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4 th ST Workshop Chamonix, 30 January - 2 February 2001

4 th ST Workshop Chamonix, 30 January - 2 February 2001. Control System Implementation and Follow-up within the CV Contracts for the LHC Y. Body, H. Jena, M. C. Morodo ST-CV. Summary. CV control systems: an introduction Implementation within industrial contracts

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4 th ST Workshop Chamonix, 30 January - 2 February 2001

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  1. 4th ST WorkshopChamonix, 30 January - 2 February 2001 • Control System Implementation and Follow-up within the CV Contracts for the LHC • Y. Body, H. Jena, M. C. Morodo • ST-CV

  2. Summary • CV control systems: an introduction • Implementation within industrial contracts • Detailed design and approval procedures • On-site installation and acceptance procedures • Conclusions 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  3. To integrate our existing heterogeneous environment ---> Openness To cope with the geographical dispersion of our processes ---> Networking To provide the operation and maintenance teams with well-adapted tools ---> Powerful local supervision A fully industrial standard control system architecture is taken as a reference Industrial approach Development and implementation of the particular solutions in collaboration with the industry ---> Contracts CV Control Systems The requirements for the LHC era: The strategy: 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  4. Trouble Diagnosis Post-mortem analysis Data archiving and web-based supervisory tools Web-access Archiving station Layer 4: Data handling and web supervision Reference Data Base Data coherence Standardization of interfaces (for TCR data remote configuration) CERN technical data monitoring Technical Data Server Layer 3: TCR remote supervision Windows NT Workstations Flexibility Process-customized solutions Process control and supervision SCADA: Wizcon Layer 2: Local supervision Reliability Availability Maintainability Profibus DP PLC: Schneider / Siemens Process regulation Layer 1: Acquisition and regulation Industrial Approach Ethernet TCP/IP 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  5. The Feasibility and Specification stages: Feasibility study Engineering Design Review Market Survey Technical Specification Call for Tenders Contract Negotiation Contract is signed The Detailed Design, Implementation and Validation stages: Development Implementation Testing and validation Provisional acceptance Operational system Refining and adjustments Guarantee period Final acceptance Contract disengagement Project and Contract Phases 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  6. Partnership CERN-Industry: the win-win relation CERN project resources Technical Specification Contract follow-up Contract External Contractor project resources Collaboration with the Industry The basis: Having a firm understanding of our own needs 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  7. Technical solution Partnership CERN-Industry: the win-win relation Planning and resources allocation Requirements to be fulfilled CERN project resources CERN responsibilities CERN privileged spokesperson Technical Specification Contract follow-up CERN-Contractor collaboration strategy Contract External Contractor privileged spokesperson Work and resources organization External Contractor responsibilities External Contractor project resources Collaboration with the Industry The basis: Having a firm understanding of our own needs 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  8. Contract Follow-up The Contract follow-up assures the Conformity with the Requirements Technical aspects • Emphasis in validation tests and acceptance procedures Project Documentation • Complete, clear, concise • In-house knowledge basis • Future system maintainability and evolution Work procedures • State- of-the-art of control engineering • Safety issues, all over design and implementation International Standards Operational tools • IEC 1131-3 PLC programming method • IEC 61506 Industrial-process control doc • IEC 61508 Functional safety • Flexible and well adapted to the CV processes operation, user-friendly --> Building control systems to be operational for 10-15 years!!! 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  9. Contractor’s Proposal Critical points :  Feasibility  Availability  Costs  Time CERN’s Approval  Meetings Discussions  Search for common solutions Approval Implementation yes no CERN’s Proposal Detailed Design and Approval Process Specification 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  10. Implementation  Handling  Availability  Costs  Further improvement Schneider Premium with redundant Power supply and network Schneider TSX 57 Premium Backup Control system with redundant architecture Siemens S7 S7- 400 H Detailed Design and Approval Process: Example Specification 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  11. Processdescription Functional Analysis Modifications - Approval Electrical schemas and Layouts Modifications - Approval Factory Tests Document Factory Tests Design and Implementation Phases: Document Handling CERN Contractor 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  12. A A A A Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Contractor CERN Works Responsible Project Leader Project Leader Subcontractor 1 Project Leader Control Approval Team ST-CV Subcontractor 2 Project Leader Non-ST Groups ST Groups Client Document Handling: Contract Roles 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  13. Control cubicle wiring diagram 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  14. Control cubicle wiring diagram 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  15. Control cubicle wiring diagram 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  16. A A A A Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Wiring diagram UIAOxxx ghg hjhjh Contractor CERN Works Responsible Project Leader Project Leader Subcontractor 1 Project Leader Control Approval Team ST-CV Subcontractor 2 Project Leader Non-ST Groups ST Groups Client Document Handling: Contract Roles 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  17. Control cubicle wiring diagram 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  18. Control cubicle wiring diagram 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  19. Factory Tests 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  20. On-site Installation and Acceptance 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

  21. Conclusions Working within large-scale industrial Contracts demands of us: • Making the Contractor fully understand our own needs • Best fit the contributions of every participant • Work procedures follow-up (emphasis to safety and quality) • Accurate validation and acceptance procedures And last but not the least, always consider that... • Efforts investment in Project Documentation is worthwhile Thank you 4th ST Workshop Y. Body, H. Jena, M.C. Morodo CERN ST-CV

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