Virtual Commissioning Using UNICOS and Ecosim Pro 672021

Virtual Commissioning Using UNICOS and Ecosim. Pro 6/7/2021 Brad Schofield 2

What is Virtual Commissioning? • Coupling of a simulation of the plant with the control system 6/7/2021 Document reference 3

What is it for? Primary aim is validation of new control systems before deployment on the real process • Can be used for studying new control strategies in existing plant • Can be used for operator training • 6/7/2021 Document reference 4

How to do it? SW only: simulate the control (somewhere. . ) as well as the plant • HW in the loop: PLC and possibly other control hardware used. Main challenges are: • • • Interfaces Timing issues 6/7/2021 Document reference 5

BE ICS approach We use Ecosim. Pro for the plant model • We aim to make the minimum possible intrusions on the controller implementation • We want to support all PLC technologies • • • Siemens Step 7 & TIA Portal Schneider 6/7/2021 Document reference 6

Ecosim. Pro at CERN • Cryogenics • • Cryo. Lib developed at CERN, now commercialized by EA Licenses • Currently ~10 licenses at CERN in total, all fixed (usb dongle) HVAC • • • Library developed by BE ICS Control validation/Virtual commissioning 6/7/2021 Document reference 7

OPC UA as a common interface Ecosim. Pro allows the creation of standalone models with OPC UA servers • All supported PLC can be accessed by OPC UA, either by: • • 6/7/2021 Schneider OFS Siemens Simatic. NET Siemens onboard OPC UA server (s 7 1500) Document reference 8

OPC UA architecture SCADA Read Control Actions OPC UA Server Write Control Actions OPC UA Client Write Simulated Schneider OFS Outputs Siemens Simatic. NET OPC UA Server Read Simulated Outputs Schneider, Siemens PLC 6/7/2021 Document reference 9

Can be seen as a part of a more generic testing interface SCADA OPC UA Server (Win. CC OA) OPC UA Client PLC Test suite OPC UA Server (OFS, Simatic. NET) PLCSim IO IOsimulation API PLCSim API 6/7/2021 Document reference 10

Timing considerations For models running at real time or faster, time sync is easy • If the model is slow, or if we want to run the closed loop faster than RT, it is more tricky • 6/7/2021 Document reference 11

Syncronization approaches • Old approach was to implement the timedependent functions in the simulation • Need to maintain a parallel baseline of control objects in Ecosim, AND implement the control in the model -> lots of work! 6/7/2021 Document reference 12

Syncronization approaches • We want to try to modify the way the time dependent code is called in the PLC instead • • PID, ramp, filter To be seen if this is feasible… 6/7/2021 Document reference 13

Use Case: SF 8 Heat Recovery Heat recovery plant for Ferney Voltaire will be installed at LHC point 8 • CV want to know if there will be issues for the cooling system if this plant suddenly fails • Modeling done by technical student this year • 6/7/2021 Document reference 14

Project: Installation of waste heat recovery in LHC point 8 Cooling towers of LHC point 8 Entering cooling water Average ~30 °C without the heat recovery heat exchanger With the heat exchanger: ~25 -28 °C Cooling water from the common basin 22 °C Clients of cooling of LHC point 8 New Installation Circulation from the city Average ~30 C° Heat Recovery Heat Exchanger Circulation to the city 6/7/2021 15

Dynamic model for cooling tower leaving water temperature T 2 Model references: Modelling and optimization of building HVAC systems, Jin Guang Yu, 2011; A simplified modelling of mechanical cooling tower for control and optimization of HVAC systems, Jin Guang Yu & al. 2007 Water supplied to cooling tower (°C) Water mass flow in cooling tower (kg/s) Ambient air wet-bulb temperature (°C) Water returned from cooling tower (°C) Air mass flow in cooling tower (kg/s) where, 6/7/2021 16

Implementation in Ecosim. Pro 6/7/2021 Document reference 17

Controls setup PLC project is identical to production, only the IO addressing & HW config is removed • Project deployed on PLC in 864 lab • SCADA set up on development server • Numerous interlocks blocked to allow controller operation • 6/7/2021 Document reference 18

SCADA 6/7/2021 Document reference 19

Simulation Scenarios 6/7/2021 Document reference 20

Scenario M 1 • Client power 20 MW • Recovery power 6. 3 MW • Wet bulb temperature 12 6/7/2021 Document reference 21

SF 8 study conclusions Existing controls will be OK, but are a bit slow to reject disturbances • Disturbance is measured, so a simple feedforward should make this much better • Can implement this and simulate • 6/7/2021 Document reference 22

UNICOS integration Current implementation is a prototype; signal connections between PLC and Ecosim are made by hand • Want to integrate this as was done with the previous OPC DA based setup • 6/7/2021 Document reference 23