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Automating the automationCERN
Dr. Enrique BlancoHead of the Process Control sectionIndustrial Controls & Safety Systems Group Beams Department
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• Introduction: CERN• Process control standardization• R&D activities
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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)
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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
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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
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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
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• 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)
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Control challenges
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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
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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
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Outline
CERN Organization
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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
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• UNICOS (UNified Industrial Control System) was born at CERN as a need to develop the LHC cryogenics control system
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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)
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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
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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
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• 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
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Industrial COTS
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UNICOS Engineering life cycle
Decomposition Automatic Code Generation
Logic specifics& Synoptics
Deployment
PLC
Reverse Engineering
Specifications
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Methodology: (1) DecompositionUnit
Equipment ModulesEquipment ModulesEquipment ModulesEquipment Modules
Equipment ModulesEquipment ModulesEquipment Modules
Control ModulesControl ModulesControl ModulesControl Modules
Control Modules
IEC 61512-1 Physical model
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Methodology: (1) Process vs. Control
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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)
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Methodology: (2) Specifications
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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
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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
///
Dependent Objectcontrol logic
Logic Placeholders
Dependent Objectcontrol logic
Dependent Objectcontrol logic
Global logic
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Methodology: (5) HMI synoptics
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• 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
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UNICOS is a CERN de facto standard
• Introduction: CERN• Process control Standardization• R&D activities
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Outline
– Communications– Reverse Engineering– Virtual commissioning: Simulation– PLC software quality control– DSLs (Domain Specific Language)– Formal methods applied to engineering
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R&D activities
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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
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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)
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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
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PLC software quality control
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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
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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