hamid shoaee control system installation [email protected] 3/16/2007 1 2007 downtime...
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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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Hamid Shoaee
Control System Installation Readiness [email protected]
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
Hamid Shoaee
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Control System Installation Readiness [email protected]
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
Hamid Shoaee
Control System Installation Readiness [email protected]
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