FCC Control Systems Concepts Why its not too

FCC Control Systems Concepts: Why it's not too early to speak about it !!! Ph. Gayet FCC Washington Workshop 26 March 2015 Ph. Gayet 2 nd FCC Workshop

Summary • • Control Systems Definitions and Model Specificities of Present Accelerator & Experiments Control Systems Identified Tracks Control Study Collaboration Ph. Gayet 2 nd FCC Workshop 2

Control System Definition Control System Feedback Desires Top Management Physical Systems A control system is a set of tools to manage, command, direct or regulate the behavior of Physical Systems Ph. Gayet 2 nd FCC Workshop 3

Classical Control Systems Model Company Overall management : - Enterprise Resource Planning (ERP) - Product Lifecycle Management (PLM) - Customer Relationship Management (CRM) - Human Resource Management (HRM) - Process Development Execution System (PDES) Level 4 Level 2 Supervision Control & Data Acquisition Level 1 Control & Interlocking Level 0 Sensor & Actuators Our domain of interest Level 3 MOMS Generic Automation Pyramid from ISA 95 Ph. Gayet 2 nd FCC Workshop Manufacturing Operation Management Systems 4

Business Process Information Network Detailed Scheduling Resource Management Maintenance Management Luminosity Optimization Management System Production Analysis Production Execution Production Tracking Configuration Management Operations Information Network Level 2 Alarm Management Recipe Control Networking Level 3 Networking Concepts: Functional Architecture Supervisory Control Operator Command Automation Network Level 1 Programmed logic Closed loop Control Phase Control Interlock & Safety Control Discrete & Process Device Communication Networks Sense Process Sense Events Level 0 Ph. Gayet Manipulate Equipment Networking Operator Interface Networking Equipment data Historian Manipulate Process 2 nd FCC Workshop 5

Functional Architecture : LHC Accelerator Device Name Servers Central Logging Campus Network 2 way Firewall Network Management Router Monitoring Tools Configuration Servers Security Checks Technical Network Management Router High Alarm Low Alarm Comm. Err. SCADA Servers CCC Consols Sequencer Setting Management. Technical Network Ph. Gayet T T Device Access T Quench Protection, Power Converters, Magnet Temperatures, survey, . . 2 nd FCC Workshop Control logic FIP/IO Device Access PLC PROFIBUS T T Beam position, Beam Loss Monitor, Beam Interlocks, Low level RF, WORLDFIP Front Ends World. FIP SEGMENT VME Front Ends OPTICAL FIBERS Network Management Router Cryogenics, Vacuum, RF, Beam transfer, Cooling, Magnet protection, … 6

Functional Architecture : LHC Accelerator Device Name Servers Central Logging Campus Network 2 way Firewall Network Management Router Monitoring Tools Configuration Servers Security Checks Technical Network Management Router High Alarm Low Alarm Comm. Err. SCADA Servers CCC Consols Sequencer Setting Management. Technical Network Device Access Beam position, Beam Loss Monitor, Beam Interlocks, Low level RF, Ph. Gayet T PLC Power interlock systems Device Access Hard-wired interlocks T Quench Protection, Power Converters, Magnet Temperatures, survey, . . 2 nd FCC Workshop Control logic FIP/IO T Quench Protection system T PROFIBUS Beam Interlock T System Soft-wired interlocks WORLDFIP Front Ends World. FIP SEGMENT VME Front Ends OPTICAL FIBERS Network Management Router Cryogenics, Vacuum, RF, Beam transfer, Cooling, Magnet protection, … 7

Preliminary Figures for LHC Level 0 LHC Accelerator Tunnel Number of channels per system for one sector P 2 Pfiber Fieldbus La Cables rge Beam instrumentation Quench Protection Systsem Cryogenics Power converter Vacuum Access control Magnet protection Ventilation AI Khz AI Mhz AO Hhz Total Scaling factor 400 2200 1300 700 250 2000 200 50 100 30 50 1200 50 50 2580 1600 4300 1300 200 100 300 500 500 800 100 500 3900 3750 300 350 80 2400 200 11480 Lenght length/ circuits Lenght Circuits Lenght circuits length DO rt d pa AI DHz DI AI Hz ue LHC 2012 Fault time distribution to nts eve Ph. Gayet ted Level 0 Sensor & Actuators ela Level 1 Control & Interlocking Controls Er Level 2 Supervision Control & Data Acquisition R 2 Level 3 MOMS 2 nd FCC Workshop 8

DCSs Level 0 and 1 Level 3 MOMS Level 2 Supervision Control & Data Acquisition Level 1 Control & Interlocking Level 0 Sensor & Actuators Ph. Gayet 2 nd FCC Workshop 9

Major Constraints for Levels 0 and 1 • • Access Restrictions Large or even enormous (experiments) amount of devices – • • • High level of Radiation (premature ageing, Single Event Upset) Timing & Triggering distribution Cohabitation of very fast and slow processes – – • Different front end platforms from commercial suppliers Specific hardware developments (instruments interface, I/O treatments Board, . . ) Long Lifetime – – Level 0 solutions should ideally equivalent to the equipment one Level 1 aligned to the platform lifetime (10 -20 years) st ts e gh en i H stm ve osts n I C Host the safety systems Networking • First estimation for FCC: accelerator (100000 for level 0, 10000 for level 1), detectors (millions for level 0) Networking Level 1 Level 0 Ph. Gayet 2 nd FCC Workshop 10

Level 3 Operations Information Networking Business Process Information Networking SPECIFICITIES for present Level 2 & 3 Automation Network • Networking Level 2 Systematic use of standard off the shelves solutions (hard & soft) – – Ph. Gayet Short back end platform lifetime (5 years max) Complex upgrade policy related to the software ecosystem. 2 nd FCC Workshop 11

Impact of Software Ecosystem on Applications LS 1 2013 2014 LS 2 2015 2016 2017 2018 2019 LS 3 2020 2021 2022 2023 2024 2025 LINUX Windows Wincc-OA (PVSS) Labview PLC development Tool CERN Middeware CERN Front end frameworlk CERN SCADA framework CERN PLC framework Applications Ph. Gayet 2 nd FCC Workshop 12

Level 3 Operations Information Networking Business Process Information Networking Specificities for present Level 2 & 3 Automation Network • Systematic use of standard off the shelves solutions (hard & soft) – – • Beam related & utilities or infrastructure DAQ & other Detector control systems Extensive use of data driven solution – • Short back end platform lifetime (5 years max) Complex upgrade policy related to the software ecosystem. Cohabitation of industrial or Home made supervision System – – • Networking Level 2 st e gh tion i H ra e ts p O Cos Configuration, Security, Settings No or Embryonic Integration of "LOMS” Ph. Gayet 2 nd FCC Workshop 13

Identified Track of Studies Across levels Level 3 Level 2 Level 1 • • • Fault pattern recognition or identification, Process simulation and optimization tools Integration of data analytics Integration of CMMS Complex event processing tools • How can we use Model driven development • • • Transparent Application Upgrade Integration of commercial and home made solutions … Is it a way to produce Generic and manageable specifications for a large type of application and such a long project • Is the new trend for control cloud concepts adapted to our infrastructure • Can we use the distribution of High throughput computing • What can improve the availability and the maintainability of the control systems • How can we reduce the number of proven solutions • • • Level 0 Ph. Gayet Self Configuration Device virtualization … Wireless communications for the last meters • Radiation tolerance • Real time constraints • Safety systems • • 2 nd FCC Workshop Self repairing or hot swappable components Fault tolerant HW/SW Compatibility with remote handling … 14

FCC Control Coordination • • • 47 topics have been identified in 8 main chapters Of the FCC Work package breakdown We have chosen to include them in the perimeter of the control coordination study They cover the four levels of the control system pyramid. • • • Ph. Gayet Control system requirements Control systems concepts and architectures Technology evolution Communications and networks Data Acquisition needs Safety systems specificities Maintenance, Reliability and availability Monitoring and performance analytics Modeling and Simulation Cyber security Cost estimates 2 nd FCC Workshop 15

Control Study Collaboration • We Want to Set up a Collaboration that : – Will profit of the past experience • In our labs or with the successful control collaboration Ph. Gayet 2 nd FCC Workshop 16

Control System Collaboration Success Stories • The Physic community has a good & successful practice for control system collaboration, the most noticeable ones are : – EPICS (Accelerator controls) • Launched in 1989 !!! • Still very active today with more than 40 facilities worldwide • Base solution for ILC, ESS, and ITER CODAC – TANGO (Synchrotron light source) • Launched in 1998 at ESRF • Now now in version 9 With more than 25 partners WORLDWIDE • Very active development – JCOP (LHC detector control system) • • • Ph. Gayet Launched on 1998 at CERN Grouping 4 LHC experiments involving dozens of Lab hundredth of developers 600 applications servers Now less than 50 people to maintain Chosen for Fixed target experiments 2 nd FCC Workshop 17

Control Study Collaboration • We Want to Set up a Collaboration that : – Will profit of the past experience • In our labs or with the successful control collaboration – Covers the 4 layers of the Control systems in order to include all Physical, Operational and Technical constraints and offer all necessary services. – Include the Experimental Physic community and the Industry in order to : • Federate the efforts to include the technological breakthrough and not miss any rupture that will happen • Take profit of the Fast pace of progress in the industry • Create condition for trustful and win/win collaboration – Keep under control the strategic domain – Avoid vendor lock issues – Knowledge transfer to industry • Find the balance between: – Open Solution – Solution based on open Standard – Off the shelves and Proprietary solution • … Ph. Gayet 2 nd FCC Workshop 18

Conclusion • Control systems will be key components for the performances of the FCC – Impact on the availability – Impact on the operation cost • They are connected to all equipment • Despite the diversity of the physical systems we have to maximize the use of common solutions • Conceptual Choices have to be made early not the technology choices • Choices shall cope with the technological evolution • We will use any opportunities given by HL-LHC to fuel the collaboration • We need Help!!! Ph. Gayet 2 nd FCC Workshop 19