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Pcapac2018 — Proceedings at a Glance 12th Int. Workshop on Emerging Technologies and Scientific Facilities Controls PCaPAC2018, Hsinchu, Taiwan JACoW Publishing ISBN: 978-3-95450-200-4 doi:10.18429/JACoW-PCaPAC2018-WEC1 THE DO’s AND DON’Ts IN PROCESS CONTROLS LESSONS LEARNED OVER 35 YEARS M. Clausen, T. Boeckmann, J. Hatje, O. Korth, M. Moeller, J. Penning, H. Rickens, B. Schoeneburg , Deutsches Elektronen Synchrotron DESY, 21220 Hamburg, Germany Abstract PLCs for Machine Interlocks Designing, implementing and maintaining process con- A very prominent usage for PLCs is the area of hard- trol systems for cryogenic plants requires different view- ware interlocks. In former times this kind of hardware points compared with those in machine controls. 24/7 protection was implemented in hard wired logic. This operations for more than a year is a basic requirement. logic slowly moved into intelligent controllers and finally Hardware and software must be designed to fulfil this into PLCs. These interlocks are well defined. They are requirement. Many projects are carried out with industrial thoroughly tested and should not be altered. Implement- partners. Companies specify the process control logic ing this logic in a PLC is a no-brainer and used basically which gets implemented by the local DESY team. Re- for every system in place. sponsibilities, time tables and milestones must be clearly defined in such a case. Several cryogenic installations PLCs as Data Concentrator have been equipped with state of the art process control The next occasion where PLCs find their way into con- systems for cryogenic controls. Where the last one being trol systems is the usage as a data concentrator. There are the European XFEL. In the course of time commercial a lot of different I/O signal types which can be connected and open source systems were implemented and main- via specific signal-conditioning modules to PLC type of tained. Control loops were basically always implemented communication controllers. Depending on the vendor in front end controllers running the real-time operating theses are PLCs with I/O modules or intelligent commu- system VxWorks and EPICS as the control system toolkit. nication controllers with I/O modules which can be pro- The approach to use PLCs will be discussed as an alterna- grammed like a PLC. tive approach. Large installations like the European XFEL In both cases the controller or the PLC will function as require good project planning. Our success story will a data concentrator and will not be used for control func- finalize our look back and initiate our look forward. tions in the field. Typically these controllers will be con- PROCESS CONTROLS AT DESY nected to a field bus like Profibus or CAN or (real-time) Ethernet. In 1982 process controls for cryogenic systems was implemented in hardware PID controllers. Only a few Communication with the Process Controller engineers had the knowledge how to operate such a sys- 2018). Any distribution of this work must maintain attribution to the author(s), title of the work, publisher, and DOI. The communication between the data concentrator and © tem. A failure over night was a night mare because no the process controller will run through one of the field diagnostics were installed. busses mentioned above. Therefore the process controller Over the years archive systems were installed. Even has to implement the necessary driver for that type of alarm systems found their way into cryogenic control connection. systems because 24/7 operations required immediate The communication must be configured for each indi- action if some conditions were suspicious. vidual I/O signal as if the signal would be connected to Over the years all of the cryogenic processes (cryogen- the process controller directly. This kind of configuration ic plants and cryogenic distribution systems) are con- will be typically limited to one channel for each I/O sig- trolled by process controllers. Some of them went through nal. Basically this is a one to one representation. two basic refurbishments. In the end all cryogenic process controls at DESY and the XFEL are implemented in EP- Reliability ICS front end controllers – so called Input Output Con- Reliability is a strong argument in favor of PLCs. For troller (IOC). sure PLCs are known for their reliable runtime behavior. This paper will describe a subset of the experiences we They run in thousands of instances and the code is gained of the years. Namely: PLC integration; testing of (should be) thoroughly tested. All of the hardware com- new equipment and project management issues. ponents are nearly mill proof and reliable as well. Crashes of PLCs are not known to the author. If the same kind of TO USE OR NOT TO USE application is run on an EPICS IOC one would have to PLCS IN PROCESS CONTROLS put the same constraints on software and hardware on the PLCs can be really useful – there is no doubt. The EPICS implementation. A Windows or Linux operating question is: ’Where should PLCs be used?’ system will hardly reach the level of reliability which a PLC based OS will provide. A ‘real’ real-time operating system like VxWorks is tuned for reliability and will work differently from OS’s which require for instance hard WEC1 Content from this work may be used under the terms of the CC BY 3.0 licence ( Control System and Component Integration 1 12th Int. Workshop on Emerging Technologies and Scientific Facilities Controls PCaPAC2018, Hsinchu, Taiwan JACoW Publishing ISBN: 978-3-95450-200-4 doi:10.18429/JACoW-PCaPAC2018-WEC2 STATUS OF THE TPS CONTROL SYSTEM Y.S. Cheng, J. Chen, P.C. Chiu, C.Y. Wu, C.Y. Liao, C.H. Huang, K.H. Hu, Y.T. Chang, Demi Lee, S.Y. Hsu, C.H. Kuo, C.J. Wang, K.T. Hsu National Synchrotron Radiation Research Center, Hsinchu 30076, Taiwan Abstract SYSTEM COMPONENTS Control system for the Taiwan Photon Source (TPS) The TPS control system provide an environment for has been delivered in mid-2014 to support commissioning operation of the accelerator system. It integrated various and routine operation of the accelerator system. The TPS subsystems together [4]. Details of some parts of control control system adopts EPICS toolkits as its frameworks. system are summarized in the following paragraph. Various subsystems interface to the control system according its specific requirements. Operation Control Server Environment experiences accumulated during last four years confirmed Various servers include file server, archiver server, the system working well. Minor revisions were made to database server, alarm server, boot servers, ...etc. are improve the system performance. Current status of the supported by the control system. There server support control system and ongoing developments will be operation of the whole system. summarized in the report. General EIPCS IOC Interface INTRODUCTION There are many different kinds of IOCs at equipment The TPS [1] is a latest generation of high brightness layer to interface various subsystems and instruments. synchrotron light source which is located at the National They need meet various requirements of functionality Synchrotron Radiation Research Center (NSRRC) in requirements, convenience and cost consideration. Type Taiwan. TPS consists of a 150 MeV electron linac, a of IOCs are summary in Table 1. Most of the devices and booster synchrotron, a 3 GeV storage ring, and equipments are directly connected to cPCI IOCs with experimental beam lines. The control system environment EPICS. The cPCI EPICS IOC is equipped with the cPCI- was ready in mid-2014 to support subsystem integration 6510 CPU board. The cPCI-7452 128 bits DI/DO module test and accelerator commissioning [2]. User service of is used for BI, BO solution. ADC and DAC modules in IP the TPS was started since 2016. (Industry pack) module form-factor are used for smaller Adequate and reliable functionality of control system channel count application, such as insertion devices is one of the key to the success of TPS commissioning. control. Event system modules are in 6U cPCI form- Control system for the TPS is based on the EPICS factor. Private Ethernet will be heavily used as field-bus to connect many devices. Power supplies of all magnets 2018). Any distribution offramework this work must maintain attribution to the author(s), title of the work, publisher, and DOI. [3]. The EPICS is based on the definition of a © standard IOC structure with an extensive library of driver except for correctors are equipped with Ethernet to the and support a wide variety of I/O cards. The EPICS EPICS IOC. Multi-axis motion controller with Ethernet toolkits have various functionalities which are employed interface is the standard for the control system. to monitor and to control accelerator system such as Ethernet attached devices are connected to the EPICS control page creation, data archiving, alarm handling and IOC via private Ethernet. Devices support VXI-11, LXI, etc. Raw ASCII and Modbus/TCP protocol are connected to The TPS control system consists about three hundred EPICS IOC directly by TCP/IP interface. Devices of this of EPICS IOCs. The CompactPCI (cPCI) is equipped category include intermediate power supply, temperature with input/output modules to control subsystems as acquisition (RTD or thermocouple), digital multi-meters, standard IOC. The other kinds of IOCs are also supported oscilloscopes, signal generator, and other instruments. by the TPS control system, such as BPM IOCs, PLC All corrector power supplies are controlled by the IOCs, various soft-IOC and etc. corrector power supply controller (CPSC) module [5]. To achieve high availability of the control system, The CPSC embedded EPICS IOC, it can access via emphasis has been put on software engineering and channel access protocol. The CPSC equips with 20 bits relational database for system configurations. Data DAC and 24 bits ADC.
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