ESS Test and Prototyping Activities

Daniel Piso Ferńandez

www.europeanspallationsource.seDecember 4, 2014

EPICS & PLCs Integration

3

One year and some months ago…

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After a year…

Thank you!

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Who owns PLCs at ESS…???

• Accelerator Division, Target Division, NSS and Conventional Facilities. Main consumers are (in quantity):– RF local interlocks– Cryogenics Systems– Vacuum Systems– Local Protection Systems– Conventional Facilities Systems

• ICS does not own by far the majority of the PLCs (but it will provide development effort).

• But it us who has the standardization capability, almost all of them need to be integrated into the EPICS control system. We are trying to do it together with our stakeholders.

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EstimationsITEM QTY

Mid Range PLC set 176High Range PLC set 38Digital Input Module 208Digital Output Module 87Analog Input Module 953Analog Output Module 91Analog Input TC Module 442Profibus Module 100Serial Module 720Distributed I/O rails 326Safety PLC Set 23

Safety Digital Input Module 85

Safety Digital Output Module 85

High speed boolean processor 310

I/O Control FieldBus I/O Control * Number of devices

Device Name Number of devices: Possible Interface DI DI-F DO DO-F AI AO TC / PT100 Serial Digital IN Digital IN

FastDigital OUT

Digital OUT Fast Analog IN Analog

OUT TC / PT100 SERIAL

VACUUM Primary pump 155 PB, Serial, IO 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 310WATTER COOLING Cooling water 155 IO 0 0 0 0 10 0 7 0 0 0 0 0 1550 0 1085 0OIL Oil 155 IO 1 0 0 0 0 0 1 0 155 0 0 0 0 0 155 0POWER SUPPLY CONTROL

Filament 155 Aux port PS 0 0 0 0 2 0 0 0 0 0 0 0 310 0 0 0Klystron Solenoid 155 Serial?? 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 310RF FAST INTERLOCK Arc Detectors 155 IO 0 6 0 0 0 0 0 0 0 930 0 0 0 0 0 0MOD Interlocks 155 IO 0 2 0 2 0 0 0 0 0 310 0 310 0 0 0 0LLRF Interlocks 155 IO 0 1 0 1 0 0 0 0 0 155 0 155 0 0 0 0CAV Interlocks 155 IO 1 3 0 0 0 0 0 0 155 465 0 0 0 0 0 0MPS Interlock 155 IO 0 0 0 1 0 0 0 0 0 0 0 155 0 0 0 0PIN Diode 155 IO 0 0 0 1 0 0 0 0 0 0 0 155 0 0 0 0Power forward/reflecting 155 IO 0 10 0 0 0 0 0 0 0 1550 0 0 0 0 0 0GENERAL SAFETY HV cable detection 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0DOOR Switch detector 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0PSS Status 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0Emergency push button 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0

For One Transmitter 6 22 0 5 12 0 8 4SUM: 930 3410 0 775 1860 0 1240 620

*Copyright Rafael Montaño

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Standardization by procurement

• A PLC hardware Open Call for Tender is about to go out.– We want to procure a framework agreement to select a

preferred vendor.– It is ONLY to buy hardware and development software

• This tender does not cover PSS, TSS and motion controls applications.

• In any case, selecting a vendor it is not the only aspect of standardization!

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Documentation

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Documentation (II)

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Documentation (III)

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Conventional Facilities Integration

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Cryogenics Integration

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PLCs in vacuum

• This is only for analog signals for protection applications.

• Monitoring signals via serial ports

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Maximum Required Sampling Rates

Vacuum System 1 sample/sec, 1 sample/10msec, 10samples/msec

Conventional Facilities Systems 1 sample/sec

Power Distribution Systems 1 sample/sec

Water Cooling Systems 1 sample/sec

Cryogenics systems 1 sample/10msec

Slow Interlock System 1 sample/10msec

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Modbus vs. s7plc

• The goal was to measure the capability of exchanging data regarding the exchange rate and the number of channels (connections) used.

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Event Correlation Test

We are measuring four times:• when a Signal is triggered on Timing-

IOC. • when PLC detects this signal on its

digital input. • when PLC sends this value to PLC-IOC.• when PLC-IOC updates this new value

from PLC

Wiki PLC

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Event Correlation Test (II)

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Event Correlation Test (III)

• Similar delay times.• Except in the test with

minimum PLC cycle time 20ms and PLC push rate 20 ms.

Avg dela

y PLC

400

Avg dela

y PLC

1500048

1216

Received on PLC delayCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms

Dela

y [m

s]

Avg dela

y PLC

400

Avg dela

y PLC

15000

50100150200250

Send from PLCCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms

Dela

y [m

s]

Avg delay PLC400

Avg delay PLC1500

0

50

100

150

200

250

Received on PLC-IOC delayCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms

Dela

y [m

s]

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He Loop Test

Cooler

Heater

Control valve

Hoses

Flow meter

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Work flow??

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What is ahead….?

• Finish the OCT and select a vendor• Finish the documentation to be provided to the

stakeholders• Understand how PLC development fit in the overall

workflows and select/develop the proper tools for operate and maintain PLC-based controls systems

• Does UNICOS fits in those workflows? To be seen…• Build internal know-how