Alice TOF Production Readiness Review Gas Control Systems

Alice TOF Production Readiness Review Gas Control Systems

General Philosophy • Modular design – Identification of Gas Modules – Applies to both Hardware and Software • Electrical and Controls Interfacing Hardware Housed in 3 U high 19” Rack mounting Trays – Standardized Layout and Construction – easy relocation of electronics (minimal re-work) • Where Possible, Use of Standard Industrial “Off the Shelf” components • Hardware and Software Well Documented Allowing Work Load to be placed On Other Sections/Outside Contractors.

Controls Hardware

Component Selection • Industrial PLCs - Schneider (Cern recommended) Quantum & Premium • Industrial distributed I/O modules - Wago • Cern Designed Radiation tolerant ELMB for Flow Cell readout • Industrial Networks – Profibus, Can. Bus for I/O interfacing • Some Gas Hardware with Profibus Interfaces “built in”. • Ethernet Network (TCP/IP Modbus with UNICOS middleware for PLC to PLC and PLC to SCADA communications)

Control System Architecture TCP/IP Modbus Schneider “Premium” PLC Schneider “Quantum” PLC Can. Bus Profibus Pump Controller Profibus DP Wago Profibus I/O Profibus MFC Can. Bus ELMB

Device Interfacing Motor Starer (required above 1 Horsepower) Wago I/O Modules with PB Coupler Flow Switch (DI) Flow Transmitter (4 -20 m. A) Pump/Mo tor PLC with Profibius Module Pressure Transmitter (0 -5 V) Pt 100 Temperature Sensor Isolating Barriers (Used between control system and gas rack when Flammable Gas Present) Motor Speed Controller – Direct Profobus Interface 4 -20 m. A Controlled Power Regulator Heating Cable

Cabling of Gas Racks Mixer Rack – Profibus daisy chain of 4 mass flow controllers

Cabling of Gas Racks Mixer Rack Electrical Box

Wago I/O System

750 -301 Profibus DP Coupler 750 -402 24 V D/I 750 -402 750 -461 750 -504 24 V D/I Temp. I/P 24 V O/P (4 ch) 750 -530 4 -20 m. A I/P (2 ch) 750 -504 24 V O/P (8 ch) (2 ch) (4 ch) 750 -530 750 -554 4 -20 m. A O/P (2 ch) (4 ch) Temp. I/P 24 V D/I (4 ch) 750 -461 24 V D/O 750 -401 750 -474 (2 ch) 24 V D/O (8 ch) 750 -600 End Module 750 -504 750 -602 750 -461 (4 ch) Separation 750 -504 Temp. I/P Module 24 V O/P (2 ch) (4 ch) 24 V O/P (4 ch) 750 -468 0 -10 V A/I (2 ch)

Controls Interface Tray

Controls Interface Tray

Controls Interface Tray

Controls Interface Tray

Industrial “Hot Swap” Power Supplies Schneider “Quantum” PLC Schneider “Premium” PLC Control Chassis For CO 2 Removal Module Control Chassis For Mixer Module Control Chassis For Pump Module (with Frequency Controller Mounted Away From Other Electronics) Control Chassis For Purifier Module Control Chassis For Distribution Module Controls Rack Overview

Control Rack Bus Distribution Main Incoming Power Isolator 3 Phase Distribution N+1 redundant power supply system Miniature Circuit Breaker 24 VDC Distribution Profibus

Electrical Schematics

Electrical Schematics

PLC Software

UNICOS (Unified Control System) • Develoed originally for the Cryogenics systems by GTD Alsthom, and now adapted in a colaboration to enable it to be equally applied to gas systems. • Device Oriented approach to PLC programming, making use of Function Blocks written in Structured Text language • For every hardware “Device” there is an equivalent software object – these objects fit into “classes” e. g. field objects, Process Control Objects etc – instances are created for each device • Each Software Object has an equivalent object at the SCADA system, allowing devices (via the PLC) to fully report states, be taken into manual control, have parameters associated with them, be given interlocks etc

Software Structure GCS ALICE TPC TOP MODULE MIXER PURIFIER COLUMN A DIST. COLUMN B FIELD OBJECTS I/O OBJECTS PUMP EXHAUST RECOVERY

Software Structure

UNICOS Program Structure

Software Design • URD (User Requirements Document) – Covers All Modules • Generation of State Diagrams • Design Approval • Design Specification (for Each Module) • Design Reviews • Implementation/Coding

Module State Diagram

SCADA Software (Supervisory Control and Data Acquisition)

M

Modes of Operation

Piping & Instrumentation Drawings (P&IDs) and Instrument Identification

Piping & Instrumentation Drawings

Standard Identification Letters

Numbering Scheme

Examples Of Identification Coding

Controls Symbols

How to Read A P&ID