ESS Test and Prototyping Activities
Daniel Piso Ferńandez
www.europeanspallationsource.seDecember 4, 2014
5
Who owns PLCs at ESS…???
• Accelerator Division, Target Division, NSS and Conventional Facilities. Main consumers are (in quantity):– RF local interlocks– Cryogenics Systems– Vacuum Systems– Local Protection Systems– Conventional Facilities Systems
• ICS does not own by far the majority of the PLCs (but it will provide development effort).
• But it us who has the standardization capability, almost all of them need to be integrated into the EPICS control system. We are trying to do it together with our stakeholders.
6
EstimationsITEM QTY
Mid Range PLC set 176High Range PLC set 38Digital Input Module 208Digital Output Module 87Analog Input Module 953Analog Output Module 91Analog Input TC Module 442Profibus Module 100Serial Module 720Distributed I/O rails 326Safety PLC Set 23
Safety Digital Input Module 85
Safety Digital Output Module 85
High speed boolean processor 310
I/O Control FieldBus I/O Control * Number of devices
Device Name Number of devices: Possible Interface DI DI-F DO DO-F AI AO TC / PT100 Serial Digital IN Digital IN
FastDigital OUT
Digital OUT Fast Analog IN Analog
OUT TC / PT100 SERIAL
VACUUM Primary pump 155 PB, Serial, IO 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 310WATTER COOLING Cooling water 155 IO 0 0 0 0 10 0 7 0 0 0 0 0 1550 0 1085 0OIL Oil 155 IO 1 0 0 0 0 0 1 0 155 0 0 0 0 0 155 0POWER SUPPLY CONTROL
Filament 155 Aux port PS 0 0 0 0 2 0 0 0 0 0 0 0 310 0 0 0Klystron Solenoid 155 Serial?? 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 310RF FAST INTERLOCK Arc Detectors 155 IO 0 6 0 0 0 0 0 0 0 930 0 0 0 0 0 0MOD Interlocks 155 IO 0 2 0 2 0 0 0 0 0 310 0 310 0 0 0 0LLRF Interlocks 155 IO 0 1 0 1 0 0 0 0 0 155 0 155 0 0 0 0CAV Interlocks 155 IO 1 3 0 0 0 0 0 0 155 465 0 0 0 0 0 0MPS Interlock 155 IO 0 0 0 1 0 0 0 0 0 0 0 155 0 0 0 0PIN Diode 155 IO 0 0 0 1 0 0 0 0 0 0 0 155 0 0 0 0Power forward/reflecting 155 IO 0 10 0 0 0 0 0 0 0 1550 0 0 0 0 0 0GENERAL SAFETY HV cable detection 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0DOOR Switch detector 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0PSS Status 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0Emergency push button 155 IO 1 0 0 0 0 0 0 0 155 0 0 0 0 0 0 0
For One Transmitter 6 22 0 5 12 0 8 4SUM: 930 3410 0 775 1860 0 1240 620
*Copyright Rafael Montaño
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Standardization by procurement
• A PLC hardware Open Call for Tender is about to go out.– We want to procure a framework agreement to select a
preferred vendor.– It is ONLY to buy hardware and development software
• This tender does not cover PSS, TSS and motion controls applications.
• In any case, selecting a vendor it is not the only aspect of standardization!
13
PLCs in vacuum
• This is only for analog signals for protection applications.
• Monitoring signals via serial ports
14
Maximum Required Sampling Rates
Vacuum System 1 sample/sec, 1 sample/10msec, 10samples/msec
Conventional Facilities Systems 1 sample/sec
Power Distribution Systems 1 sample/sec
Water Cooling Systems 1 sample/sec
Cryogenics systems 1 sample/10msec
Slow Interlock System 1 sample/10msec
15
Modbus vs. s7plc
• The goal was to measure the capability of exchanging data regarding the exchange rate and the number of channels (connections) used.
16
Event Correlation Test
We are measuring four times:• when a Signal is triggered on Timing-
IOC. • when PLC detects this signal on its
digital input. • when PLC sends this value to PLC-IOC.• when PLC-IOC updates this new value
from PLC
Wiki PLC
18
Event Correlation Test (III)
• Similar delay times.• Except in the test with
minimum PLC cycle time 20ms and PLC push rate 20 ms.
Avg dela
y PLC
400
Avg dela
y PLC
1500048
1216
Received on PLC delayCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms
Dela
y [m
s]
Avg dela
y PLC
400
Avg dela
y PLC
15000
50100150200250
Send from PLCCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms
Dela
y [m
s]
Avg delay PLC400
Avg delay PLC1500
0
50
100
150
200
250
Received on PLC-IOC delayCT5msPI20msCT5msPI50msCT5msPI100msCT10msPI20msCT10msPI50msCT10msPI100msCT20msPI20msCT20msPI50msCT20msPI100ms
Dela
y [m
s]
21
What is ahead….?
• Finish the OCT and select a vendor• Finish the documentation to be provided to the
stakeholders• Understand how PLC development fit in the overall
workflows and select/develop the proper tools for operate and maintain PLC-based controls systems
• Does UNICOS fits in those workflows? To be seen…• Build internal know-how