UNICOS-CPC applied to Cryogenics and specifications Benjamin Bradu EN-ICE-PLC February 2014.

UNICOS-CPCapplied to Cryogenics

and specifications

Benjamin Bradu

EN-ICE-PLC

February 2014

Summary

UNICOS-CPC for LHC cryogenics Overview of the cryogenic systems Functional decomposition UNICOS implementation

Control System Specifications Specification documents Functional Analysis UNICOS-CPC Design

LHC cryogenics

3

Point 1

Point 2

Point 3

Point 4

Point 5

Point 6

Point 7

Point 8 Sector refrigeration plant

3.3 km

Sector Refrigeration plant

4

UpperCold Box

Interconnection Box

Cold Box

WarmCompressor

Station

LowerCold Box

Distribution Line Distribution Line

Magnet Cryostats, DFB, ACS Magnet Cryostats, DFB, ACS

ColdCompressor

box

Sha

ftS

urf

ace

Ca

vern

Tun

nel

LHC Sector (3.3 km) LHC Sector (3.3 km)

1.8 KRefrigeration

Unit

New4.5 K

Refrigerator

Existing4.5 K

Refrigerator

1.8 KRefrigeration

Unit

WarmCompressor

Station

WarmCompressor

Station

WarmCompressor

Station

ColdCompressor

box

Even pointOdd point Odd point

MP StorageMP Storage MP Storage

UpperCold Box

Interconnection Box

Cold Box

WarmCompressor

Station

LowerCold Box



ColdCompressor

box

UpperCold Box

Interconnection Box

Cold Box

WarmCompressor

Station

LowerCold Box



ColdCompressor

box

Sha

ftS

urf

ace

Ca

vern

Tun

nel


1.8 KRefrigeration

Unit

New4.5 K

Refrigerator

Existing4.5 K

Refrigerator

1.8 KRefrigeration

Unit

WarmCompressor

Station

WarmCompressor

Station

WarmCompressor

Station

ColdCompressor

box



UpperCold Box

Interconnection Box

Cold Box

WarmCompressor

Station

LowerCold Box



ColdCompressor

box

UpperCold Box

Cold Box

WarmCompressor

Station

LowerCold Box


ColdCompressor

box

Sha

ftS

urf

ace

Ca

vern

Tun

nel


1.8 KRefrigeration

Unit

New4.5 K

Refrigerator

Existing4.5 K

Refrigerator

1.8 KRefrigeration

Unit

WarmCompressor

Station

WarmCompressor

Station

WarmCompressor

Station

ColdCompressor

box



UpperCold Box

Interconnection Box

Cold Box

WarmCompressor

Station

LowerCold Box



ColdCompressor

box

Nitrogen TanksDryer for adsorbersMP Buffer

PLC for LHC cryogenics

5

Refrigeration plants

6

Refrigeration @ 1.8 K(2.4 kW @ 1.8 K)

Réfrigeration @ 4.5 K(18 kW @ 4.5 K)

Courtesy to L. Tavian

Storage and distribution

7

Storage

Distribution

Courtesy to L. Tavian

Process Control Object decomposition

Identify Process Control Objects (PCO) Defined as units or Equipment modules in IEC 61512-1 Collection of actuators and/or other units Can carry out a finite number of processing activities Contains all the necessary equipments to carry out these activities Can execute procedural sequences Can drive other PCO Can be driven by another PCO

A “Top PCO” is a PCO without master Driven by operator to start/stop the complete plant

Example of PCO : A Compression Station : 2 compressor + 4 valves

8

Process Decomposition : Top PCOs

MP Buffer

Interconnection BoxSector (Magnets)

Refrigerator @ 4.5 K


Process Decomposition : 2nd PCO layer

Warm Compression

StationCold-Box @ 4.5 K

MP Buffer

Interconnection BoxSector (Magnets)

Cold-Box @ 1.8K

Sector Refrigeration Plant

Warm Compressionstation



ARC SectionLong Straight Section

3rd PCO layer in a compression station

11

High Stage

Compression Station

Boosters

Pressure Control

Connect

Oil LP

Oil HP

3rd PCO layer in a cold-box @ 4.5K

12

Precooler

T23

T45

T67

T89

TA

Shields

Adsorber1

Adsorber3

Connect CB

Vaccum

Adsorber2

Cold-Box @ 4.5K

Helium Main Flow

LoadInterface

Ending PCO

13

Adsorber3Input Valve

Output Valve

Hand ValvesOnOff Valves

Motor

Slide Valve

Booster 2

I/O Objects

UNICOS break down in PLC

Device Type = Object Class

PLC instance SCADA Instance

Equipment modules/Units Process Control Objects (PCO)

Control modules Field Objects

I/O acquisition I/O Objects

Operation team must be able to act on each object

In degraded operation conditions operation crew can overcome process logic requests Field Objects Control

Objects

I/O

Board

s

ControlValve

Equ

ipm

ent

mod

ule

(Tur

bine

1)

AI position

AO position

ControlValve

DI End switch

DO position

OnOffValve

Equ

ipm

ent

mod

ule

(Ads

orbe

ur)

UN

IT (

CR

YO

PL

AN

T)

CP

O

Equ

ipm

ent

mod

ule

(C

old

Box

)

E

quip

men

t M

odul

e(C

ompr

esso

r S

tatio

n)

AI position

AO position

LHC Compressor station decomposition

15

LHC Cold-Box Decomposition

16

Specifications for UNICOS-CPC

17

Specification Document Set

18

Requirement documents

Process & Instrumentation DiagramInstrument List(1)

Functional Analysis(1)

Design documents

UNICOS xml specification1

UNICOS Logic Templates1

PLC code SCADA objects

P

C

1 : Template provided by CERN-EN-ICE

Generators + C

What is a good set of specifications?

Easy to understand for other people Terminology/Acronyms definitions “Comments” in documents

Easy to find particular information Same place according to information type Limit cross references in documents

Easy to modify Information located at a unique place No doubloons

19

Functional Analysis

Descriptive document Oriented for Continuous Process Control (CPC) Exhaustive document No PLC language inside No platform oriented Structured English, drawings and diagrams can be used Hierarchically oriented

Describe the automatic behavior of the process General description of process Decomposition of the process into control units Exhaustive descriptions for each control unit

Actuator behaviors Regulation loops Alarms and interlocks Possibilities given to operators

Table of content of a Functional Analysis

21

Thank you for your attention

Any Questions ?

UNICOS-CPC applied to Cryogenics and specifications Benjamin Bradu EN-ICE-PLC February 2014.

Documents

tavian slide

adsorbers mp buffer

io objects unicos

process decomposition

ice generators c slide

lhc coldbox decomposition

ending pco

rd pco layer