AB-CO review Support for Cryogenics
Jan 01, 2016
AB-CO reviewSupport for Cryogenics
Philippe Gayet AB/CO ISCERN, 20/09/05
Outline
Scope Hardware Type, Responsibility sharing, Status Basic software Issues UNICOS Framework status ACR HW and SW production answers On site commissioning Support Software Quality Answers for PVSS Conclusion
Philippe Gayet AB/CO ISCERN, 20/09/05
Scope of Support for Unicos team
AT-ACR for accelerator cryogenics AT-ECR for experimental cryogenics PH-TA3 for magnets
Not in scope of this talk but done by the same team
AT-VAC for PVSS AT-ACR for cryo expert application(Enrique’s
Talk) PIC for PVSS QPS (Herve’s talk)
Philippe Gayet AB/CO ISCERN, 20/09/05
Hardware for ACR
Quantum
Premium
AB-CO
AT-ACR
Ethernet IT-CS
Tele
fast
Digital
Phoeni
x
Analog
PMAModbus
DPPA
PA
PA
PLCSafety
BUS X
AT-ACR
GatewayWFIP
GatewaySiemens
ET 200Boards
WFIP Networks
WFIP agents
CentralData server
Central & local control room
Operator consoles
Philippe Gayet AB/CO ISCERN, 20/09/05
Hardware Resp. sharing With ACR
Procurement Installation
SCADA AB/CO AB/CO
QUANTUM/Premium AB/CO AB/CO
FIP Gateway AB/CO AB/CO
S7 Gateway AB/CO AB/CO
Profibus from protected areas to S7 Gateways AB/CO AB/CO
S7 Profibus RIO in protected areas AB/CO AT/ACR
S7 RIO QRL specific AT/ACR AT/ACR
Fieldbus couplers (optical, DP/PA, etc…) AB/CO AB/CO & AT/ACR
Intelligent Valve Actuators AT/ACR AT/ACR
Local Profibus Network AT/ACR AT/ACR
FIP network AB/CO AB/CO
LHC RadTol tunnel RIO (FIP Agent) AT/ACR AT/ACR
Philippe Gayet AB/CO ISCERN, 20/09/05
Quantum
PCU
EWS
Hadware for PH-TA3 & ECR
Quantum RIOField interface
Sch
nei
der
Pro
pri
etar
y b
us
Local Control room
Central control room
OWS
Profibus network
CentralData server
UNITY
PCU
PremiumField interface
Profibus network
Profibus network
AB-CO
Philippe Gayet AB/CO ISCERN, 20/09/05
Hardware Resp. sharing ECR/PH-TA3
Procurement Installation
SCADA AB/CO AB/CO
PLC AB/CO AT/ECR
Fieldbus couplers (optical, DP/PA, etc…) AB/CO AT/ECR
Intelligent Valve Actuators AT/ECR AT/ECR
Local Profibus Network AT/ECR AT/ECR
Philippe Gayet AB/CO ISCERN, 20/09/05
HW Status & Maintenance
HP Proliant for Scada (15 + 4 + 2) Schneider PLC (110 + 15 + 5) Profibus components (waiting for profibus card for Quantum for ECR) We have to Buy & Install Siemens Gateway (24) (P8 OK)
All equipements for ACR are or will be referenced in : ABCAM for asset management LHC Layout db for intervention
Same service can be extended to ECR, Ph-Ta3 AB-CO will monitor the HW evolution and propose preventive
maintenance AB-CO will provide a central spare parts repository Servers will be in CCC with the same service as the other critical server
for LHC Operation On site intervention will have to be organized by AB-CO
Philippe Gayet AB/CO ISCERN, 20/09/05
Basic software Issues
Migration from XP OWS/DS to Proliant Linux DS with UNICOS/PVSS V3 Servers configuration & monitoring (IN) Use of Proliant Linux servers instead of present Windows gives to
CO an additional workload (application configuration)
Migration Of Schneider PLC to UNITY OS Done for FI and small PCU Still some Pb with large PCU
Availability of reliable Online programming capacity on Unity Quantum New release of Schneider development tool New version of object (20% of memory liberated) ongoing validation Problem is one of the Schneider priority
Consolidation of PLC communication CERN Application Firmware PB contact with Schneider on hardware bug correction no result
yet
Philippe Gayet AB/CO ISCERN, 20/09/05
UNICOS Framework status
New framework UNICOS/PVSS V3 deployed Faster, interface to Timber, LASER, DIP(GTPM)
Communication Schneider/Siemens Migration Of Schneider PLC to UNITY OS
Existing methodology and at least 3 systems ready (1 ECR, 2 ACR)
Tools for software production Thermometers calibration in Siemens Schneider DB & Field Object part (Concept , UNITY, PVSS) Schneider logic for sectors Concept, Unity to be tested Siemens DB & logic ready for first prototype
Philippe Gayet AB/CO ISCERN, 20/09/05
ACR HW and SW production answers
First time (new controls): All tunnel cryogenic system (ACR/IN with AB/CO support) – 2006-
07 If only support needed if more
SM 18 cryo infra and 6 kW Linde ABB -> UNICOS - 1st semester 07
NOT in present roadmap nor in budget Ex-LEP refrigerator upgrade to UNICOS (pt. 4 and 6) – early 06
limited AB-CO resources available to establish specification as usual Resources OK for programming
Already performed in other LHC points (duplication): Precoolers and upgrade (all pts) – 1st semester 06 QUI Pt.1.8 and 6 but need upgrade for all - 1st semester 06 QURC Pt. 1.8, 6 – end 05 Pt. 1.8 18 kW refr. ABB -> UNICOS – SD 06-07 Dryers pt 2, 4, 6, 8 - end 2005 – beginning 06
OK program ready
Philippe Gayet AB/CO ISCERN, 20/09/05
AB
-CO
-IS
AT
-AC
RApplication status
QSD
Sector 1-2Sector 2-3Sector 3-4Sector 4-5Sector 5-6Sector 6-7Sector 7-8Sector 8-1
QSRBQURAQUIQUI
Point 4Point 3Point 2Point 1.8 Point 5Point 6 Point 7Point 8 Surface(buildings+areas)CavernQURCQURC
QSCQSRAQUIQURCQURC QURCQURC QURCQURCQUI QUI
Shaft
QRL LHC machine cryostatQRLQRLQRLQRLQRL QRLQRLTunnel
QSVQSCBQSC QSCQSCC
QURA QURA QURA
QSCAQSCC QSRB QSRB QSRBQSRA QSRA QSRAQSCCQSCAQSCBQSCQSCC QSCQSCAQSCCQSCQSCCQSCB QSCQSCQSCCQSCAQSCBQSCQSCCQSV QSVQSVQSV QSV QSV QSVQSDQSDQSDQSD
QSCA : Compressor set for existing 4.5K refrigeratorQSRA : Upper cold box for existing 4.5K refrigeratorQURA : Lower cold box for existing 4.5K refrigeratorQSCB : Compressor set for new 4.5K refrigeratorQSRB : Cold box for new 4.5K refrigeratorQUI : Interconnection cold boxQSV : Gaseous Helium StorageQSD : Liquid Nitrogen Storage QSCC : Compressor set for new 1.8K refrigeratorQURC : Cold box for new 1.8K refrigeratorQRL : Main ring transfer Line
QSD
Sector 1-2Sector 2-3Sector 3-4Sector 4-5Sector 5-6Sector 6-7Sector 7-8Sector 8-1
QSRBQURAQUIQUI
Point 4Point 3Point 2Point 1.8 Point 5Point 6 Point 7Point 8 Surface(buildings+areas)CavernQURCQURC
QSCQSRAQUIQURCQURC QURCQURC QURCQURCQUI QUI
Shaft
QRL LHC machine cryostatQRLQRLQRLQRLQRL QRLQRLTunnel
QSVQSCBQSC QSCQSCC
QURA QURA QURA
QSCAQSCC QSRB QSRB QSRBQSRA QSRA QSRAQSCCQSCAQSCBQSCQSCC QSCQSCAQSCCQSCQSCCQSCB QSCQSCQSCCQSCAQSCBQSCQSCCQSV QSVQSVQSV QSV QSV QSVQSDQSDQSDQSD
QSCA : Compressor set for existing 4.5K refrigeratorQSRA : Upper cold box for existing 4.5K refrigeratorQURA : Lower cold box for existing 4.5K refrigeratorQSCB : Compressor set for new 4.5K refrigeratorQSRB : Cold box for new 4.5K refrigeratorQUI : Interconnection cold boxQSV : Gaseous Helium StorageQSD : Liquid Nitrogen Storage QSCC : Compressor set for new 1.8K refrigeratorQURC : Cold box for new 1.8K refrigeratorQRL : Main ring transfer Line
LN2LN2LN2
Sector 1-2 Sector 2-3 Sector 3-4 Sector 4-5 Sector 5-6 Sector 6-7 Sector 7-8 Sector 8-1
QSRB
QURA
QUIQUI
Point 4Point 2Point 1.8 Point 6 Point 8
Su
rface(b
uildin
gs+areas)
Cavern
QURCQURC
QSC
QSRA
QUI
QURC QURC QURC QURC QURC QURC
QUI QUI
Sh
aft
QRL QRL QRL QRL QRL QRL QRL QRL Tu
nn
el
HPstorage
LN2LN2
HPstorage
HPstorage
HPstorage
HPstorage
QSCB
CentralHP
storage
QSC QSCQSCC
QURA QURA QURA
QSCA QSCC
QSRB QSRB QSRBQSRA QSRA QSRA
QSCC QSCAQSCB QSCQSCC QSCQSCA QSCCQSCQSCC QSCB QSCQSCQSCC QSCA QSCB QSCQSCC
To Copy from existing version in Unity V2
To port from concept to Unity V2 PVSS
To be specified by ACR & Developed by CO
To be Developed & Deployed by ACR/IN
Ready in Unity V2 PVSS, upgrade on request of ACR
Philippe Gayet AB/CO ISCERN, 20/09/05
On site commissioning Support
Commissioning of individual sub-systems Tunnel cryogenics, ex-LEP refrigerators, QUI, QURC’s, dryers, pre-coolers, SM18 infra and
refr. All on critical path for hardware commissioning, Requires presence of AB-CO software specialist at start-up (no on-call support) to shorten, optimize and make safe and reliable tests (first few days only are sufficient)
Global system commissioning, upgrades and consolidations Participation of AB-CO to the commissioning activities to optimize collective behavior of sub-
systems and optimize general process during the tests at least during first sectors and systems testing.
Cryogenics and HC will work on 2x8 shift; any stop will disrupt the HC planning and hold up to 10 persons / day -> it requires fast troubleshooting -> on-call service 24h/24h
3rd operation and consolidation Availability of AB-CO specialist for controls improvement and upgrade during the first years of
operation 24 h/ 24h on-call support for installation in operation (ABB installations prior to transfer to
UNICOS ?) Resources:
No sufficient support from AB-CO to cover the commissioning of more than 1 – 2 subsystems at the time-> 4 sector in parallel -> forget!
No on-call support during non-working hours for urgent troubleshootingof controls Mainly “call centre” type technical support (we need AB-CO support in the control room during
machines start-up) to improve efficiency, share of responsibility and achievements, better understanding of problems, team work !
3 Staff PLC +2 staff S
CADA + (1 contract staff) available part ti
me for this support
Philippe Gayet AB/CO ISCERN, 20/09/05
Software Quality
SW verification prior to cooldown to minimize on-line modifications during runs No Pb if specification delivered on due time (3 months prior to
delivery) Maintain and ensure SW modification consistency and up-
to-date version, QA and logging of SW modifications QA for specification required from ACR side QA is not always compatible with the present way of Cryo system
commissioning but an effort is done on our side on the subject.
Ensure control system improvement and modification are correctly tracked and updated in default SW version. A central software repository is used with manual tracking we will use CVS for versioning as fast as possible
The encountered problems were mainly due to the different upgrade of PLC
platform
Philippe Gayet AB/CO ISCERN, 20/09/05
Answers for PVSS
Support for GTPM applications necessary for fast restart after major stop Interface ready exchanged information to be define by ACR
Support for supervision screens and fixed displays production, maintenance and upgrade
First production done in frame of software contract Evolution to be done by ACR operation team (no PVSS knowledge required) training done By
AB-CO Slow response and “load” of the control system
Mostly due due to low performance Operator consoles and PVSS 2.12 (outdated now) Trends: still progress needs to be made
Please elaborate you specs as it is a tools under IT-CO responsibility Data logging: data extraction without formatting and ready to analyse
Already available in PVSS, & in Timber. Data logging: continuous change of naming in DB makes difficult the creation of
automatic routines for data collection and analysis We are now migrating to production environment no change anymore unless you require them
Diagnostics info: not always available or difficult to implement We are nom migrating to production environment
PVSSIII: on-line modification not possible ????
Philippe Gayet AB/CO ISCERN, 20/09/05
Conclusion
Hardware installation & support & maintenance OK ACR production application under way without major PB
BUT Still some dark area of responsibility to clarify
Support for ring software Synoptic maintenance Specification elaboration Long term Operation support (different level of responsibility within
the same control system) Still some technical PB to address
Online modifications Communication reliability
Resources not compatible with ACR requests on commissioning support