UNICOS: UNIFIED INDUSTRIAL CONTROL SYSTEM CPC (CONTINUOUS .

Industrial Controls &Safety SystemsBeams DepartmentUNICOS: UNIFIED INDUSTRIALCONTROL SYSTEMCPC (CONTINUOUS PROCESS CONTROL)BASIC COURSESESSION 0:UCPC FROM SPECS TO IMPLEMENTATIONUCPC 6UNICOS-Continuous Process ControlCERN, UNICOS team

UNICOS AND CPCIndustrial Controls &Safety SystemsBeams Department Process. Methods of changing or refining raw materials to create endproducts. Process control refers to the methods that are used to control processvariables when manufacturing a product. Manufacturers control the production process for several reasons:Reduces variability: increase qualityIncreases efficiency: increase profitsEnsures safety: optimize conditionsSession 0: From specs to implementation2

UNICOS AND CPCIndustrial Controls &Safety SystemsBeams Department UNICOS is a framework to create control applications. UNICOS-CPC (Continuous Process Control) is basic package todevelop integrated PLC based process control applications.Session 0: From specs to implementation3

UNICOS, JCOP AND UNICOS-CPCUCPCpackageIndustrial Controls &Safety SystemsBeams DepartmentUNICOSJCOP FrameworkWinCC OA (PVSS)PLCs CPCCryogenicsGasCollimatorsInterlocksCooling andVentilationProcess Control applications4

A LOOK TO THE PASTIndustrial Controls &Safety SystemsBeams Department [1998] UNICOS (UNified Industrial Control System) was born at CERN as a needto develop the LHC cryogenics control system. The goal was to create anindustrial control system covering the three layers of the typical automationpyramid. [2002] UNICOS replace the PcVue SCADA and adopt ETM’s PVSS under theCERN recommendation. [2004] UNICOS offered the choice of creating applications based on SIEMENSS7 PLCs [2009] UNICOS turned into de facto standard framework to develop industrialcontrol applications at CERN:Cryogenics, Cooling, HVAC, Vacuum, Interlocks, [2010] The UNICOS framework has been extended to other kinds of applications(i.e.: supervisory: [QPS,SURVEY], monitoring, ) [2012] Re-engineering processSession 0: From specs to implementation5

Industrial Controls &Safety SystemsBeams DepartmentTECHNOLOGIESSupervision LayerWinCC OA SCADAControl LayerSiemens S7-300, S7-400, S7-1500Schnedier Premium, Quantum, M580Codesys (Somachine, TwinCat3)Local operationSimatic HMI (WinCC flexible, TIA portal)Schneider MagelisIndustrial communicationsProfibus, Profinet, Ethernet/IPModbus TCPSUPERVISIONCommunications NetworkCONTROLIndustrial FieldbusFIELDSession 0: From specs to implementation6

APPLICATIONS Industrial Controls &Safety SystemsBeams DepartmentLHC CryogenicsDetector and Test facilities cryogenicsMagnet Control SystemVacuum installations : ATLAS, CMS, ISOLDELHC collimators: Environmental temperaturesATLAS Big wheels (motion)AMS servomotors controlDetector gas control systemsCooling and HVAC installationsWinding machines: HTS cable (hybrid with a Safety system)SM18 Magnet test bench protection system.Session 0: From specs to implementation7

UNICOS-CPC ESSENTIALS Industrial Controls &Safety SystemsBeams DepartmentUNICOS CPC provides libraries (control and supervision layers)A well defined set of standard device types (objects), modeling mostof the equipment and needs of continuous processes and therelationships between them. 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)A formalized way of : Define the control units of a process (ISA-88 standard: Batch processes)Programming the specific process logic for those unitsSession 0: From specs to implementation8

Industrial Controls &Safety SystemsBeams DepartmentUNICOS CPC OBJECT MODELObjects statusPlantOperatorParent ObjectProcess inputsManual RequestsAuto. RequestsPLC internal Object LogicParametersControlEngineerPLC ObjectOrdersProcess outputorChild Auto RequestsStatusInformation toother objector tooperatorSession 0: From specs to implementation9

Industrial Controls &Safety SystemsBeams DepartmentOBJECTS & LAYERS INTEGRATIONSupervision LayerOWSCERNControlRoom(s)SCADAServer(s)In the Supervision layer the object presents the relevantinformation to the operator and allow manual commandsSCADAObjectHumanRequestsPlantOperatorSCADA ObjectInformationdisplayHMIParametersManual RequestObject statusManual RequestObject statusControl LayerPLCObjectObject logicAuto. RequestsOrdersParametersProcess InputsField LayerProcessSession 0: From specs to implementation10

UNICOS-CPC OBJECTS I/O Objects Field Objects Control Objects Interface ObjectsSession 0: From specs to implementationIndustrial Controls &Safety SystemsBeams Department11

I/O OBJECTS Functionality Industrial Controls &Safety SystemsBeams DepartmentBase componentsPLC Periphery interface and/or internal memory variablesTypes AI, AIR: Analog Input or Analog Input Real(e.g. temperature transmitter) DI: Digital Input(e.g. end contact) AO,AOR: Analog Output or Analog Output Real(e.g. control valve position order) DO: Digital Output(e.g. onoff valve position order)Session 0: From specs to implementationWidget examples12

FIELD OBJECTS Functionality Industrial Controls &Safety SystemsBeams DepartmentModel the real field equipments (e.g. pumps, valves )As a general rule, the field objects are connected to the I/O Objects. Nodirect connection to the PLC periphery.Types OnOff: Binary Objects(e.g. on/off valve, motor, pump) Analog: Analog objects(e.g. control valve, heater) Anadig: Analog inputs and Digital outputs objects(e.g. valves/heaters controlled by on/off pulses) AnaDO : Similar functionality of an OnOff Analog object(Motor with VFD, Thyristor, Heater, etc.) Local: Field localized objects :(e.g. manual valve)Session 0: From specs to implementationWidget examples13

Industrial Controls &Safety SystemsBeams DepartmentCONTROL OBJECTS Functionality Main objects holding the control logic Feedback controllers Handle the abnormal situations: Alarms and interlocksTypes PCO: Process Control Objects/Unit. It implements the control logic(e.g. Compressor Station) Controller: feedback control objects(e.g. PID controller) AA, DA: Analog/Digital Alarm Objects. It models alarmsand interlocks. Analog alarms include alarm and warningthresholds(e.g. Temperature Too High)Widget examplesOptions for an AA: Explicit threshold: Initialized in PLC and then modified from SCADALogic: Set by control logic in the PLCAPAR : Linked object APAR sets the valueSession 0: From specs to implementation14

INTERFACE OBJECTS Industrial Controls &Safety SystemsBeams DepartmentFunctionality Parameterization and status Can be connected to the periphery Light objectsTypes DigitalParameter, WordParameter, AnalogParameter: Parameters(e.g. Threshold )Can be set by an operator (SCADA - PLC)Widget examples WordStatus, AnalogStatus: Status(e.g. stepper position, PA valve feedback)PLC - SCADASession 0: From specs to implementation15

Industrial Controls &Safety SystemsBeams DepartmentPROCESS VS. CONTROL-Each control module or equipment module is a device-Equipment modules and Units are embedded in a unique object class:PCO (Process Control Object)Point 4 Cryogenic SystemLHC 1.8KCryoplantsCompressorQSCCxCompressor 1ControlDevicesField DevicesI/O DevicesOperationin multiplescenariosPCOStandardUnicosProgrammingand cGeneration of thePCO objects (FromSpecifications)PCOPCOPIDPV ValveDigitalInputDigitalOutputCV DOInterface: I/O Boards-Fieldbus-Other PLCsSession 0: From specs to implementationAnalogAIAOAutomaticGeneration of theobjects andconnectionsbetween objects(FromSpecifications)16

OPERATION MODES Industrial Controls &Safety SystemsBeams DepartmentAuto ModeThe object is driven by the control logic of a higher object of the hierarchy. Interlocks apply to the request Manual Mode (requested by operators via the OWS) Forced Mode (requested by operators via the OWS) The automatic return to the auto mode is possible by the control logic.Interlocks apply to the requestThe automatic return to the auto mode is impossible by the control logic.Interlocks apply to the requests.Local mode Hardware Local Mode The object is driven locally by the process field (activated via a DI)E.g. maintenance purposesSoftware Local Mode (requested by operators via the Local panels) The Local software is writing directly in the manual requests of the objectsPriority over "Auto" and "Manual" mode. The "forced mode" setup by thenormal SCADA can override the software local mode.Interlocks apply to the requests.Session 0: From specs to implementation17

Industrial Controls &Safety SystemsBeams DepartmentDI OBJECT CONNECTIVITYLogical connectivityPhysical connectivityStatus of DI Objectsmay be used by allobjects anywhere inthe program.Process LogicPCOProcessControlDevicesOnOffField DevicesOnOffInterlockLogicLocalAnalogPosition StatusDII/O DevicesDIDIHardware FeedbackI/O BoardsSession 0: From specs to implementation18

DO OBJECT CONNECTIVITYIndustrial Controls &Safety SystemsBeams DepartmentLogical connectivityPhysical connectivityDO Objects receivetheir orders only fromField Devices (OnOff& Anadig, AnaDO)PCOProcessControlDevicesProcess LogicOnOffField DevicesAnadigOpenCloseAuto Position RequestDOI/O DevicesDOHardware Output OrderI/O BoardsSession 0: From specs to implementation19

Industrial Controls &Safety SystemsBeams DepartmentAI OBJECT CONNECTIVITYStatus of AI Objectsmay be used by allobjects anywhere inthe program.Process ogicGTAnadigField DevicesOnOffPosition StatusAII/O DevicesAIAIAIHardware FeedbackI/O BoardsSession 0: From specs to implementation20

AO OBJECT CONNECTIVITYAO Objects receivetheir orders only fromField Device AnalogPCOProcessControlDevicesIndustrial Controls &Safety SystemsBeams DepartmentProcess LogicControllerAnalogPositionRequestField DevicesI/O DevicesAnalogAuto Position RequestAOAOHardware Output OrderI/O BoardsSession 0: From specs to implementation21

LOCAL OBJECT ess LogicPCOIndustrial Controls &Safety SystemsBeams DepartmentStatus of LocalObjects may beused by allobjectsanywhere in theprogram.LocalOpenClosedField DevicesDIDII/O DevicesI/O BoardsSession 0: From specs to implementation22

Industrial Controls &Safety SystemsBeams DepartmentONOFF OBJECT CONNECTIVITYPCOMasterRun OrderValvePositionProcessControlDevicesProcess LogicOpenCloseObject Dependent LogicObjectInterlock LogicStart/StopInterlockOnOffField DevicesLocalDriveOpenClosedDIDIDIOpenCloseDOI/O DevicesI/O BoardsSession 0: From specs to implementation23

Industrial Controls &Safety SystemsBeams DepartmentANALOG OBJECT CONNECTIVITY(NO PID)PCOMasterRun OrderValvePositionProcessControlDevicesProcess LogicPositionRequestObject Dependent LogicObjectInterlock LogicStart/StopInterlockAnalogField ositionRequestAOI/O DevicesI/O BoardsSession 0: From specs to implementation24

Industrial Controls &Safety SystemsBeams DepartmentANADIG OBJECT CONNECTIVITY(NO PID)OperatorPCOMasterRun OrderValvePositionProcessControlDevicesProcess LogicPositionRequestObject Dependent LogicObjectInterlock LogicStart/StopInterlockAnadigField ositionIncreaseDOPositionDecreaseDOI/O DevicesI/O BoardsSession 0: From specs to implementation25

Industrial Controls &Safety SystemsBeams DepartmentCONTROLLER OBJECT CONNECTIVITYRun OrderPCOMasterActiveModeProcess LogicObject Dependent LogicRegulation, PositionRequest, PID bjectInterlock LogicField gFeedbackAIAIPositionRequestAOI/O DevicesI/O BoardsSession 0: From specs to implementation26

Industrial Controls &Safety SystemsBeams DepartmentUNICOS CPCENGINEERING LIFE CYCLEDecompositionSpecificationsAutomatic CodeGenerationLogic specifics& SynopticsDeploymentReverseEngineeringPLCSession 0: From specs to implementation27

Industrial Controls &Safety SystemsBeams DepartmentDECOMPOSITION quipmentModulesModulesControl ModulesControl ModulesControl ModulesControl ModulesControl ModulesIEC 61512-1Physical modelSession 0: From specs to implementation28