2007 downtime readiness review

Hamid Shoaee

Control System Installation Readiness [email protected]

3/16/20071

2007 Downtime Readiness Review

Hamid Shoaee

For

LCLS Controls Group(in the following departments)

Controls

Power Conversion

Klystron

Hamid Shoaee


3/16/20072

Agenda

LCLS Control System Installation Readiness Objectives & Scope

Schedule & the Process

Cable Plant, racks and other infrastructure

I&C Systems status and schedule

Issues & Concerns

Hamid Shoaee


3/16/20073

AAAA SSSS OOOO NNNN DDDD JJJJ FFFF MMMM AAAA MMMM JJJJ JJJJ AAAA SSSS OOOO NNNN DDDD JJJJ FFFF MMMM AAAA MMMM JJJJ JJJJ

LCLS Installation and Commissioning Time-LineLCLS Installation and Commissioning Time-LineInjector Controls Injector Controls

Installation Installation CompleteComplete

Gun/Inj./BC1 Gun/Inj./BC1 Commissioning Commissioning

Gun/Inj./BC1 Gun/Inj./BC1 InstallInstall

(8/21 – 2/20)(8/21 – 2/20) linac/BC2 linac/BC2 Install Install

Inj./Linac/BC2 Inj./Linac/BC2 Commissioning Commissioning

LTU/und. LTU/und. Install Install

2006200620062006 2007200720072007

LTU/und.LTU/und.hall “ready”hall “ready”

ControlsControlsCheckouCheckou

t t

LTU/und. LTU/und. Commissioning Commissioning

First Spont. First Spont. LightLight

2008200820082008

Oct. 19, 2006Oct. 19, 2006

SLAC linac tunnelSLAC linac tunnel research yardresearch yard

Linac-0L =6 m

Linac-1L 9 m

Linac-2L 330 m

Linac-3L 550 m

BC1L 6 m

BC2L 22 m

DL2 DL2 L L =275 m=275 m

‘Wall region’

undulatorL =130 m

6 MeV 135 MeV 250 MeV 4.30 GeV 13.6 GeV

Linac-XL =0.6 m

21-1b,c,d

...existinglinac

L0-a,b

rfgun

21-3b24-6dX

25-1a30-8c

Commission now 2007 down, Sept-Nov

LCLS Accelerator RegionsLCLS Accelerator Regions

Nov. 1, ’07

DownDown:: Sep., Oct., Nov. of 2007Sep., Oct., Nov. of 2007RunRun:: Dec. 2007 through ~Aug. 2008Dec. 2007 through ~Aug. 2008ToTo:: SL2-stopper in BSY (just past linac sector-30)SL2-stopper in BSY (just past linac sector-30)

Remove 8 RF Remove 8 RF sections (24-7, 8)sections (24-7, 8)Remove quad Remove quad Q24801Q24801Add 4 new bends in Add 4 new bends in sector-24sector-24Add 6 new quads Add 6 new quads (3 types)(3 types)Add 1 ‘wide’ BPMAdd 1 ‘wide’ BPMAdd 1 Add 1 xx-collimator-collimatorAdd 1 OTR screenAdd 1 OTR screen

Modifications in Sector-24 for BC2 (Emma)Modifications in Sector-24 for BC2 (Emma)

Hamid Shoaee


3/16/20076

Linac Modifications (Fall ‘07)

Remove 8 RF sections (24-7, 8)

Remove quad Q24801

Add 4 new bends in sector-24

Add 6 new quads (3 types)

Add 1 ‘wide’ BPM

Add 1 x-collimator

Add 1 OTR screen

Hamid Shoaee


3/16/20077

Linac Modifications (continued)Linac Modifications (continued)

Add 4 new wire scanners in sector-24Add 4 new wire scanners in sector-24Add 3 OTR screens (1 BC1, 2 in sec-25)Add 3 OTR screens (1 BC1, 2 in sec-25)Move LOLA (trans. deflector) from sec-29 to 25-2 Move LOLA (trans. deflector) from sec-29 to 25-2 (powered by the 24-8 klystron)(powered by the 24-8 klystron)Add pulsed horizontal dipole magnet in sec-25 (BXKIK)Add pulsed horizontal dipole magnet in sec-25 (BXKIK)Move 2 LI28 Wire Scanners, 44 & 544, by 20-30 metersMove 2 LI28 Wire Scanners, 44 & 544, by 20-30 metersBPM electronics upgraded (resolution improved)BPM electronics upgraded (resolution improved)

More feedback loops (energy & bunch length)More feedback loops (energy & bunch length)

Hamid Shoaee


3/16/20078

Linac Modifications (continued)Linac Modifications (continued)

Power SystemsPower SystemsBC2 racks & PS (install racks and PS at sector 24)BC2 racks & PS (install racks and PS at sector 24)

I&C SystemsI&C SystemsI&C racks and systems (install racks at sector 24)I&C racks and systems (install racks at sector 24)

Cable PlantCable PlantSector 24 ( install new trays and cable plant from sector 24 racks Sector 24 ( install new trays and cable plant from sector 24 racks into Linac; terminate at racks and at loads)into Linac; terminate at racks and at loads)BTH West (pull cables from B005, 105, 106 through BSY into BTH West (pull cables from B005, 105, 106 through BSY into BTH West and coil cables; no loads & no racks installed yet)BTH West and coil cables; no loads & no racks installed yet)B136 through BSY to BTH WestB136 through BSY to BTH WestRemove cut cables from FFTBRemove cut cables from FFTB

Hamid Shoaee


3/16/20079

Plans & Process for BC2 Controls System Installation

Controls installation takes place in several steps:Design, procurement and Installation of the cable plant including trays, long haul DC and I&C cables

Cables Termination and connection to beam line components (Mechanical Systems)

Procurement & preparation of electronics racks

Installation of electronics chassis and modules including crates, IOCs, timing modules in the racks

Rack installation in the field, AC & cable plant connection

Controls Installation Schedule Overview

Cable Plant Design & Installation Process

From the list of devices to be installed…

Develop racks layout & cable tray designGenerate rack profiles for electronics modulesIdentify DC & I&C cabling requirements & document in CAPTAR

Produce installation bid package from CAPTAR and tray designsGenerate installation bid package & award contractProcure trays, cables, connectors, etc.Install cable plant and terminate to beam line components

Hamid Shoaee


3/16/200714

Typical Sector Cable List(Michael De salvo, Mario Ortega)

DATE 3/12/2007 SECTOR 24 TOTAL MATERIAL COST $39,070SYSTEM MEAN LENGTH WIRE SCANNER (4) VAC GAUGE (0) VAC PUMP (13) BCS (2) BPM (2) TOTAL IC HV CV CABLE FT Ft COST TOTAL

RG214 220 4 4 4 880 $2.89 $2,543

LMR400 170 8 10 10 1700 $1.20 $2,040

1/4" HELIAX 170 0 0 $0.90 $0

2.0HEL 85 2 2 170 $13.04 $2,217

TYPE C 220 4 13 19 19 4180 $0.26 $1,087

3C18OS 170 2 2 2 340 $0.70 $238

18PR 22 GA 170 2 2 340 $1.96 $666

9C18TLN 170 2 2 340 $2.75 $935

4PR18TLN 170 0 0 $1.36 $0

RG58 170 4 4 4 680 $0.85 $578

32C18TLN 170 1 1 170 $9.04 $1,537

12C18TLN 220 4 4 4 880 $3.09 $2,719

4PR22TLN 220 4 4 4 880 $1.20 $1,056

RG59 170 1 1 170 $0.53 $90

FIBOPT11 170 1 1 170 $6.00 $1,020

FIBOPT9 170 1 1 170 $2.00 $340

50C18TLN 1500 1 2 2 3000 $2.49 $7,470

36PR16OS 170 1 1 170 $2.49 $423

COAX TRUNK 170 10 10 1700 $8.30 $14,110

TOTALS 4675 60 41 19 8 15940 TOTAL $39,070

TOTAL FT 15940

Hamid Shoaee


3/16/200715

Sector 24 Connector List

First draft BC2 cable design

13k feet$245k (cable)$10k (connectors)

CAPTAR NUM CONNECTOR TYPE COST EA TOTALN214 8 N214 MALE PLUG $26.95 $215.60N400 20 FEMALE-N BULKHEAD $14.30 $286.00

1/4HELSF 0 1/4" HELIAX SF FR $0.00N-PLIC 4 1 5/8" N-Female H7PNF $243.24 $972.96SHV-C 38 SHV TYPE C TEFLON $34.30 $1,303.40

4 $0.00AMP36,DIN96 4 AMP HIGH DENSITY CAMAC $26.00 $464.00

TT19P 2 $0.00TT8P,S & PLB6P,S 0 $37.39 $0.00

BNC58 8 BNC 58 MALE PLUG $2.52 $20.162 $0.008 $0.008 $0.00

BNC59 2 BNC 59 MALE PLUG $2.44 $4.882 $0.002 $0.004 $0.002 $0.0020 COAX TRUNK $5.00 $100.00

120 TOTAL $3,367.00

Racks will be pre-loaded in B24 before field installation

Hamid Shoaee


3/16/200718

BC2 Controls Sub-Systems

Cable plantRacks, crates, IOC, etc.NetworksMagnet power supply controlVacuum controlSafety systems

PPS, MPS, BCSMotion control

Wire scanners, Collimators, ChicaneTimingBeam instrumentation and diagnostics

BPM, Toroid, OTR/YAG, Bunch length monitorLLRF

Hamid Shoaee


3/16/200719

LCLS Controls systems

For each system…Technical leads have developed a schedule covering all phases leading to installation and commissioningThe schedules include development of appropriate field documents (EI, WD), rack profile/cable plant design, procurement, installation and system checkoutContinue Interfacing with Mario Ortega, Bob Fuller, Mike DiSalvo to coordinate procurement and installationWe will be reviewing each schedule to identify bottlenecks, dependencies on other systems, resource availability

Hamid Shoaee


3/16/200720

Safety Systems for BC2,L2,L3

PPSThe Linac PPS does not require modification to run LCLS beam to SL-2.There is an AIP project to convert the Linac and BSY to the LCLS PLC-based system in 2008

MPSWe will use the current (1553-based) MPS for BC2.Two new ion chambers will be requiredThe system will include 10 LDIM inputs

OTR21 (2ea)OTR22 (2ea)OTR_CAV (2ea)BC2 Mover (2ea)CE21 (2ea)

We will need to commission AP25 (currently installed but powered down) to accommodate a new PICP module and an LDIM (already installed).

BC2 MPS Schedule

Check out 12/3

Hamid Shoaee


3/16/200722

Concurrently developing new LCLS MPS

Response time of less than one pulse at 120 HzDecoupling from Master Pattern Generator (MPG)

Fast communication and processing

Knowledge of beam rateIntegration of EVR to MPS and fault devices

New hardware extended 1.2 km past current MPSNon-CAMAC

Ready for photon section

Hamid Shoaee


3/16/200723

LCLS MPS Features

Has response time low enough to protect the undulator (less than 8.3 ms)

Communicates with LCLS timing system (EVG)

Supports new beam loss monitoring hardware and rate limiting methods

Easily extendable and is designed around standards based COTS components

Flexible input and output methods

Hamid Shoaee


3/16/200724

Overview

Hamid Shoaee


3/16/200725

Core Hardware and Software

Hardware and Software

Completion Date Quantity Cost per Unit

Digital Input Card 04/16/2007 30 700

Digital Output Card Done 4 700

MVME 6100 08/31/2007 27 3000

EVR 05/31/2007 1 2500

Reflective Memory 04/02/2007 25 2000

Reflective Memory Hub

04/02/2007 5 2500

Total 169800

Note: These are material costs only. Development labor, installation, etc. costs are not included.

Hamid Shoaee


3/16/200726

Other MPS Devices

Hardware and Software Completion Date Quantity

Beam Loss Monitors 05/01/2008 52–154

Beam Loss Monitor ADC (Argonne)

05/01/2008 10–25

PLIC Scope Card 05/01/2008 3

Hamid Shoaee


3/16/200727

Milestones

Task Completion Date

User Interface 11/01/2007

Linac Installation 11/01/2007

BC2 Commissioning 12/03/2007

LTU-Undulator Commissioning 05/01/2008

Preliminary Design Review 04/16/2007

Final Design Review 09/03/2007

Readiness Review 10/17/2007

Hamid Shoaee


3/16/200728

BCS (Beam Containment System)We will use & extend the existing BCS for BC2 commissioningTwo possible configurations are being considered

1. New BCS PIC System installation in Sector-24A 50 conductor trunk from the Sector-28 BCS rack to a new rack in Sector-24. Long hauls from Sector-24 BCS Rack to the beam line devices in Sector-24 (2 cables per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure Switch)

2. Use BCS PIC system in Sector-28(Depends on being able to drive PIC/LION HV and signal four sectors)

Long hauls from Sector-28 to the beam line devices in Sector-24 (2 cables per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure Switch)

For either configuration…Install VME Crate and associated hardware/software/networkInstall new LION Gas system.AC Power to Sector-28 & Sector-24 racks.

BC2 BCS ScheduleCheck out

11/23

Hamid Shoaee


3/16/200730

Magnet Power Supply Control

The software design is mature and will require little if any changes for BC2Procurements are well under way and orders have been placed for power supplies, racks, etc.There is a detailed schedule covering bench testing, rack loading, wiring, pre-installation checkout, through field installationThe system will be ready 11/30

11/30/07

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3/16/200732

Vacuum controls uses BC1 design, with detailed procurement list in place

Vacuum controls check out by 11/20/07

Wire scanners, Collimators and BC2 motion control use the same design as BC1, and will

be available 11/20/07

Networks will be ready early in October to allow Controls checkout

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3/16/200736

Timing SystemThe scope is to deliver triggers and timestamp data to all subsystems requiring such. The system can be split into two parts

1. Long-haul distribution of triggers from the EVG to EVRs in Linac and beyond2. Short-haul back end consisting of the HW & SW to receive the EVG timing signal and

generate triggers. This is well-understood and defined. Part 1 requires some engineering development as the event system can only have a maximum link length of 300 meters. We can daisy-chain, but only for 3 hops before exceeding the jitter budget. We need a better solutionThis is a tractable item and should not have a high level of risk. Another item of concern with the long-haul distribution is timing phase error due to temperature drift – a mechanism is needed to correct for this. This will need some R&D and we need to decide based on short- versus long-term requirements if users can live with this for now. We have to anyway since time is short

We have a procurement for the "back end" of the timing system consisting of all the HW (fan-outs, EVRs, crates, cables) to deliver triggers to the end subsystem. The long haul procurement list is pending a design decision

Timing System Schedule

Hamid Shoaee


3/16/200738

Beam Instrumentation & Diagnostics

Profile MonitorsThere are 3 OTRs in the LINAC: OTR21, OTR22, OTR_TCAV – These use BC1 designs and electronicsDesign in April, procurement in May, system test July ~ August.

ToroidsThere are two toroids in linac: IMBC2I and IMBC2OWe need to re-spin the data acquisition board for small revisions to the artworkElectronics will be ready in August for system testing

Bunch Length MonitorBL21 and BL22, similar to BL11 and BL12 in BC1Procurement in April and test in May ~ June.

Dumps and StoppersSL2 might need some new data monitoring.

Hamid Shoaee


3/16/200739

Beam Position MonitorsThe linac BPMs have to be upgraded for better resolution for undulator commissioning in May-June ‘08Do we need to upgrade for the BC2,L2,L3 commissioning?

Do the existing BPM electronics work at 200 pC?Do they trigger reliably at low charge?What resolution do they provide?

Test next week with A-Line beamIf we need the linac BPM upgrade

Install 20 racksDesign and install cable plant for 79 BPMsRe-spin BPM analog front-end designFabricate and test 120 BPM chassisInstall 79 BPM chassis

If we can defer the upgradeWe still have to install the cable plant for all of the linac BPMs in this down time Of the 17 BPMs in switchyard we will connect to only 2And one BPM in BC2

LLRF Schedule

Hamid Shoaee


3/16/200741

BC2 Controls Risk Matrix

System Risk

Magnet Power Supply control In good shapeRacks, Crates, IOC No issuesVacuum Control In good shapeMPS, PPS, BCS Existing systemsMotion Control In good shapeOTR/YAG In good shapeNetworks Large amount of workLLRF Large amount of workTiming Design issuesToroids New designBPM New designCable Plant Tight Schedule, BPM Upgrade

Hamid Shoaee


3/16/200742

Testing & Checkout Strategies

For each subsystem, we will use test stands to verify the complete systemTest stands currently in place include:

TimingVacuumMagnet power suppliesMotion control – wire scanners, collimator, etc.

Rack loading & testingNeed to accomplish as much as possible in B024 prior to Sept. transport to field site.In-field loading (Davis-Bacon) and intra-rack cabling is less efficient.

Hamid Shoaee


3/16/200743

Rack Assembly Area

Hamid Shoaee


3/16/200744

Issues & Concerns

Schedule & ResourcesSchedule is very tight, just fits in down timeControls is the systems “integrator” – delays in other systems directly impact our installationCable Plant Installation

Coordination of activities with other installation groups is very important and could jeopardize scheduleLinac BPM upgrade could be an added challenge

System FunctionalityTiming System – small concernBPM, Toroid – need verification of design

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3/16/200745

Summary

Controls in general is in good shape for 2007 installation

No major design or production issues dominate the plan

The schedule is challenging with little float

While a large number of sub-systems will be installed on time, some will need attention to stay on schedule

2007 downtime readiness review

Documents