CERN SUMMER STUDENT REPORT. Gas Environment Recoverable Detection (GERD) HMI

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1 CERN SUMMER STUDENT REPORT Gas Environment Recoverable Detection (GERD) HMI Mari-Liis Sillat National Institute of Chemical Physics and Biophysics (EE) Supervisor: Andromachi Tsirou CERN 2016

2 Introduction This report summarizes the work done by me during the CERN Summer Student programme from 27 th of June until 26 th of August The work was carried out under the supervision of Andromachi Tsirou. The main goal of the work was to create a simple Human-Machine Interface (HMI) for the SNIFFER smoke detection system. The tools for the work were provided by EP-CMX-DA. The main tool used was Simatic WinCC Open Architecture (WinCC OA) aka PVSS. I have a Master s degree in Mechatronics and have previous work experience in industrial automation. This project was given to me based on my experience and turned out to a great balance between applying my previous knowledge and learning new things. In this report I give resources that I found useful for getting to know the system components and I assume no previous knowledge on the topic, so the work can be continued by other summer students. However, this report will not repeat the information given by the learning materials so it is assumed that the reader will go over the Reference materials. All of the work described in this report was done by me, if not stated otherwise. GERD and previous work GERD is a smoke detection system designed to work in the detectors and alert the security team of smoke. The system consists of SNIFFER modules (Figure 1), which are made up of smoke sensors (0.3, 0.6 and 1.2 % obs/m), oxygen, pressure and flow sensors. The SNIFFER modules are all placed together on a rack, but the air is sucked from different parts from all over the CMS into the SNIFFER modules. Inside the SNIFFER modules the air is analyzed and the result is communicated over ProfiSafe. GERD is a replacement for an older system that aims to significantly reduce the costs. This is achieved by using fewer sensors for analysis and multiplexing the incoming air from different parts of the sensor. This means that for each measurement point, where air is sucked from, there is not a dedicated SNIFFER module but a number of measurement points share the same SNIFFER module. The multiplexer (Figure 2.1) is responsible for opening and closing pneumatic valves (Figure 2.2) to choose one (or many) channels (measurement points) and send the air to analysis. A group of channels within one multiplexer is called an Insel or Isle. The whole GERD consists of the following parts: - A multiplexer on each Insel and pneumatic valves for each channel; - Pipes leading from the CMS part to the multiplexer and the SNIFFER modules; - The SNIFFER modules; - Pumps that extract the air from the CMS parts; - Software; - Monitoring screen (ME and WinCC OA).

3 Figure 1 SNIFFER modules 1 2 Figure 2 The Insels - a multiplexer and pneumatic valves

4 The control program in the Programmable Logic Controller (PLC) was already written; uses Siemens S7 PLCs. As the goal of this work was to show the running measurements on an HMI screen then the sensor values needed to be read from the PLC. Table 1 gives an overview of the different sensors connected to the SNIFFER system. Figure 3 shows the structure of the saved Insel channel s sensor values and how they are given in the PLC DB400. Sensor name Raw sensor Scaled actual value Notes value w/ unit Opacimeter % The smoke sensor. The % alarm is triggered at upper % limit OxygenSensor % PressureSensor mbar mbar FestoFlowmeter l/h FestoFlowmeter l/h PressureSensor bar Table 1 Sensor types Each Insel has 10 channels of sensors. Only one channel of each Insel is measured at a time so the channels have been multiplexed and measurements can be taken consecutively. The same sensors are used to measure each channel, just at a different point in time and the values are stored in different locations in memory. Each Insel has four sensors: an opacimeter for smoke detection, an oxygen sensor which measures the percentage of oxygen in the air, and two pressure sensors. In addition to these sensors, each Insel also has a flowmeter and pressure sensor on the Festo pipes. The sensor information is given in the DB400 datablock of the PLC. The data is ordered so that the four Figure 3 Insel sensors

sensors of each channel of each Insel are given in order and then the Festo sensors. In total there are 11 Insels so there are 11 Insels x 10 channels x 4 sensors = 440 channel sensors.

5 sensors of each channel of each Insel are given in order and then the Festo sensors. In total there are 11 Insels so there are 11 Insels x 10 channels x 4 sensors = 440 channel sensors. There are also two flow and pressure sensors on the two general pumps. These sensors are given after the 440 Insel sensors. Figure 3 shows how the sensor data is ordered in DB400. The 440 Insel sensors come first, then the flow and pressure sensors on the first pump. Then the first Insel Festo local flow and pressure sensors are given. Then the flow and pressure sensors on the second pump, followed by all of the rest of the Insel Festo local flow and pressure sensors. So in total, 466 sensors. Overview of performed tasks As mentioned above, the project was already well on its way and my task was to create the HMI for it. The tasks could be separated into some steps, described in the following subchapters. Setting up The first task was to set up the WinCC OA and JCOP framework. The software had to be installed on a remote machine that had access to the PLC data. The software (WinCC OA and 3.11 SP1 patches) installation was done through the CERN Computer Management Framework (CMF). The JCOP framework installation was done following the Course Materials for Students [1] (part 3). The JCOP framework installation added functionality to WinCC OA, such as the JCOP Device Editor and Navigator, framework installer etc., as well as standard framework panels and scripts. Figure 4 shows the list of additional framework components that were installed to be able to work with the requirements of this project, added by accessing JCOP Framework Installation. The version number of the components was also very important to get all the components to work with each other. Figure 4 List of framework components Familiarizing with WinCC OA and JCOP The Course Materials for Students [1] was a great starting point for getting to know the WinCC OA platform and the JCOP framework principles. The materials gave a good overview of what WinCC OA is used for and how to start working on your project with it. Another great overview was given in the PVSS/WinCC OA Getting Started [3] guide.

The JCOP framework imposes some design rules and guidelines on the HMI systems. To comply with the guidelines, the JCOP design document [2] was consulted.

This was done from SysMgm Driver S7 Driver. Figure 5 shows the way the PLC was set up in the configurator.

6 The JCOP framework imposes some design rules and guidelines on the HMI systems. To comply with the guidelines, the JCOP design document [2] was consulted. For example, the naming conventions and the look and feel conventions were essential to follow. Connecting with the Siemens PLC To read data from the S7 PLC, the S7 driver had to be set up. This was done from SysMgm Driver S7 Driver. Figure 5 shows the way the PLC was set up in the configurator. The device name was already known to be CPU319 so it was added as a new device on the configurator screen. As can be seen from Figure 5, the IP and other parameters were set up as well. Figure 5 The S7 driver configuration Figure 6 Adding the S7 manager To manage the connection to the PLC, a manager was set up in the WinCC OA project console (Append a new manager on the right-hand side toolbar of the Console). Figure 6 shows the Manager Properties window, where S7 Driver is selected. After the manager was set up, the connection could be checked by reading from the DB400.DBW0 (default value was 17) in PARA. Reading the sensors and Insel data The data was read from for different data blocks in the PLC. Table 2 summarizes the data areas and gives an overview of what data was read from there. To get a clear overview of all the datablocks, I highly suggest checking the attached files DB400 sensors spec.docx, DB1.pdf, DB400.pdf, DB32 data view.pdf and Pump_Writing_Symbols.pdf. For creating the DB400 sensor datapoints the JCOP Framework Device Editor and Navigator (DEN) was used. Firstly, a new PLC was added to the TK_PLCS list (see Figure 7) and the S7 PLC was configured to be a Tracker PLC. The PLC setup was

done in the From File tab of the PLC configuration window (the window on the right on Figure 7). Four steps from the Select Step dropdown list were performed, in consecutive order: 1.

7 done in the From File tab of the PLC configuration window (the window on the right on Figure 7). Four steps from the Select Step dropdown list were performed, in consecutive order: 1. Common DPs created the common datapoints of the PLC type; 2. System Parameters set up the PLC parameters, such as IP and number of sensors and saved them in the common datapoints; 3. Sensors set the addresses of each sensor within the DB400; 4. Set Names set names for connected channels/sensors. Datablock DB400 DB432 DB1 MW272 MW338 Table 2 PLC datablocks where data was read from Description Sensor information The Insel Multiplexer data RunMode manual or automatic mode The current status Running sensor values for each Insel The pump control words The steps required an Excel to be set up with the data. The Sensors file included all of the addresses and IDs within the DB400 datablock of the sensors. The Names file allowed to add specific names to each sensor. The location of the files can be seen from Figure 7 (data folder within the project directory). Figure 7 Adding and configuring the PLC and sensors in DEN

Before the Sensors step could be finished, the sensor models had to be created (Configuration Mode in DEN; then right-click on the system name dist_1 Register Device Type Edit device definitions.

8 Before the Sensors step could be finished, the sensor models had to be created (Configuration Mode in DEN; then right-click on the system name dist_1 Register Device Type Edit device definitions..) After the model was created it was configured to suit the sensor. I did not create all of the models, as they had to be created following the guidelines of the framework, but I configured them to suit the respective sensors, for example adding the raw value conversion so the datapoint would include a real value. Figure 8 shows the Edit Model window with the converted value setting for the Opacimeter. The upper and lower limit converted values and the converted value Figure 8 Configuring the Opacimeter sensor model When all of the above steps were finished then the sensor datapoints were accessible through the PARA module as well as the GEDI and usable in the screens. The datapoint type that included the sensor info was called TkPlcReadSensors. Going through the steps described above made it possible to read the data from the DB400 datablock. However, the HMI needed to use the other datapoints from Table 2, so I created another datapoint type called Sniffer_Insel manually and added the address configurations. The Sniffer_Insel datapoints group information per Insel, unlike the TkPlcReadSensors DPT where the information was just per sensor. Figure

9 9 shows the structure of the datapoint type and gives an example of the addressing of the data for the first Insel (Insel01). The datapoint elements in the Sniffer_Insel DPT are the following: - sniffermux.wrote a 32-bit binary value, where the multiplexer bits are read/written. This element allows to see which valves of the Insel are currently open as well as write over the value to open up an arbitrary combination of valves; - status shows the current status of each Insel as an integer (for the meaning of the values, see the status help screen on the HMI); - currentvalues shows the pressure, oxygen and opacimeter values of the currently chosen channel. For the oxygen sensor and opacimeter, the flags show the status of the sensor (same help screen as for the status); - writepumps these memory areas allow commands to be sent to the pumps. For the combination of codes/destinations/parameters to be written see [4] page 35; - channelnames this value is a dynamic array of strings and it is not read in from the PLC but manually filled with the names of the channels. The first element in the array corresponds to the first channel etc. Figure 9 Sniffer_Insel DPT The names of the connected channels were pre-set. These values are used in the Festo panel for indication of which channel is being currently measured and in the smoke panel to display the name of each channel. For the Sniffer_Insel DPT elements the polling time was set to be every 10 seconds. Sidenote: Potentially this DPT could be developed further to include references to all of the sensor values and channel groups. For instance, there could be a separate DPT to group all of the sensors by the channels (so it would include the two pressure sensors, the smoke and opacity sensors and the flow and pressure of the Festo pipes). Then these could be grouped by Insel in the Sniffer_Insel DPT. This way all of the data that the HMI screen uses could be accessed through the Sniffer_Insel DPT which would make adding the reference panels easier.

10 HMI panels The initial design for the HMI panels was previously done in WinCC Flexible. I had to redo these panels in WinCC OA. So the design was previously outlined, I just had to realize it in the WinCC OA platform. The design consisted of three main panels that contained different information: - The Home/Sniffer panel - gives an overview of the current pressure, oxygen and smoke levels in each Insel as well as the pressure and flow rate in the Festo pipes; - The Festo panel - shows the pressure and flow readouts from the Festo devices. It also allows to select which valves to open/close in each Insel; - The Smoke panel - shows the smoke and oxygen readings from the sensors for each channel of each Insel that is connected. Additionally to these three main panels, two help screens were added with information about the Insel status and slave status. Since all of the main panels consisted of repeating views or tables then these table cells were first created as reference panels (in the panels/objects subfolder in the project directory). This allowed the reference panels to be easily reused for each Insel or sensor. The Sniffer Panel Figure 10 shows the layout of the Sniffer panel. This is the home screen for the HMI Figure 10 The Sniffer panel The Start All Pumps/Stop All Pumps buttons (Figure 10.1) allow to turn all of the pumps on or off simultaneously.

11 The table view consists of reference cells panels/objects/sniffer/refsniffertablecell (Figure 10.2) which include the following fields (columns from left to right): - The Insel name; - The Status field shows the status of the Insel. Click the? for more information on the status; - Pressure1 & Pressure2 show the pipe pressures in mbar; - The Smoke and Oxygen fields show the current value of the current channel as well as status flags in the respective Flags fields. For more information on the flags, click the?; - The Pump control allows to turn the pump of the Insel on or off. Stopping/starting the pump should result in a change in the Status and sensor values; - The Inhibit LED control allows to turn the Inhibit LED on and off. Switching the LED will result a change in the Status value; - The FESTO fields show the pressure and flow values in the Festo system. - The Select field shows which channel of the Insel is currently active in the multiplexer. Each of the refsniffertablecell reference panels require the following inputs ($parameters): Name Description dplocalflow The Festo local flow sensor datapoint, from TkPlcReadSensor datapoint type. dplocalpressure The Festo local pressure sensor datapoint, from TkPlcReadSensor datapoint type. dpsnifferinsel Each Insel data is stored within the Sniffer_Insel datapoint type. sinselname The name for the Insel that will show in the first column of the table. Table 3 Sniffer panel reference $-parameters The Navigation bar (Figure 10.3) is also a reference cell and allows to navigate between the three panels. The Festo panel Figure 8 shows the layout of the Festo panel. In the upper-left corner of the panel (Figure 11.1) the flow (l/h) and pressure (bar) values of the Festo pipes are shown for the two general pumps. These are instances of the reference panels panels/objects/festo/refpumppanel. The Manual Mode button (Figure 11.2) allows switching between manual and automatic mode. In automatic mode, the channel selection is done automatically by the PLC program and so user input will be overwritten fairly quickly. On the other hand, in manual mode the user-selected valve will stay open until a new selection is made by the user or the mode is switched back to automatic.

12 The table view consists of reference cells panels/objects/festo/reffestotablecell (Figure 11.3) which include the following fields (columns from left to right): - Name of the Insel; Figure 11 The Festo panel - A drop-down list of channel names that are connected. Selecting a channel will open the valve. In automatic mode shows the current channel name. If the selection is empty then that means that there is no real connection or that multiple channels have been opened simultaneously; - A display of the currently selected channel. v1 is the first valve, v2 is the second etc; - The All valves selection allows to either open all (1) of the valves or close all (0) valves of the Insel. A red (0) means that no valve is open and a green (1) means that all valves are open; - The Qmask shows which valves are currently open and also allows user input to open the valves. The order of the valves is the same as in the v1-v10 display. The user can input an arbitrary combination of open and closed valves. For example: will open valve 1 and close all of the others; will open valves 2, 4, 6, 8 and 10 and close the others; 0001xxxxxx will open valve 4, close valves 1, 2 and 3 and leave the other valves unchanged (any character besides 1 and 0 will leave the valve value unchanged). When the input field is selected, the background of the field will turn yellow to indicate that it has been selected. If the run mode is automatic then the field will not be updated with new values as long as the field is active. To confirm the input, click on the appearing green tick-mark or press Enter. To cancel, click anywhere outside the field (the background will turn white again).

- The Pressure and Flow fields show the pressure and flow values in the currently selected channel; Each of the reffestotablecell reference panels require the same input parameters ($parameters) as

13 - The Pressure and Flow fields show the pressure and flow values in the currently selected channel; Each of the reffestotablecell reference panels require the same input parameters ($parameters) as the refsniffertablecell and can be seen in Table 3. Each of the refpumppanel reference panels require the following inputs ($-parameters): Name dpgeneralpumpflow dpgeneralpumppressure spumpnumber Table 4 The refpumppanel $-parameters Description The Festo general flow sensor datapoint, from TkPlcReadSensor datapoint type. The Festo general pressure sensor datapoint, from TkPlcReadSensor datapoint type. Will affect the number in the pump name The smoke panel Figure 12 shows the layout of the Smoke panel. 2 1 Figure 12 The Smoke panel In each Insel group (Figure 12.1), all of the connected channels are displayed as table rows (Figure 12.2), where the first column from the left is the channel name, the next is the smoke readout in %O/m and the rightmost value is the oxygen value in %. Each of the refsmokecell reference panels require the following inputs ($-parameters):

14 Name Description dpo2value The oxygen sensor datapoint for the specific Insel channel, from TkPlcReadSensor datapoint type. dpsmokevalue The smoke sensor datapoint for the specific Insel channel, from TkPlcReadSensor datapoint type. dpsnifferinsel Each Insel data is stored within the Sniffer_Insel datapoint type. ichannelnumber The channel number as an integer. Based on this the channel name will be chosen from the dpsnifferinsel.channelnames DPE which is an array of strings where the name of the first channel is on the first position of the array etc. Table 5 The refsmokecell $-parameters All of the panels have a Help button which gives the same information as above. Unfinished tasks The HMI needs improvement or additional setup in the following areas: - Porting the program to the Simatic HMI. The development on the HMI was done on a PC but the actual program would run on a Simatic HMI which still needs to be set up; - Assigning the SMS contacts for alarm notification. The alerts for the opacimeter have been already set up, but the users who will get alerts by SMS have not been configured yet; - Assigning three user levels. Currently the user has access to all of the controls and panels but there should be access levels which hide some of the controls for some users. - In the case of maintenance work the alarms must be disabled. Conclusion Even though all of the tasks were not completed, I still think that my work was quite successful. The panels show the real-time information from the PLC and the user can control the pumps with the HMI. In hindsight I feel like I could have worked much faster and finished everything up but at the same time I feel like the task was a perfect balance of being easy enough so I didn t have a stressful time and yet challenging enough so I got to learn quite a lot about how the automation systems work in CERN. In general, I am very happy for getting this project because I feel like I actually achieved something useful.

15 References [1] PVSS-JCOP Course Materials for Students [WWW]: JCOPFw+Course+Downloads [2] Joint Controls Project (JCOP) Framework Sub-Project Guidelines and Conventions [PDF]: [3] Getting Started with PVSS/WinCC-OA: [4] Simoes, J. L. SNIFFER Project Software Design Document (March 2009)

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