Hall D Solenoid Controls System and Monitoring Plan

Transcription

1 Hall D Solenoid Controls System and Monitoring Plan Ellio6 Wolin Director s of the Hall D Solenoid 1

2 Outline I. Safety and Controls II. Controls and Monitoring Strategy In Hall D For the Coil test III. Current Status IV. Summary and Conclusions 2

3 I. Safety and Controls All pressure, mechanical, electrical systems self protected Fail safe against control system failure Hard wired magnet power supply safety interlock system Can inisate fast or slow dump, depending on problem detected PLC based control system NO major role concerning safety too easily defeated Automates tedious operasons Puts cryo system into safe state if problem detected Can inisate slow dump Note: slow dump inisated by interlock system if PLC not acsve 3

4 II. Controls and Monitoring Strategy Full system Uniform look and feel across all devices Designed for shi[ personnel (physicists) Coil test system is subset of final system Expert only system No physicist operators Only expert displays and monitoring/archive screens 4

5 Hall D Three Tier Controls Architecture Experiment Control System (ECS) Uses AFECS for high level state machines and operator GUI s. Integra(on layer Supervisory Control and Data AcquisiSon System (SCADA) Uses EPICS for communicason, archiving, alarms, display. Provides uniform look and feel Detector Control System (DCS) Autonomous detector control, lowlevel state machines. (PLC, Ethernet, OPC, CAN, SMB) Allen Bradley PLC HV System LV System Other Systems No general purpose computers used in this layer! Solenoid Target Gas Cooling

6 Detector Control System 24x7 autonomous operason Adjunct to personnel and machine safety system All PID and control loops reside here No general purpose computers Allen Bradley PLC prefer simple analog sensors/actuators can t avoid serial (e.g. RS232) devices 6

7 Channel Types and Counts Mechanical ~600 channels Electrical ~29000 channels Type Number of Devices Control Points per Device Channel Count Control Mechanism FDC cooling system PLC Cryogenic target PLC Solenoid magnet PLC Gas systems PLC Misc PLC Tagger/beamline Ethernet Goniometer 6 axes Ethernet VXS, VME, HV, LV crates OPC? SNMP? HV, LV channels OPC? SNMP? Discriminators Ethernet Cockro[ Walton bases CAN Board temperatures SMB (I2C) Misc Ethernet So[ware Channels Ethernet TOTAL

8 Solenoid Control System PLC based Chose Allen Bradley reputason extensive selecson of components and I/O modules experience and expersse at JLab (Hall C, Cryo group) review in 2009 confirmed PLC choice Single PLC processor for coil test extremely reliable in pracsce dual redundant system for final experiment 8

9 Measurement/ Control Solenoid Final System (es(mated) Solenoid Coil Test Notes for Coil Test Temperature Analog (Si diode, Pt) and RS232 (C glass and C resistor, Lakeshore Cryotronics) Pressure 10 4 Analog Vacuum 8 2 Analog, Kurt Lesker Strain 30 8 Analog, 4 axial + 2 radial Heim columns, 2 He vessel head Valve posison 14 9 Analog, JLab design and commercial Liquid Level 2 2 Analog, CryomagneScs, LN2 and LHe Flow 6 2 RS232, Teledyne/HasSngs Voltage RS232 (power supply) and analog (voltage taps, quench detector) Current 4 4 Analog and RS232, set + 3 readback Relay 2 2 Analog, UPS and PLC heartbeat B Field 6 2 Hall Probe and pickup coil All signals are condisoned/isolated before connecson to PLC

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12 Coil Test Control System Use Allen Bradley (expert) tools Display screens Alarms Archive all tags fast (1 Hz), slow ( Hz) or on change selected tags special runs very fast (10 Hz) for turn to turn short detecson EPICS usage Interoperate with Cryo Group EPICS system cross post relevant process variables Paging and Guard Shack nosficason 12

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14 Web Accessible (read only) 14

15 Web Accessible (read only) 15

16 III. Current Status All channels checked end to end during construcson Cryo channels All cables installed OperaSon verified in Test Lab CalibraSons completed Electrical channels Almost all are ready Some recently added/modified not needed for a few weeks will be installed during muls week cooldown phase 16

17 PLC Program ready All devices operated Full algorithm from narrasve implemented some calibrasons must be done during operasons EPICS Cryo Group process variables available as PLC tags Relevant PLC tags served out to Cryo EPICS system Paging and Guard Shack communicasons implemented Everything in final checkout HMI and Web screens ready Will tweak consnuously Archive system Tested and ready 17

18 Controls Channels Limits Legend Response = 1 Response = 2 Response = 3 Response = 4 Response = 4.1 Fast Dump Slow Dump PLC AcSvated Slow Dump Hard Wired NoSfy Operator via HMI Screen IndicaSon Do Response 2, 4, AND alert on call operator Strain Gauges Signal Name Descrip(on Limit Response SC1_SG_B Strain Gauge, Coil Face, Top None NA SC1_SG_T Strain Gauge, Coil Face, Bo6om None NA SC1_SG1 Strain Gauge, Axial Heim Column #4 10,000 lb F 10,000lb 2 SC1_SG2 Strain Gauge, Radial Heim Column 2 O'Clock 7,500 lb F 7,500 lb 2 10,000 lb F 10,000lb SC1_SG3 Strain Gauge, Axial Heim Column #9 10,000 lb F 10,000 lb 2 12,500 lb F 12,500lb SC1_SG4 Strain Gauge, Axial Heim Column #16 10,000 lb F 10,000 lb 2 SC1_SG5 Strain Gauge, Radial Heim Column 10 O'Clock 7,500 lb F 7,500 lb ,000 lb F 10,000lb 3 SC1_SG6 Strain Gauge, Axial Heim Column #21 10,000 lb F 10,000 lb 2 Coil Temperatures Signal Name Descrip(on Limit Response SC1_TCR1 LHe Coil Temperature (Top) T 4.2K 3 SC1_TCR2 LHe Coil Temperature (Center) 4.2K T 4 SC1_TCR3 LHe Coil Temperature (Bo6om) 4.2K T 4 SC1_TCR4 LHe Coil Temperature (Bo6om) 4.2K T 4 SC1_TCR5 LHe Coil Temperature (Center) 4.2K T 4 SC1_TCR6 LHe Coil Temperature (Top) 4.2K T 3 SC1_TSD_FT Coil Flange Temperature (Top) 3K T 7K 4 SC1_TSD_FB Coil Flange Temperature (Bo6om) 3K T 7K 4 18

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20 26 Oct 2010 Jefferson Lab Hall D Solenoid Director's Review 20

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23 26 Oct 2010 Jefferson Lab Hall D Solenoid Director's Review 23

24 IV. Summary and Conclusions Safety system does not rely on PLC control system PLC will take preempsve acson if problem developing Will move system to safe state and page expert If PLC acsve, unlikely hard wired safety system will operate Coil test control system Implements subset of final system Almost ensre magnet cryo and electrical control system implemented Only test one coil at a Sme Expert only interfaces Coil Test Plan Complete step by step plan developed Coil test control system ready! 24

25 Backup 25

26 We treat the PLC as an unreliable operator incorrect usage of control GUI by operators misunderstandings, bugs bad calibrasons AC Power loss, UPS failure damaged cables processor failure experiment will use dual redundant PLC system 26

27 SCADA (Supervisory Control and Data AcquisiSon) EPICS (Experimental Physics and Industrial Control System) JLab has extensive experience with EPICS accelerator control based on EPICS all three halls use EPICS can read each other s controls informason acsve collaborason, many new developments Will use Linux only EPICS, no VxWorks possibly Java only EPICS Control System Studio (CSS) or Labview for graphics Channel Access (CA) foundason for communicasons Many tools in EPICS toolkit alarm system (SNS) archiver (SNS) stripchart tool (Labview, CSS, others) save and restore facility (SNS) 27

28 Experiment Control System AFECS Agent Framework for Experiment Control Systems Java agent based control system from JLab DAQ group used for CODA3 run control allows integrason of slow controls with run control high level state machine scripsng language hierarchical similar to SMI++ used at LHC 28

29 Clear dissncson between systems for shi[ personnel and for experts Very strict requirements for operators uniform look and feel very important Very loose requirements for experts uniform look and feel not important Uniform presentason to shi[ operators is a major funcson of the SCADA layer 29

30 Ethernet CounSng House Allen Bradley PLC Linux Computers Hall D ControlNet and Ethernet/IP T ar g et Target Control Crate F D C HV Crate M a g n e t Solenoid Control Crate Control Network ConfiguraSon G O N I Goniomenter Control

31 Ten Module Remote Chassis Power supply Remote Chassis Communicator Also using Point I/O Remote Chassis DC Input Module 31

32 PLC Redundant Chassis Layout Seven Module Chassis Power supply Redundancy Module PLC Remote Chassis Communicator CommunicaSon Module Blank Slots 32

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35 Ladder Logic Program

36 FuncSon Block Program One PID FuncSon block can have over 160 parameters in it. 36

37 Controls Channels Limits Legend Response = 1 Response = 2 Response = 3 Response = 4 Response = 4.1 Fast Dump Slow Dump PLC AcSvated Slow Dump Hard Wired NoSfy Operator via HMI Screen IndicaSon Do Response 2, 4, AND alert on call operator Strain Gauges Signal Name Descrip(on Limit Response SC1_SG_B Strain Gauge, Coil Face, Top None NA SC1_SG_T Strain Gauge, Coil Face, Bo6om None NA SC1_SG1 Strain Gauge, Axial Heim Column #4 10,000 lb F 10,000lb 2 SC1_SG2 Strain Gauge, Radial Heim Column 2 O'Clock 7,500 lb F 7,500 lb 2 10,000 lb F 10,000lb SC1_SG3 Strain Gauge, Axial Heim Column #9 10,000 lb F 10,000 lb 2 12,500 lb F 12,500lb SC1_SG4 Strain Gauge, Axial Heim Column #16 10,000 lb F 10,000 lb 2 SC1_SG5 Strain Gauge, Radial Heim Column 10 O'Clock 7,500 lb F 7,500 lb ,000 lb F 10,000lb 3 SC1_SG6 Strain Gauge, Axial Heim Column #21 10,000 lb F 10,000 lb 2 Coil Temperatures Signal Name Descrip(on Limit Response SC1_TCR1 LHe Coil Temperature (Top) T 4.2K 3 SC1_TCR2 LHe Coil Temperature (Center) 4.2K T 4 SC1_TCR3 LHe Coil Temperature (Bo6om) 4.2K T 4 SC1_TCR4 LHe Coil Temperature (Bo6om) 4.2K T 4 SC1_TCR5 LHe Coil Temperature (Center) 4.2K T 4 SC1_TCR6 LHe Coil Temperature (Top) 4.2K T 3 SC1_TSD_FT Coil Flange Temperature (Top) 3K T 7K 4 SC1_TSD_FB Coil Flange Temperature (Bo6om) 3K T 7K 4 37

38 Shield Temperatures Signal Name Descrip(on Limit Response SC1_TP1 Nitrogen Outer Shield Temperature (Right) 75K T 85K 4 SC1_TP2 Nitrogen Center Shield Temperature (Right) 75K T 85K 4 SC1_TP3 Nitrogen Inner Shield Temperature (Right) 75K T 85K 4 SC1_TP4 Nitrogen Outer Shield Temperature (Le[) 75K T 85K 4 SC1_TP5 Nitrogen Center Shield Temperature (Le[) 75K T 85K 4 SC1_TP6 Nitrogen Inner Shield Temperature (Le[) 75K T 85K 4 SC1_TP7 LN2 Supply Line Temperature(Chimney ) 75K T 85K 4.1 SC1_TP8 LN2 Return Line Temperature (Chimney ) 75K T 85K 4.1 Voltage Taps Signal Name Descrip(on Limit Response QD1 QD2 Quench detector channel 1, voltage across upstream cooling lead V 80 mvdc 1 Quench detector channel 2, voltage across downstream cooling lead V 80 mvdc 1 QD4U Quench detector channel 4 upper, Voltage across Coil 1 V 50 mvdc 1 All VTT s Voltage across any sub coil or splice V 30 mvdc 4 Can Temperatures Signal Name Descrip(on Limit Response SC1_TP_DSCLW Downstream Current Lead Warm End 275K T 300K 4 SC1_TP_USCLW Upstream Current Lead Warm End 275K T 300K 4 SCC_TP_NR LN2 Return 75K T 100K 4 SCC_TP_ NS LN2 Supply 75K T 85K 4 SCC_TCG_HT LHe Tank 3K T 6K 4 SCC_TCG_HCD LHe Cooldown 3K T 6K 4 SCC_TCG_HS LHe Supply 3K T 6K 4 SCC_TCG_HR LHe Return 3K T 6K 4 SCC_TCG_WH Warm He (GAS) T 5K 4 SC1_TCG_USCLC Upstream Current Lead Cold End 3K T 5K 1 SC1_TCG_DSCLC Downstream Current Lead Cold End 3K T 5K 1 38

39 Can Pressures Signal Name Descrip(on Limit Response SCC_PI_A Vacuum A 1E 5 Torr P 1 SCC_PI_B Vacuum B 1E 5 Torr P 1 SCC_PI_HT Tee mount off Liquid He Level probe P 1.5 Atm 3 SCC_PI_HS Helium Supply Pressure P 4 Atm 4 SCC_PI_HR Helium Return Pressure P 1.5 Atm 2 SCC_PI_NT Tee mount off Liquid N2 Level probe P 2 Atm 4 Liquid Levels Signal Name Descrip(on Limit Response SCC_LLH He Liquid Level L 35% 4.1 SCC_LLN N2 Liquid Level L 35% 4.1 Flow Indicators Signal Name Descrip(on Limit Response SC1_FI_DSCL Downstream Cooling Lead Flow Indicator V 10.6 SLPM 1 SC1_FV_DSCL Downstream Cooling Lead Flow Valve PosiSon 0% L 100% N/A* SC1_FI_USCL Upstream Cooling Lead Flow Indicator V 10.6 SLPM 1 SC1_FV_USCL Upstream Cooling Lead Flow Valve PosiSon 0% L 100% N/A* * Requires no acson as long as sufficient flow exists 39