MARCO UNICOS based control system CERN 10 09
MARCO UNICOS based control system CERN 10. 09. 2012 Lukasz Zwalinski – PH/DT Maciej Ostrega – PH/DT
Presentation overview MARCO • I/O requirements & system architecture & hardware • Control rack assembly • Software principals • Software development • User interface • Access control • Supervision layout • SCADA interface • Supervision tools • Touch screen • Online pressure enthalpy diagram 10 th September 2012 L. Zwalinski, M. Ostrega
I/O number & system architecture & hardware Control system architecture I/O requirements I/O Type Number DI DO AI AO 32 32 34 8 Selected hardware conforming CERN standard Component S 7 -300 CPU 315 -2 PN/DP S 7, MICRO MEMORY CARD S 7 -300, 8 AI, RES. 9/12/14 S 7 -300, 8 AO, U/I, 11/12 BITS S 7 -300, 8 AI , 2/3/4 Wire Resist Res 9/12/14 S 7 -300, 32 DI, 24 V DC, 1 X 40 PIN S 7 -300, 32 DO, 24 V DC, 0. 5 A SIMATIC 8" TOUCH TFT MULTI PANEL MARCO Type 6 ES 7315 -2 EH 14 -0 AB 0 6 ES 7953 -8 LL 20 -0 AA 0 6 ES 7331 -7 KF 02 -0 AB 0 6 ES 7332 -5 HF 00 -0 AB 0 6 ES 7331 -7 PF 01 -0 AB 0 6 ES 7321 -1 BL 00 -0 AA 0 6 ES 7322 -1 BL 00 -0 AA 0 6 AV 6643 -0 CB 01 -1 AX 1 Piece 1 1 5 1 1 10 th September 2012
Rack assembly – completed thanks to MPI Control rack waiting to be placed into MARCO frame. MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
UNICOS CPC 6 - framework UNICOS‐CPC 6 framework Ø UNified Industrial COntrol System Ø Continuous Process Control UNICOS framework supports 3 control system layers: Ø supervision (SCADA: Win. CC-OA) Ø control (PLC: Siemens S 7 and Schneider) Ø field layer The package of programming tools includes: Ø baseline library (with modular PID algorithm) Ø code generator Ø skeleton templates and example of objects list Object definitions provided by UNICOS are split into: Ø I/O Objects (Digital Input, Digital Output, Analog Input) Ø Field Objects (On. Off, Analog, Ana. Dig, Controller, etc. ) Ø Process Control Objects (PCO) Offers homogenous user interface More information can be fond at CERN EN/ICE web pages: http: //j 2 eeps. cern. ch/wikis/display/EN/UNICOS-CPC+Documentation https: //edms. cern. ch/file/1228441/1. 3. 1/UCPC 6_Operator_Training. pdf MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
On/Off object example MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
On/Off object example SCADA inputs: SCADA Outputs: Name Type Meaning Sts. Reg 01 SHORTINT 16 Status register 1 Sts. Reg 02 SHORTINT 16 Status register 2 Man. Reg 01 SHORTINT 16 Manual register 1 Name Type Man. Reg 01 SHORTINT 16 Manual Register 1 Meaning Description Bit. Position Manual Register 1 - MAu. Mo. R BIT 1 Manual Auto Mode Request: The operator requests the Auto Mode. 0 MMMo. R BIT 1 Manual Mode Request: The operator requests the Manual Mode 1 MFo. Mo. R BIT 1 Manual Forced Mode Request: The operator requests the Forced Mode. 2 MSoft. LDR BIT 1 Manual Software Local Mode The operator requests the Software Local Mode 3 MOn. R BIT 1 Manual On Request: The operator requests the On/Open position 4 MOff. R BIT 1 Manual Off Request: The operator requests the Off/Close position 5 MEn. Rstart. R BIT 1 Manual Enable Restart Request: The Operator requests a Manual Restart after Full Stop 9 MAl. Ack. R BIT 1 Manual Alarm Acknowledgement Request: The operator requests Interlocks or Alarms acknowledgement 15 MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
On/Off object example SCADA inputs: Name Type Meaning Sts. Reg 01 SHORTINT 16 Status register 1 Sts. Reg 02 SHORTINT 16 Status register 2 Sts. Reg 01 On. St Off. St Au. Mo. St MMo. St Fo. Mo. St LDSt SHORTINT 16 BIT 1 BIT 1 IOError. W BIT 1 IOSimu. W BIT 1 Au. MRW BIT 1 Status Register 1 On Status Off Status Auto Mode Status Manual Mode Status Forced Mode Status Local Drive Status Input/Output Error Warning Input/Output Simulated Warning Auto Manual Request Warning Status. Pos. W BIT 1 Position Warning Start. ISt BIT 1 TStop. ISt BIT 1 Start Interlock Status Temporary Stop Interlock Status Al. Un. Ack BIT 1 Au. Ih. Fo. Mo. St BIT 1 Al. St BIT 1 Au. Ih. MMo. St BIT 1 Sts. Reg 02 SHORTINT 16 Out. On. OVSt BIT 1 Au. On. RSt BIT 1 MOn. RSt BIT 1 Au. Off. RSt BIT 1 MOff. RSt BIT 1 HOn. RSt BIT 1 HOff. RSt BIT 1 Fu. Stop. ISt En. Rstart. St BIT 1 Soft. LDSt BIT 1 Alarm Un. Acknowledged Auto Inhibit Forced Mode Status Alarm Status Auto Inhibit Manual Mode Status Register 2 Output On Order Value Status Auto On Request Status Manual On Request Status Auto Off Request Status Manual Off Request Status Hardware On Request Status Hardware Off Request Status Full Stop Interlock Status Enable Restart Status Software Local Mode Status Register 1 On/Open Status Off/Closed Status Current status of the Auto Mode Current status of the Manual Mode Current status of the Forced Mode. Current status of the Local Mode. The object is driven locally. 0 1 2 3 4 5 Current status of the IOError 6 Current status of the IOSimu 7 Auto and manual requests discrepancy when Manual/Forced mode active. 8 There is discrepancy between the order status and the position status according to Time Delay and Dead-band. 9 Current status of the Start Interlock 10 Current status of the Temporary Stop Interlock 11 Alarm Un. Acknowledged: The alarm or at least one of the alarms associated to the object is not acknowledged Auto Inhibit Forced Mode status: Current status of the Auto Inhibit forced mode. 12 13 Alarm Status 14 Auto Inhibit Manual Mode Status 15 Status Register 2 - Output On Order Value Status 0 Auto On/Open Request Status 1 Manual On/Open Request Status 2 Auto Off/Close request status 3 Manual Off/Close request status 4 Hardware On/Open request 5 Hardware Off/Close request status 6 Full Stop Interlock Status Manual Restart after full stop status 10 11 Current status of the Software Local Mode. 12 When true, the alarm or any of the device dependant alarm objects have MARCO Al. BW BIT 1 Out. Off. OVSt BIT 1 Alarm Blocked Warning Output Off Order Value Status been blocked by the operator 13 Output Off Order Value Status 14 10 th September 2012 L. Zwalinski, M. Ostrega
UNICOS project development Specification XML Local SCADA Server Instance Generator Siemens PLC Logic Generator 2 software production iterations completed. MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Supervision layout § Header Ø fixed area (toolbar) § Process area Ø Synoptic § Footer Ø Contextual area Ø Historic MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Win. CC-OA access 1) Right click on the Current user name or click on the key 2) Click Login as 3) Enter an authorized NICE user / password Main Access Groups: § Monitor § Operator § Expert § Admin MARCO Only NICE authorized users (defined previously) are allowed to be log in the Win. CC-OA. 10 th September 2012 L. Zwalinski, M. Ostrega
Supervision layout: Process Area Static info ü Text ü Drawings Sensor Animated Widgets ü Sensors ü Actuators ü Controller ü Process unit ü Alarms Actuator Widget interactions MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
PLC actions representation on Win. CC-OA panels MARCO plant MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
PLC actions representation on Win. CC-OA panels MARCO alarm panel MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
PLC actions representation on Win. CC-OA panels Electrical diagnostic Stepper Accumulator limiters Accumulator Auto SP calculation MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Supervision tools Alarm list Event list MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Supervision tools Device Tree overview MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Recipes and user defined trends User defined trends Recipe component Recipe: Massive parameterization (optional) Ø Alarm thresholds Ø Set Points Ø PID parameters MARCO 10 th September 2012 Trends: Ø Trend tree Ø Individual trends via object face plate Ø Dynamic trends L. Zwalinski, M. Ostrega
PCO Alarms with SMS or email notification Digital and Analog Alarms Types: • Full Stop interlock (FS): Stop the unit/actuator (all dependent units/actuators are set to their fail-safe position) and wait manual acknowledgement before restarting. • Temporary Stop Interlock (TS): Stop the unit/actuator (all dependent units/actuators are set to their fail-safe position) and restart automatically when the interlock disappears. • Start Interlock (SI): Prevent the unit from starting (all dependent units/actuators stay in their fail-safe position). MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS SIMATIC MP 277 8" TOUCH MULTI PANEL ACCESS CONTROL PANEL NAVIGATION BUTTON MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS ON/OFF FACEPLATE ON/OFF WIDGET MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS ANALOG INPUT FACEPLATE ANALOG INPUT WIDGET MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS PID CONTROLLER FACEPLATE WIDGET MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS ANALOG WIDGET ANALOG FACEPLATE MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS ANADO FACEPLATE ANADO WIDGET FULL STOP INTERLOCK MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS ANALOG ALARM FACEPLATE ALARM ACKNOWLEDGE BUTTON MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS DIGITAL ALARM FACEPLATE ALARM BLOCKED MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS PCO FACEPLATE PCO ALARMS PCO WIDGET MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
MARCO touch panel in UNICOS MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Online p-H diagram * Still to be implemented in MARCO Win. CC-OA applications MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
Thank You for Your attention. UNICOS framework - more details can be found: http: //j 2 eeps. cern. ch/wikis/display/EN/UNICOS-CPC+Documentation MARCO 10 th September 2012 L. Zwalinski, M. Ostrega
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