New control system – pilot New control system – pilot project SE1project SE1

S. PoulsenS. Poulsen

ST-EL-COST-EL-CO

STTCSTTC

November 12th, 2002November 12th, 2002

OverviewOverview

IntroductionIntroduction ProblemProblem ProjectProject ResultResult ConclusionsConclusions FutureFuture

IntroductionIntroduction

OverviewOverview– Present pilot project LHC 1Present pilot project LHC 1

– Make general conclusionsMake general conclusions

– Propose future activitiesPropose future activities

Situation 1999 LHC 1Situation 1999 LHC 1

Substation controlled with CERN Substation controlled with CERN Technology (ST and SL divisions)Technology (ST and SL divisions)

MICENE interface to most equipmentMICENE interface to most equipment– Data acquisition developed at CERN in 80sData acquisition developed at CERN in 80s

Some equipment with modern protectionSome equipment with modern protection LEP-wide concept and technology for LEP-wide concept and technology for

electrical equipment and controlelectrical equipment and control

Problems in 1999Problems in 1999

CERN LEP technology obsolete and discontinuedCERN LEP technology obsolete and discontinued Repairs and configuration changes difficult or Repairs and configuration changes difficult or

impossibleimpossible Control experts close to retirementControl experts close to retirement Complicated integration with new industrial Complicated integration with new industrial

electrical SCADA systemelectrical SCADA system Performance degradingPerformance degrading Conclusion : Future uncertain !Conclusion : Future uncertain !

ProposalProposal

Pilot project using industrial technologyPilot project using industrial technology Proposal selected from supplier of SCADA Proposal selected from supplier of SCADA

system for integration and cost reasonsystem for integration and cost reason ConstraintsConstraints

– No development of hardwareNo development of hardware– No major re-cabling of electrical equipmentNo major re-cabling of electrical equipment– Reuse of MICENE interconnection chassis’Reuse of MICENE interconnection chassis’

Technical solution Technical solution (in (in blueblue))

B. 212

LHC Zone

Substation

Data Acquisisition Front End – Remote terminal unit

Interconnectionchassis

PLCs SEPAMs Power Meters

FIR

Optical fibre link Communication network

SCADA server

TCR console

MICENEreplacement

Project DocumentationProject Documentation

Before: Project note issuedBefore: Project note issued– Define scope and boundariesDefine scope and boundaries– Define hardware requirementsDefine hardware requirements– Define functionalityDefine functionality– Define practical implementation issuesDefine practical implementation issues

After: Project conclusion issuedAfter: Project conclusion issued– Status report and major conclusionsStatus report and major conclusions

Lessons learntLessons learnt

Modification of switchboards for measurement Modification of switchboards for measurement time consuming and impracticaltime consuming and impractical

Interconnection cables with equipment critical Interconnection cables with equipment critical Chassis re-cabling difficultChassis re-cabling difficult Co-ordination between CERN and supplier Co-ordination between CERN and supplier

difficult during installationdifficult during installation

Improvements for future !Improvements for future !

Concentrate power measurements in rack or in one Concentrate power measurements in rack or in one device per switchboard (LV)device per switchboard (LV)

Include critical interconnection cables in supplyInclude critical interconnection cables in supply Minimise interconnection chassis re-cablingMinimise interconnection chassis re-cabling Prepare installation completely before intervention Prepare installation completely before intervention

of supplierof supplier

Additional resultsAdditional results

Local visualization of substation status in Local visualization of substation status in synopticsynoptic

Local logging of events (no risk of Local logging of events (no risk of communication network outage)communication network outage)

Local visualization of measurements for Local visualization of measurements for MV and some LV via dedicated power MV and some LV via dedicated power measurement modulesmeasurement modules

Long-term performanceLong-term performance

Reliability satisfactory guarantee periodReliability satisfactory guarantee period Problems solved quicklyProblems solved quickly Regular new software versions installed by Regular new software versions installed by

suppliersupplier No major maintenance by CERN except No major maintenance by CERN except

restarting the system occasionallyrestarting the system occasionally

General Architecture General Architecture based on pilotbased on pilot

B. 212

LHC Zone

Substation

Data Acquisisition Front End

MICENEreplacement PLCs SEPAMs Power Meters

FIR

Optical fibre link Communication network (IT-CS)

SCADA server ElectricalData logging

Web server forSCADA data

TCR console TDS EquipmentController

Perspectives LHC 1–2002/2003Perspectives LHC 1–2002/2003End of prototypeEnd of prototype

New cryogenics substation with modern New cryogenics substation with modern protection to be integratedprotection to be integrated

New switchboard in SEM11 with modern New switchboard in SEM11 with modern protection (no extra controls hardware)protection (no extra controls hardware)

Reconfiguration of control system offered Reconfiguration of control system offered at CHF 4000 (foreseen in frame contract !)at CHF 4000 (foreseen in frame contract !)

Recycling of original data acquisition Recycling of original data acquisition hardware installed for prototypehardware installed for prototype

Related activities Related activities initiated after pilotinitiated after pilot

On-going control renovation program over 5 yearsOn-going control renovation program over 5 years Done: Complete upgrade in LHC 1, LHC 4, LHC Done: Complete upgrade in LHC 1, LHC 4, LHC

5, LHC 6, LHC 8, BE, BE9, SM18, ME9 (LHC 1 5, LHC 6, LHC 8, BE, BE9, SM18, ME9 (LHC 1 to be redone)to be redone)

Done: Partial upgrade in BA1, BA2, BA3, BA4, Done: Partial upgrade in BA1, BA2, BA3, BA4, BA5, BA6, BA7 but MICENEs not yet replaced BA5, BA6, BA7 but MICENEs not yet replaced (BA4 scheduled for 2003)(BA4 scheduled for 2003)

Not Done:Underground will follow equipment Not Done:Underground will follow equipment installation and communication infrastructure, installation and communication infrastructure, LHC 2, (3 and 7)LHC 2, (3 and 7)

Conclusions 1Conclusions 1Disadvantages of approachDisadvantages of approach

Limited control over contractors staff, schedule, etc.Limited control over contractors staff, schedule, etc. Less flexibility (contractual terms)Less flexibility (contractual terms) Less reactivity (contract changes difficult !)Less reactivity (contract changes difficult !) Specific software difficult to debug off-siteSpecific software difficult to debug off-site Difficult to have special functionalitiesDifficult to have special functionalities Quality control important (ISO not sufficient…)Quality control important (ISO not sufficient…) Risks : Future of supplier ? Suppliers strategy ? Risks : Future of supplier ? Suppliers strategy ?

CERN strategy ? The technology ? The LHC CERN strategy ? The technology ? The LHC requirements ? In 10 years ? Integration with CERN requirements ? In 10 years ? Integration with CERN systems ?systems ?

Conclusions 1Conclusions 1Advantages of approachAdvantages of approach

Results based !Results based ! Responsibility of problems clear !Responsibility of problems clear ! Reliability satisfactoryReliability satisfactory Industrial hardware cost effectiveIndustrial hardware cost effective Changes are possible (if paid…)Changes are possible (if paid…) Knowledge of system not “owned” by CERN Knowledge of system not “owned” by CERN

personnelpersonnel Technology not CERN specific (training fast and Technology not CERN specific (training fast and

cost effective)cost effective)

Main conclusions of pilotMain conclusions of pilot

Industrial control equipment can be used at CERNIndustrial control equipment can be used at CERN Work can be formed by small team with help of Work can be formed by small team with help of

contractors and limited industrial supportcontractors and limited industrial support Contractors can assist execution with simple well-Contractors can assist execution with simple well-

defined tasks but not tasks that need experience defined tasks but not tasks that need experience and management of complexityand management of complexity

In the future choices have to be made about In the future choices have to be made about priorities. We cannot control all equipment and we priorities. We cannot control all equipment and we have to decide where to concentrate !have to decide where to concentrate !

Future activities - 1Future activities - 1

TrainingTraining– Electrical operation personnel and operatorsElectrical operation personnel and operators– Training investment proportional to investment Training investment proportional to investment

in systemin system– More important with industrial systems since More important with industrial systems since

knowledge comes from outside firm and knowledge comes from outside firm and development is separated from CERNdevelopment is separated from CERN

– Best way of learning is “doing”Best way of learning is “doing”

Future activities - 2Future activities - 2

Energy managementEnergy management– SEPAMs and power measurement modules SEPAMs and power measurement modules

provide information about power consumption provide information about power consumption on a feeder basis down to LV switchboardson a feeder basis down to LV switchboards

– Information presented in Web pages or Information presented in Web pages or customised energy reportscustomised energy reports

– Use information for forecasting, monitoring Use information for forecasting, monitoring and maybe more efficient operationand maybe more efficient operation

Future activities - 3Future activities - 3

Integration of electrical control in ST Integration of electrical control in ST infrastructureinfrastructure– Done: Transmission of signals for real-time Done: Transmission of signals for real-time

monitoring via TDSmonitoring via TDS– To do: Exchange of information for off-line To do: Exchange of information for off-line

analysis (data logging and events). Data format analysis (data logging and events). Data format and structure to be discussedand structure to be discussed

– Probably other issues for discussion in CSWGProbably other issues for discussion in CSWG

Thank you !Thank you !

Hope to have answered your questions ?Hope to have answered your questions ? Any more questions now or later ?Any more questions now or later ?

– S. Poulsen (contract manager)S. Poulsen (contract manager)– J.-C. Gallois (energy and installation)J.-C. Gallois (energy and installation)– G. Burdet (field buses, PLCs and software)G. Burdet (field buses, PLCs and software)