big wheels• HTS winding machine• AMS beam test servo systems• LHC Elevators

Gas systems• LHC Detector Gas• Linac 4 hydrogen supply• CO2 cooling plants• CLOUD

Vacuum• ISOLDE • REX • LHC Detectors: ATLAS, CMS

Detector Controls• Magnet Control system• ECAL detector cooling• CMS tracker thermal

screen• ALICE Cooling water valves


UNICOS is a CERN de facto standard

• Introduction: CERN• Process control Standardization• R&D activities


Outline

– Communications– Reverse Engineering– Virtual commissioning: Simulation– PLC software quality control– DSLs (Domain Specific Language)– Formal methods applied to engineering


R&D activities

Enrique Blanco 30

Communications: TSPP

CERN

• TSPP: Time Stamp Push Protocol (event driven)

• Needs SCADA drivers development• Currently being wrapped out with OPC UA

Reverse engineering

- Getting the original specifications from any UNICOS based project

- Compare original specifications with current status



Dynamic simulation

- Allows a better understanding of the process

- Dynamic processplant verification &optimization Process

Knowledge

- Offline tests of improved regulation

(e.g. PID tuning)

- New control algorithms application (e.g. model

embedded based)Advanced Control

Off-line commissioning

reduces drastically the real commissioning

effort

Virtual Commissioning

- Complex and critical plants do not allow training online

- High operator turnover

requires appropriate training

Training of

operators

• Virtual commissioning– Simulation techniques (static and dynamic)– HIL (Hardware in the Loop)


Testing and Commissioning

Communications : S7 protocol

SUPERVISION

CERN Industrial control architecture vs Simulation

CONTROL

FIELD

Industrial Fieldbus

Communications: OPC

C++ application (OPC client) EcosimPro

Process Model(C++ class)

Simatic

WinLC (PLC Simulator)

Simatic OPC Server

• Development– Standards: Languages IEC61131-(3-8)– Frameworks: Structure and maintainable code– Issues Management, versioning (e.g. JIRA, SVNs)– Deploying tools– Coding standards or guidelines


PLC software quality control

35

DSL (Domain Specific Languages)

• Complex, repetitive, tedious automation tasks can be handled by appropriate languages which allow to generate advanced PLC code.

Device specification list

Templates

UNICOS application sources

UAB CPC Wizard

Inputs

Code Generation Import & Compile

ControlCode

CERN Enrique Blanco

Enrique Blanco 37

Formal verification: ConceptTesting vs Model Checking (Formal methods)Testing:

- Error prone due to human manual testing- Non-exhaustive action

CERN

RequirementIf I0.0 is FALSE and I0.1 is FALSE , then Q0.0 is FALSE

Q0.0 := (I0.0 AND I0.1) OR Var1

automating the automation cern dr. enrique blanco head of the process control section industrial...

Documents