fundaÇÃo para a ciÊncia e tecnologia fct trainee program follow up joão rodrigo alvelos ferreira...
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FUNDAÇÃO PARA A CIÊNCIAE TECNOLOGIA
FCT Trainee Program Follow UpJoão Rodrigo Alvelos Ferreira | Started March 2013
October 2014TE-VSC-ICM
CAREER PATH
2005 – 2010 | Faculty of Engineering – University of Porto
MSc. in Electrical and Computer EngineeringMajored in Robotics and Automation
2009 – 2010 | University of Southern Denmark
MSc. in Electrical Engineering and RoboticsERASMUS Programme
2010 – 2013 | Portugal Telecom – PT Inovação
Software EngineerMEO IPTV and Large Scale Software Solutions
Since 2013 | CERN - Switzerland
Control and Automation EngineerTE/VSC – Interlocks Controls and Monitoring
THE SECTION
• Monitoring, maintenance & consolidation of the vacuum control systems of all accelerators and detectors.
• Follow up, maintenance & update of the program suites for vacuum monitoring tools and databases for all accelerators and detectors. Logistics & storage of strategic spares for all Vacuum Controls.
• Definition & management of vacuum interlocks for all accelerators.
• Definition of the Vacuum Control’s Systems for the new projects.
MANDATE OF THE TE-VSC-ICM SECTION
PROJECTS | Contribution to the LHC Vacuum Controls
LHC | Sector Valve Cryogenic Interlocks
The LHC Sector Valves isolate the different vacuum sectors in the LHC. They are currently interlocked with the adjacent Sector Valves and local pressure and temperature values.
A new software interlock had to be implemented, closing the sector valves in case of temperature rise in the cryogenic system, which might lead to a pressure rise.
LHC | Sector Valve Cryogenic Interlocks
• Reverse engineer the communication protocol between PLC and SVCU cards, in order to understand how to send commands (DONE)
• Implement new code to obtain and process the CRYO_MAINTAIN signal from the Cryogenic System PLCs (DONE)
• Implement the new interlock input and logic in the existing SVCU PLC control block (DONE)
• Test the system in the lab, guaranteeing it works as intended (DONE)
• Implement all the interlocks and deploy the solution to the LHC PLCs (WAITING FOR PERMISSION TO TEST ON THE LHC AND IMPLEMENT IN PRODUCTION)
SVCU Crates in the LHC
LHC | NEG Pumps
Getter pumps were installed during the LS1 in order to increase the pumping speed in the Long Straight Sections in the LHC.
These are essentially NEG cartridges, a material that once activated helps complete or maintain ultra high vacuum by adsorpting small ammounts of gas. The NEG is activated by being heated to a suitably high temperature, for a defined time.
A control system had to be developed to remotely activate the pumps once they’re installed in the LHC. Activation must be performed under certain conditions (the NEG must be under vacuum) and remotely monitored through the Vacuum SCADA.
NEG Cartridges
LHC | NEG Pumps
Control Architecture of the NEG Pumping System
Block communication in the NEG pumping system
Faceplates for the NEG devices in the SCADA
LHC | Thermocouples for Warm Magnets
Thermocouples were installed during the LS1 to measure the temperature of the warm magnets in the LHC-LSS. These measurements must be available in the vacuum SCADA and archived to the relevent databases.
Thermocouple
• Developed the software to measure and aggregate the temperatures supplied by the thermocouples, integrating them into the vacuum SCADA.
• The system allows the generation of alarms based on freely defined thresholds.
• Provides an interface to the SCADA, so that the temperatures may be remotely monitored and archived.
LHC | TC and NEG Commissioning
Equipment Layout in LHC Point 1
LHC | TC and NEG Commissioning
NEG Pumps
• Checking the position and placement of each junction box, cable and pump.
• Connecting all the cables according to the documentation.
• Checking the continuity of each circuit and measuring all the resistance values.
• Connecting all the crates in the racks, testing the power supplies and control hardware.
• Testing remote control in monitoring through the SCADA.
Thermocouples
• Checking the position and placement of each VRJGT box and cable.
• Testing each individual thermocouple input for correct temperature measurement, comparing local and PLC measurements.
• Testing each individual thermocouple input for correct reaction to temperature fluctuations.
• Testing remote monitoring through the SCADA.
PROJECTS | Contribution to NA62 Vacuum Controls
NA62 | Development and Management
New PLC Developments• Devices for the Cryogenic Pumps and RS232
gateway
• Device for Full Range Profibus DP Pressure Gauge
• Devices for VP-3 and VF-2 Pulsed Valves
VacDB Management• Managing the project in VacDB Editor, inserting
the required devices and properly configurating their parameters
• Testing the code exports and upgrading the PLC software
NA62 | Cryogenic Pumps
Full Cryogenic Pump assembly
The vacuum level in the main NA62 tube must be particularly high, which is why seven cryogenic pumps are installed throughout its length.
These pumps consist of a complex assembly with valves, cryogenic head, compressors and gauges, all controlled by a PCA700C controller. This controller must be interfaced to the SCADA in order to provide remote control and monitoring.
NA62 | Cryogenic Pumps
Hardware Architecture Control Architecture
Command Control Flow
NA62 | Cryogenic Pumps
NA62 SCADA with CRYO Controller faceplate
NA62 | Profibus DP Gauge and VP-3 Pulse Valve Controller
Peiffer MPT200 Full Range Gauge VAT VP-3 Pulsed Valve Controller
NA62 | VacDB Management
PROJECTS | SUBU Controls Consolidation
SUBU | Control System Consolidation
The SUBU Chemical Polishing machine performs the chemical polishing of copper RF cavities for several particle accelerators using a mix of chemicals known as SUBU. The machine was designed and built in the early nineties.
• Current control system is based on the Siemens S5 series of PLCs and a customized touch panel solution.
• S5 has been discontinued: Siemens does not provide support anymore and spares will become increasingly hard to find.
• To guarantee that the machine can be kept in operation the control system must be upgraded. The HMI (currently a touch panel developed specifically for this machine) must also be updated to a PC based SCADA solution.
SUBU | Control System Consolidation
REVERSE ENGINEERING
Fully reverse-engineer (wiring, PLC connections, existing equipment, control strategies) the system from on site analysis and testing, feedback from the operator and existing documentation.
HARDWARE SPECIFICATION
Understand and document current hardware installation.
Produce a new, up to date, hardware specification that allows for proper choosing of new control hardware.
PROCESS SPECIFICATION
Understand, document and redefine the Polishing and Leaching processes.
Re-implement the processes under the new software.
SUBU | Control System Consolidation
IMPLEMENTATION OF THE NEW CONTROL SYSTEMImplementing the new control system (SCADA + PLC) using UNICOS, CERN’s in-house framework for process control.
FINAL THOUGHTS | Acknowledgments
Fundação para a Ciência e Tecnologia
Dr. Paulo Gomes
All those I had the chance to work with
