sps renovation final design and status
DESCRIPTION
SPS RENOVATION Final design and status. R.Mompo , P.Dahlen , Y.Bastian, I.Romera, M.Zerlauth. SPS LAYOUT and Magnet Powering. SPS (7 kms ) composed of 6 sextants Main dipole and quad magnets powered in series , power converters located in respective BA - PowerPoint PPT PresentationTRANSCRIPT
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SPS RENOVATION
Final design and status
R.Mompo, P.Dahlen, Y.Bastian, I.Romera, M.Zerlauth
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SPS LAYOUT and Magnet Powering
• SPS (7 kms) composed of 6 sextants
• Main dipole and quad magnets powered in series, power converters located in respective BA
• Auxiliary (corrector) magnets powered individually (some exceptions) from respective BA
• Ring-line magnets (quadrupole, octupoles, sextupoles) powered in series in whole SPS ring from BB3
• Current interlock system built in 1974 (mains) 1980 (Aux)
BB3
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SUMMARY Description Cost Manpower PRO CON
ConsolidationOption #1
- - - Risk of lengthy failure
Option #2 (Boolean PLC)
180kCHF 0.5 FTE (MS) + 0.1 FTE (ICE)
Simple + standard, no cabling, diagnostic
Ring line remains, no remote test, info only by sextants/ring
Option #3 (Boolean PLC +
cable)
300kCHF 0.75 FTE (MS) + 0.1 FTE (ICE)
Simple + standard, diagnostic per demi-sextant
Additional cabling + patches, no remote test
Option #4 (Boolean PLC + PLC
comms)
300kCHF 0.75 FTE (MS) + 0.1 FTE (ICE)
Simple + standard, diagnostic per demi-sextant
Special (non-safety part in PLC, no remote test
Option #5 (Analogue I/Os)
400kCHF 1.5 FTE (MS) + 0.4 FTE (ICE)
Diagnostic per magnet without major
Completely new SW projects, no remote test
Option #6 (Profibus)
>1.2MCHF 2 FTE (MS) + 0.1 FTE (ICE)
Full Monty Considerable investment, validation time for rad tolerant
I/Os, feasibility?
During last MPE-TM meeting, we concluded that they were 2 realistic options (#3 or #4) to renovate the SPS interlock system !
Finally, we have chosen option #3 ! I will explain why in the following slides...
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Main Dipole and Quadrupole Magnets
Ring-Line Magnet
Auxiliary Magnet
SPS Magnet families
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Principle of the SPS interlock system
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Principle of the SPS interlock system
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Principle of the SPS interlock system
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Principle of the SPS interlock system
Each magnet has an interlock box to collect signals from thermo-switches and for visual indication («trefle»)
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PLC architecture (1/2)
• Configuration of WIC PLC for the “Mains” and “Aux. circuits.
• In BA1 * , BA2, BA3, BA4, BA5 and BA6:
• * In BA1, there is no “Aux.” crate (circuits combined with TT10 transfer line not renovated during LS1).
Ethernet
Crate 1: Type 1 Power supplies
Profibus
SITOP Modular power
supply
6EP1 334-3BA00
SITOP Modular power
supply
6EP1 334-3BA00
SITOP SelectDiagnostics
module 6EP1 961-
2BA00
Redu
ndan
cy m
odul
e6E
P1 9
61-3
BA21
From PLC power suppliesMagnets and
PCs statusTo Power
converters To BIC
Remote test
From Magnets
PCsstatus
To Power converters
SITOP Modular power
supply
6EP1 334-3BA00
SITOP Modular power
supply
6EP1 334-3BA00
SITOP SelectDiagnostics
module 6EP1 961-
2BA00
Redu
ndan
cy m
odul
e6E
P1 9
61-3
BA21
Mod
ule
32 D
O
6ES
7 32
2-1B
L00-
0AA0
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
ET 200 M
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Crate 2: Type 2PLC for SPS main circuits
Crate 3: Type 1Power supplies for deported unit
Crate 4: Type 3Deported unit for SPS aux. circuits
Impedance adaptation crates
CP 343-1 IT
P L C
3 1 5 F -
2 D P
Mod
ule
8 DI
/ 8
DO6E
S7 3
23-1
BH01
-0AA
0
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
32 D
O
6ES
7 32
2-1B
L00-
0AA0
6 “new” racks
5 existing racks =
cohabitation
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PLC architecture (2/2)• Configuration of WIC PLC for the Ring-Line located in BB3:
Ethernet
Crate 1: Type 1 Power supplies
Profibus
SITOP Modular power
supply
6EP1 334-3BA00
SITOP Modular power
supply
6EP1 334-3BA00
SITOP SelectDiagnostics
module 6EP1 961-
2BA00
Redu
ndan
cy m
odul
e6E
P1 9
61-3
BA21
CP 343-1 IT
P L C
3 1 5 F -
2 D P
Mod
ule
8 DI
/ 8
DO6E
S7 3
23-1
BH01
-0AA
0
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
8 DO
(rel
ay)
6ES
7 32
2-5H
F00-
0AB0
Mod
ule
32 D
O
6ES
7 32
2-1B
L00-
0AA0
From PLC power supplies
PCs status To Power converters
To BIC
From Magnets
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
ET 200 M
Mod
ule
24 D
I Saf
ety
6E
S7 3
26-1
BK02
-0AB
0
Crate 2: Type 2PLC for SPS Ring Line circuits
Crate 3: Type 4Deported unit for SPS Ring line circuits
Impedance adaptation crates
1 existing rack =
cohabitation
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Powering scheme of the main dipoles
EDMS: 681304
• If a dipole magnet overheats (or any powering failure):
Þ All 14 PCs must be switched off!
• If we put a WIC in each BA (to protect 1 sextant), how do we propagate the info to the PCs located in the other BAs?
• Do we need to introduce a PLC-PLC communication between the WICs ??? (=> use of non- safety PLCs ).
• Long distances: Issues on reliability/ dependability/ reaction time?
• How do we send a «Beam Dump» signal to the BICs?
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Powering scheme of the main quadrupoles
EDMS: 681372
• In a way simpler, as all PCs are located in 1 BA (BA3).
• But the WIC installed in BA3 must also receive the info from all other sextants?
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Powering scheme of the “Ring-Line”
• The “Ring-Line” is composed of:
o Quadrupole, sextupole, octupole magnets
o Divided in 4 circuits (166 magnets, 8 PCs)
o All PCs are in BB3
• One of the main objective of this renovation (despite replacing the old electro-mechanical crates) is to split the “Ring-Line” in half sextants
o In 2012, we lost 24h to identify the origin of a problem in the Ring-Line (impedance of the line changing due to ageing of the TS).
From the WIC side, it is seen as:
4 x (6 x 2) = 48 circuits !
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Powering scheme of the “Ring-Line”• Since we had to put in place patch panels for the «Ring-Line», it became obvious
that we could also centralise all the quadrupole signals in BA3 (where the PCs are located)
=> Advantage: Avoid using crates belonging to EPC
BA4
BA1
BA2
BA3 BA5
BA6
SPS-RING
NE48 (2x24p) cable
Ring line as is today (4 circuits = 4x NE4 cables going around the machine)
NER48 «Radiation-tolerant» cable
«Bouchons» to cut the Ring Line:4 «bouchons» on each side
2x4 NE4 per sextant
Patch in pos. 62250
Patch in pos. 11310
Patch in pos. 12100
Patch in pos. 21450
Patch in pos. 22100
Patch in pos. 31482
Patch in pos. 32100
Patch in pos. 41450
Patch in pos. 42250
Patch in pos. 51450
Patch in pos. 52250
Patch in pos. 61450
Dedicated PLC in BB3RA 8518
Dipole & Quadrupole interlock line(Split by ½ sextant)
x2
+ 2x1 NE4 per sextant Dedicated PLC in BA3
RA 1777
+
+
+
+
+
+
-
-
-
-
-
-
Patch in PA3 RA2301
This doesn’t solve our communication pbm for the dipoles!
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Communication between BAs
EDMS: 682971
Interlock crate (present in each BA)
Centralisation crate for the mains Quads
Around year 2000, EPC introduced some major changes:1. Local PLCs to pilot each PC.2. A Master_PLC.3. A Hardware Interlock Loop (HIL)!
Crates named «chassis CO» and “CISBOX” are used to distribute signals between «BAs».
Overview of the layout of all BAs (for the mains):
Water interlock crate (EN/CV)
Dipole & Quads PC’s
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Communication between BAs
EDMS: 682971
Overview of the layout of all BAs (for the mains):
• Modifications after LS1:
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Hardware Interlock Loop (HIL)
EDMS: 684948
• 3 current loops• Red: main dipole• Green: main quadrupole• Blue: Sextupole PCs of the
Ring-Line
• If a loop is open, all PCs of the same loop will trip and send a beam dump signal to the BIC in BA3.
• HIL loop and functionality remains under the responsibility of TE/EPC
Thanks to this HIL loop, our WIC PLCs in each BA do not need to communicate between them!
=> In case of a fault in 1 sextant, the WIC sends a «FPA» to the 2 PCs of the corresponding BA. This will cause the opening of the HIL loop and the trip of the other PCs!
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Beam Dump (Current Situation)• The Beam Dump Request:
o The beam dump requests are centralized in BA3.
o 3 input signals (Dipole, Quads, Sextupoles).
o + 1 input from the ROCS system (that checks the consistency between the output of the PCs and the loaded functions)
o + Other PCs are interlocked via the Software Interlock System (SIS).
o ... + inputs for all other systems.
CIB.BA3.S3.Beam Dump Control.
In the future, we could think of replacing this crates (EPC) by a FM352 PLC (High speed Boolean Processor).
Our proposal:1. Keep those inputs as is.2. Add a signal sent by the WIC to the BIC in
each respective BA.
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Status of the renovation
• Functional Specification (EDMS 1295506): o A first version is being circulated to gather comments from all groups involved with detailed
explanation of all changes (What will stay, what will be removed, cabling convention etc...).
• Underground work:o EN/EL has installed the cables for us in BA3 and BA5 (2/6 sextants).o 13 patch panels are in place in the tunnel.
• Surface work:o 5/6 “new” racks installed in each BA. UPS and UTP installation scheduled.o 15/31 PLC crates are cabled, remaining ones should be ready by end of August 2013 (Spie).o Patch panels (x17) are ordered, need to be cabled (+ control cables) .
• PLC/PVSS programming:o David Willeman’s (EN/ICE) contract ends in Feb. 2014 o We depend on David to get the PLC programs (… true as well for Booster, Linac4 etc...)
We agreed on deadlines to get the programs before!
• HWC:o Discussion started to optimize the strategy, given the little time dedicated to the powering tests
before the SPS restart (planned for July-Aug. 2014).• For the final checks, we need the PC to be «déconsigné».
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Conclusions
• In the case of a renovation, to design an efficient magnet interlock system, one has to know in details how a machine is operated... (Machine layout, naming convention, interaction with other systems, standard operation mode as well as non standard operation modes i.e. MD, different people). o “Each machine at CERN is a different Kingdom”, dixit Karel Cornelis
• In «old» machines (same issues for the «Booster» and the «PS») the optic of the machine is often modified, therefore some flexibility must be anticipated at the level of our WIC configuration (to avoid hardware & software modifications at every changes).
• Production of hardware and cable installation is going on as scheduled.
• Potential issue with David Willeman’s contract ???
• During LS1, our colleagues from EN/EL will replace all cables in sextant 1.o Part of the standard procedure to replace periodically cables exposed to radiation
=> We are impacted.
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Thank you for your attention!