HL-LHC Working Group - Control architecture #2 LHC control

HL-LHC Working Group - Control architecture #2

LHC control architecture and instrumentation

M. Pezzetti, TE-CRG

On behalf of the TE-CRG-CE section

CERN, 6th June 2019

https://indico.cern.ch/event/818202/

Outline

- INTRODUCTION of CERN Nomenclature and existing topology concerning process control

system;

- LHC control standard “Frigo” & “Tunnel” architectures

- Communication within control layers

- Identification of interfaces to CRG control system for powering, cabled and bus data

exchanges

- Technology evolution from LHC until now and perspective.

- Conclusion

2

The goal is to evaluate possible control architectures, interfaces with existing ones, and typical needs for racks and cables.

The following subjects should be considered: introduction and presentation of reference so far for HiLumi cryogenics, LHC controls architecture.

Outcome of the discussion should be studies for possible scheme for instrumentation and controls of HiLumi cryogenics.

A summary document with schemes and list should be the final deliverable.

LHC - Refrigerator LHC - Tunnel

SUP

ER

VIS

ION

I/O

- P

LCE

LEC

TR

ICA

LC

AB

LEA

CTU

ATO

RS

Universal transmitter….

Flow Meter

M. Pezzetti, HL-LHC WG Control #2, 06.06.2019 3

“Control reference architecture“ 3 Layers

4

FIELD LAYER:

- Instrumentation (radiation areas): TT, PT, LT, DI, EH

- Signal conditioning (radiation areas) CERN in-house “Radtoll Electronics”

- SPLIT intelligent positioners / industrial sensors (non radiation areas)

COMM PROTOCOL : WorldFip, Profibus PA – DP, 0- 24V & 4-20mA, (Fiber Optic).

PROCESS CONTROL LAYER:

- FECs (Industrial PCs Linux SLC6 ; FESA application interfacing WorldFip data)

- PLCs (Siemens / Schneider; UNICOS Framework)

COMM PROTOCOL : S7, Modbus, Ethernet IP.

SUPERVISION LAYER:

- SCADA data servers (HP prolient machines, Linux SLC6, WinCC OA-Siemens)

- Windows clients in control rooms: local and central control rooms

COMM PROTOCOL : CMW, DIP & WinCC OA COM manager.

SCADA : Supervison system, DS Linux running Siemens-WinCC OA;

PLC : Programmable Logic Controller (CERN PLC Siemens/Schneider);

FEC: Front End Computer (Running Linux & CERN/FESA framework);

CMW : CERN protocol*;

DIP : CERN protocol*; (not used in the LHC only LHC Detectors;

WorldFip : CERN custom RadTol protocol (will be replaced by NanoFIP);

FiberOptic :Siemens/Schneider dedicated protocol;

Profibus PA – DP : Industrial comm protocol;

Control

The LHC cryo process control system is composed of 3 layers :

Outline


system;

LHC control standard “Frigo” & “Tunnel” architectures



exchanges


- Conclusion

5

Alc

ov

es

RM

PA

Profibus DP

WorldFIP

Return Module SL & SR

RM

PA

Profibus DP

WorldFIP

Return Module SL & SR

RMSLSector L (3.3 Km)

LHC Cryogenics Control System Refrigerators Architecture (Px)

LHCA

QURA

LHCCA

QURCA

QSCCA

LHCCB

QSCCB

LHCB

QSRB

QSCB

QUI

QSDNQSAA

Comp 4.5K Comp 1.8KMain DryerComp 1.8K Comp 4.5K

QURCB

Cold Box 4.5K

LN2 Buffer

CB 1.8KCB 1.8K

Connection

Box

UCB 4.5K

QSRA

QSKA

QSCA

QSAB

Main Dryer

Local & Central

Control Rooms

SCADA Data Servers

RMSRSector R (3.3 Km)

Tu

nn

elC

av

ern

Su

rfa

ce

Shaft

QSDN

Profibus DP

PA

6

LHC Cryogenics “Electrical” System Refrigerators Architecture (Px)

400V

230V

Cryo Field Boxes

Redundant

24 VDC

Cabling, AL / Linde resp.

Cryo plant “Frigo”

EN/EL resp

Other building

50 m Feedback signal

(Fiber Optics solution)

Cryo

Field Boxes

NE48 cables

NE02 cables

EM01

PLC

IO

7

HW cable for Order

(48 V)

3.3 kV cell

For technical details please

refer to additional slide..

Equipment protection system

8

Cryogenics

M

Machine protection system

Process control system

Motor-Compressor

HH

H

Pre alarm (beep)

In LHC the process control system assure 2 levels of protection :

- Pre-alarm (named as beep with no action)

- Level of alarm defined as H (with action – interlock)

The “machine protection system” is a separate apparatus within the process control system that ensure

the ultimate “HH” level of protection (if the process control system interlock fail to stop the plant) and it is

associated to an interlock in the process control system.

Outline


system;

- LHC control standard “Frigo” & “Tunnel” architectures - Communication within control layers


exchanges


- Conclusion

9

LHC cryogenic tunnel architecture

LSS LSSARC

RadTol electronics -

Crates

LHC Tunnel (3.3 Km)

Protected

areas PA PA

Radiation

areas

PA PA

sha

ft (

~1

00

m)

Tu

nn

elA

lco

ves

TT CV

Local & Central

Control Rooms

SCADA Data Servers

UNICOSPLCs

Ethernet (TN)

DP DP DP DP

Profibus DP FESAFECs

WorldFIP

TT, PT, LT, EH, DI

Ehsp, LTen

10

LHC tunnel Cryogenics Control System – “Network topology”

11

Cryogenics Control System - Network topology

WorldFip Copper cable

WorldFip Fiber

Profibus Fiber

Ethernet UTP

Profibus DP Copper cable

FIP:

- TT, PT, LT, GL, GH

- EH

Profibus:

- GT

- CV, PV, QV


Cryogenics Control System – Profibus Network “deported” topology

PUPRB

Radiation area Protected area

With COTS equipment's in presence of

radiation the solution is to deport the

sensible electronics and leave in the

radiation the “less” sensitives component.

Here the PROFIBUS valves positioner

installation example.

To be noted from PU to PRB there are 8

wires to be pulled plus the 24 VDC cable

(on/off valves).


Cryogenics Control System – WorldFip Network topology

Protected area

WF

ip

WF

ip

The Radiation Tolerant (“RadTol”) electronics dedicated to the signal conditioning

of the cryogenic instrumentation has been installed either in the tunnel or in the

alcove protected area for geographical position (cabling saving).


Outline


system;


Communication within control layers- Identification of interfaces to CRG control system for powering, cabled and bus data

exchanges


- Conclusion

15

LHC cryo control Communication topology

16

Outline


system;



Identification of interfaces to CRG control system for powering,

cabled and bus data exchanges- Technology evolution from LHC until now and perspective.

- Conclusion

17

Surface

Shaft

LHC TunnelRadiation area

LHC tunnel protected

(shielded) area

QRLMagnets

QYC01

Optical Fiber

Ethernet Outlet

OWSEthernet TN

7 Power cables& Grounding

Profibus DP

LHC Tunnel – Sector Control Architecture

Redundant 24VDCPLC + IOPower

Redundant 24VDCFeed from EOD

SCADA DS

F.Box

UJ/UA/UL UJ/UA/ULRE RE

LSS ARC LSS

DFB

QYC0* QYC0* QYC01 QYC0* QYC0*QYC01 QYC0* QYC01 QYC0*

QYC01 QYC0*

IP SH

PLCLSS

PLCARC

QYC01 QYC0*

FEC FEC

FEC

FEC

FEC

FEC

FEC

EWSCIET DS

Ethernet Outlet

CCR, CCC, LCR, ...

Crate

Crate

Crate

Crate

Crate

Crate

Crate Crate Crate Crate Crate Crate

OLMOLMOLM OLM

OLM OLM OLM OLM

Crate

Crate

Crate

Crate

Optical Fiber

Cu Cu

CuCu

Optical FiberOLM

DPPA

ET200MET200s

OLM

DPPA

ET200M

OLM

DPPA

ET200M

OLM

DPPA

ET200MET200s

OLM

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPART

SIPARTET200sET200s

OLM

Optical Fiber

World FIP

F.BoxF.Box F.Box F.Box F.BoxF.Box F.Box

F.Box

DFB

F.Box

F.BoxF.Box F.Box

DFB

F.Box

DFB

F.Box

DFB

F.Box

DFB

F.Box

F.BoxF.Box F.Box



Except EH > 25 WFeed from Normal Network


Outline


system;




exchanges

Technology evolution from LHC until now and perspective. - Conclusion

19

LHC - Refrigerator LHC - Tunnel

SUP

ER

VIS

ION

I/O

- P

LCE

LEC

TR

ICA

LC

AB

LEA

CTU

ATO

RS

Universal transmitter….

Flow Meter

From Premium to M580

Ethernet IO

NanoFIP

NanoFIP

From S7 to 1500 Tia portal ?

CERN RadTol

Electronics (CRG-CI)

Profinet ?

“Future evolution” Cryogenic process control system architecture


Conclusion

21

The LHC process control system has proven to be well suited for the

cryogenic operation purpose.

The 33% cost of a CERN control system is cabling, unfortunately in LS3

there is not foreseen a major breakthrough for wireless communication.

For HL-LHC there will be need a cabling campaign as LHC (apart some

optical fiber installation in “HL-LHC Frigo”).

For tunnel cabinet space reservation we can base the LHC experience (maybe a

extra space for FIP crate in alcove to be discussed with CI expert).

During the installation of new cryoplant CERN has acquired and design new

technical solution (cabling connectors or Profibus redundancy..etc). After almost of

10 years of operation a certain experience has been gathered (i.e. field

instrumentation protection during TS/EYET or LS, high voltage test for ELQA,

critical instrumentation for degraded mode, redundancy, etc….)

HL-LHC cryogenic should profit with this industrial dynamic and past LHC

operational experience.

Additional slide

22

QSCA Electrical power architecture (detailed)

Documents

HL-LHC Working Group - Control architecture #2 LHC control