UNICOS A FRAMEWORK TO BUILD INDUSTRY LIKE CONTROL SYSTEMS PRINCIPLES & METHODOLOGY

1. UNICOS A FRAMEWORK TO BUILD INDUSTRY LIKE CONTROL SYSTEMS PRINCIPLES & METHODOLOGY Renaud Barillère CERN IT-CO Philippe Gayet CERN AB-CO

2. Outline • Industrial Control in CERN Accelerator Control • Industrial Control Framework Objectives • Process Control Analysis • UNICOS Model • Process Control Specification • Application Production • Conclusion Philippe Gayet CERN

3. CERN Accelerator Control Architecture Philippe Gayet CERN

4. Industrial Supervision Layer Operator Consoles Interface to operators (Monitoring & Command emission) <5 Years SCADA Servers Real time DB & Archiving Industrial Control layer PLC Process Control Ethernet Network & TCPIP communication services One Communication protocol per supplier Life time Control Logic Actions PLC Process Control & Field interface COTS from different supplier Industrial Field layer PLC Field interface >10 Years control system connection to the process directly or through field-buses Fieldbus Networks Industrial Control Architecture Link to other accelerator control system And services (alarms, logging,…) Accelerator Presentation Tier Accelerator Middle Tier Accelerator Resource Tier Philippe Gayet CERN

5. First Cryogenic commissioning Cryogenic Startup Control project Start up LHC Startup 2000 2001 2007 Late Specifications Workload 2006 Industrial Control Framework Objectives • Integrates industrial control layers together respecting interlayer independence • Integrates the Industrial Control to the accelerator control infrastructure and services (alarms, Logging,..) • Offers a methodology to produce functional analysis directly programmable by application development teams • Supplies Application Development Tools available for various development teams (CERN, Experiment collaboration, Outsourcing) • Allows long term maintenance by reduced CERN teams • Offers homogenous and efficient user interface for operation crew from equipment commissioning to long term operation Philippe Gayet CERN

6. Unit Equipment Modules Equipment Modules Equipment Modules Equipment Modules Equipment Modules Equipment Modules Equipment Modules Control Modules Control Modules Control Modules Control Modules Control Modules Process control Analysis IEC 61512-1 Physical model Philippe Gayet CERN

7. Control Valve AI M value PID An Input position An Output position Equipment module On-Off Valve DI End switch UNIT Equipment module I/O Boards DO position AI M value PID Control Valve AI position Equipment module AO position On-Off Valve DI End switch DO position Process Control Objects I/O devices Field devices UNICOS Break Down • IN UNICOS • Each control module or equipment module is a device • Each device type is an Object Class • Each device is instantiated in the control layer as PLC Object • Equipment modules and Units are embedded in a unique object class : Process Control Object • All PLC Object classes are based on the same model Philippe Gayet CERN

8. Operator Parent Object Objects status Process inputs Manual Requests Auto. Requests Parameters PLC internal Object Logic Programmer Status Orders Process output Information to or other object Child Auto Requests or to operator Object Model (Control Part) PLC Object Philippe Gayet CERN

9. Object status Object status Object status Output Object Input Object Field Object Manual Requ. Manual Requ. Manual Requ. Process Inputs Process Inputs Process Inputs Parameters Parameters Parameters Object logic Object logic Object logic Auto. Requests Auto. Requests Auto. Requests Orders Orders Orders I/O Board or Fieldbus Input Channel Output Channel PROCESS PLC Objects Interactions Philippe Gayet CERN

10. Operator UNICOS Operation Principles • Operation team must be able to act on each device • In degraded operation conditions operation crew can overcome process logic requests Philippe Gayet CERN

11. Object status SCADA Proxy PLC Object Human Manual Requ. Requests SCADA Object HMI Process Inputs Parameters Object logic Parameters Information display Auto. Requests Orders Object status Manual Request Process Layers Integration In the Supervision layer a proxy is associated to each object This proxy will present the relevant object info to the operator And allow manual command emission Industrial Supervision Layer Industrial Control Layer Philippe Gayet CERN

12. Auto Manual Requests Arbiter Auto Manual Requests Conflicts Philippe Gayet CERN

13. Graphical components (Widgets / Faceplaces) • Navigation tools • Objects explorer • Trends and alarms handling • Access control • Interconnection to accelerator services Application Basic Components Supervision UNICOS FW UNICOS SCADA Middleware UNICOS PLC Middleware UNICOS object library PLC Philippe Gayet CERN

14. I/O devices Field devices PCO devices Objects Specification Philippe Gayet CERN

15. Instantiation generation device type templates Supervisiondevice instance Devices Specification Device instantiation devices DB Scripts Instance Generator PLC device instance Device instantiation Application Generation Supervision UNICOS FW UNICOS time stamped Middleware UNICOS library PLC Philippe Gayet CERN

16. Introducing Process Logic Philippe Gayet CERN

17. Input objectsStatus Or other objects status Parent PCO Control Logic Operator Process Inputs PCO Process dependant part Interlock Logic Configuration Logic Manual Requests Auto Requests PCO predefined inputs PCO standard logic Parameters PCO predefined outputs Programmer PCO Standard part Global control logic Status Dependent Object control logic Dependent Device control logic Information to other objects or to operator via SCADA .. Order Order Order Device instantiation Child Process Control Objects and Child Field Objects Auto Request Place holders for process Dependent logics UNICOS Process Control Object Model Philippe Gayet CERN

18. Interlock Logic Configuration logic Global logic Dependent Object control logic PCO Placeholder Specification For Each PCO the process engineers supply the logic associated to each PCO in a template document Logic Placeholders Interlock Logic Configuration logic Global logic Dependent Object control logic Dependent Object control logic Dependent Object control logic Philippe Gayet CERN

19. Instantiation generation device type templates Supervisiondevice instance Devices Specification Device instantiation devices DB Scripts Instance Generator PLC device instance Basic Logic generation Device instantiation Logic Generator Logic Files Logic DB Logic skeleton Logic templates Placeholder Skeletons Logic Skeleton Generation Supervision UNICOS FW UNICOS time stamped Middleware UNICOS baseline PLC Philippe Gayet CERN

20. Synoptic Specification Synoptic views, … Manual production Logic Specification Control Logic Manual production Process Logic & HMI Production Supervision UNICOS FW Device instantiation UNICOS time stamped Middleware Device instantiation UNICOS baseline PLC Philippe Gayet CERN

21. Advanced Application Production Philippe Gayet CERN

22. Instantiation generation device type templates Supervisiondevice instance META-MODEL Device instantiation devices DB Scripts Instance Generator Meta-Model PLC device instance Meta-ModelGenerator Logic generation Device instantiation Logic Generator Logic Files Logic DB Complete Logic code Logic templates Replace generic skeleton By Actual logic model Model based Generation Supervision UNICOS FW UNICOS time stamped Middleware UNICOS baseline PLC Philippe Gayet CERN

23. Conclusion • Concepts: • Process breakdown • CLOSE to IEC 61512-1 • Operation and Diagnostics oriented • Methods • From process analysis to code production • Tools • Common language for process experts and developers • Versatile suite of tools open to extension • UNICOS based application • LHC GCS, experiment magnets • LHC accelerator and experiment cryogenic Philippe Gayet CERN

24. PROGRAM $Application$_AI_$PLC Nb$_Status VAR $Application$_AI_$PLC Nb$_Status_Crono : CRONO; $Application$_AI_$PLC Nb$_Status_WTB : WORD_TO_BIT; $Application$_AI_$PLC Nb$_Status: SECT_CTRL; _TimeRef : DINT; $Equipment$_$Location$_$Name$_StsReg01 AT %QW$StsReg01$ : WORD; $Equipment$_$Location$_$Name$_HFSt AT %QD$HFSt$ : REAL; $Equipment$_$Location$_$Name$_PosSt AT %QD$PosSt$ : REAL; $Equipment$_$Location$_$Name$_AuMoSt : BOOL; $Equipment$_$Location$_$Name$_FoMoSt : BOOL; $Equipment$_$Location$_$Name$_IoErrorW : BOOL; $Equipment$_$Location$_$Name$_IoSimuW : BOOL; $Equipment$_$Location$_$Name$_FoDiPro : BOOL; END_VAR PLC code or SCADA DB Template Produced code or DB Generator Principle Specification DB Philippe Gayet CERN

25. First Cryogenic commissioning Cryogenic Startup 2000 2001 2007 Late Specifications Workload Control project Start up LHC Startup 2006 Philippe Gayet CERN