Controls SystemInstallation Status Ernest Williams for Controls Department
Outline • LCLS Control System Installation • Project Staff and Assignments • Schedule & the Process • Cable Plant, racks and other infrastructure • I&C Systems status and schedule • Software Status • Issues & Concerns • Summary
Project Staff • Dedicated LCLS Control System Deputy (E. Carrone) to help drive the project. • E. Williams: Installation Manager. • M. De Salvo: Coordination Manager. • Each subsystem “owned” by a System Lead, responsible for schedule, resources and costs. • Additional support provided by services from PCD. • Cable Shops and Fab Shops. • Controls Coordination Forum: every Thursday at 9.00 am.
Plans & Process for LCLS Controls System Installation • Controls installation takes place in several steps: • Design, documentation, procurement and Installation of the cable plant including 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, networks & timing modules in the racks • Rack installation in the field, AC & cable plant connection
Cable Plant Design & Installation Process • From the list of devices to be installed… • Develop racks layout & cable tray design • Generate rack profiles for electronics modules • Identify DC & I&C cabling requirements & document in CAPTAR • Produce installation bid package from CAPTAR and tray designs • Generate installation bid package & award contract • Procure trays, cables, connectors, etc. • Install cable plant and terminate to beam line components
The readiness status of all controls racks are reviewed weekly (sheet on SharePoint)
Rack Profiles on SharePoint • For each I&C rack we track the equipment to be installed in each “row” • Green – Installed • Yellow – Not installed, but there are no issues • Red – Cause for concern
Controls Installation Schedule Overview LTU/Undulator/e-DumpControls InstallationOverview
Control System Cable Plant & Racks • Nearly 100% of cable plant is installed and terminated. • All Instrumentation Racks are installed and operational
Control System Crates & IOCs, Modules • VME Crates are all installed and operational • All IOCs are installed and operational • We are in the end-to-end checkout phase • There are currently no anticipated major delays in completing most of the pre-beam checkout.
IOCs • Large number of IOCs running reliably for LCLS Accelerator • 136 Coldfire-based embedded IOCs • Mainly used for BPM and LLRF front-end processors • 104 MVME6100 IOCs • 33 MVME3100 IOCs • Beamlines will also use some number RTEMS-based IOCs for Slow controls
Magnet Power Supply Control • Magnet Control System ready to support end-to-end checkout • Alarm Handler, SCORE, ChannelWatcher and Archiver configs are ready
Safety Systems • Separate talks later today on Safety Systems • BCS • Mature design • Project is on schedule • PPS • The Initial Acceptance Test of the Undulator Complex has been executed. • New documentation control process in place
MPS Systems • MPS • Concurrently developing new LCLS MPS • Response time of less than one pulse at 120 Hz • New hardware extended 1.2 km past current MPS • Non-CAMAC • Ready for photon section • Pre-beam checkout will begin mid November
Networks • Accelerator Network Infrastructure supports I&C Ethernet and MPS • The project consists of: • Network architecture design • Cable Plant Davis Bacon Phase IV & Phase V Contracts • Fiber Termination Contract • e-Controls networks Integrate with other networks: • Undulator Alignment Diagnostics System Network • Conventional Facilities • Photon Sections • SLAC Scientific Computing and Computing Services (SCCS) centralized networking groups are helping with all networks • New network tech hired on to support Terri Lahey
Network Design • Accelerator Switches reside in service buildings 911, 912, 913 and 921, and FEE • Undulator accelerator switches are in service buildings B913 & B921 to reduce heat-load • The network consists of Cat6 long hauls between service building patch panels and cat6 boxes at racks • Tunnel walkup stations: one each COW and wireless access • Other IOCs are located in service buildings: MPS, BPM, etc. • Fiber Trunks support Ethernet switches and MPS
Davis Bacon & Fiber Contracts • Phase IV: • install and test cat6 long hauls • Phase V: • fiber pull • Fiber Termination Contract • terminate and test fibers for e-beam, photon, & timing • SCCS/Lahey created contract using knowledge/process learned from BC2 fiber termination contract
Networks Procurements • Fiber trunks purchased • The order for network switches is in purchasing • DIGI terminal servers have been ordered • Patch panels have been ordered • Remaining: fiber jumpers and FODU (Fiber Optic Distribution Units)
Timing System • The scope is to deliver triggers and timestamp data to all subsystems requiring such. • The system can be split into two parts • Long-haul distribution of triggers from the EVG to EVRs in LTU and beyond • Short-haul back end consisting of the HW & SW to receive the EVG timing signal and generate triggers. This is the extension of the timing for BC2 • 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.
Beam Diagnostics • Profile Monitors: • OTR30 and OTR33 installed and checked out. Waiting on air from Central Facilities • OTRDMP controls are ready but device will be installed in the tunnel this week. End-to-End checkout follows. • YAGXRAY controls is in progress. Waiting on fiber pull this week. • TOROIDs (Controls are ready): • IM31 (system checkout complete) • IM36 (system checkout complete) • IMUNDO (waiting on cable termination) • IMUNDI (waiting for device installation and cable termination this week.) • IMDMP (waiting on cable termination)
Beam Diagnostics (Cont’d) • BPMs • All new Stripline BPMs controls pre-beam checkout complete • Cavity BPM controls pre-beam checkout in progress. • Cavity BPM Calibration software is now in development.
Beam Diagnostics (Cont’d) • Alignment Diagnostic System (ADS) • Interface to EPICS in good shape undergoing checkout
Facilities • HVAC • EPICS Interface complete and undergoing checkout. • Chiller/Boiler • EPICS Interface complete and undergoing checkout • LCW • EPICS Interface complete and undergoing checkout
Vacuum • Vacuum Pump Controllers • Vacuum Guage Controllers • Vacuum Valve Controllers • PLCs for interlocks and control • Cabling and Connectors • Drawing and documentation in progress and in good shape.
Testing & Checkout Strategies • Rack loading & testing • Will accomplish as much as possible in B024 prior to transporting racks to the field. • In-field loading (Davis-Bacon) and intra-rack cabling is less efficient. • Networks and Timing will be the first system to be made operational in field to allow booting of IOCs and testing
Rack Assembly Area (B024 ) B913 & B921 PS racks B911 & B912 PS racks
Procedure for AC Power Release to Rack Systems • Purpose: • To provide for safe AC power application to the individual rack distribution systems (plug molds, outlets, breaker panels, ect.) and equipment in the racks • Constraints: • Ensure that with the application of AC power to each rack no electrical hazards are created via rack equipment, cable plant or conductors (either within or leaving the rack). • Procedure • Identify/list all potential hazards, correct or neutralize any potential electrical hazard, request and receive approval from LCLS Controls Manager and the LCLS Installation Manager (R. M. Boyce) for the release/application of AC power to identified rack. • Once approval is given appropriate breakers will be unlocked and control of breakers turned over to responsible system engineer.
PP-6 After Contractor Turn-over & LCLS Safety Lockout PP-7 After Contractor Turn-over & LCLS Safety Lockout
Software Installation Status • All IOCs have loaded their software from a central EPICS file server. The server is ready to support pre-beam checkout and commissioning. • All controls software will be installed and checked out according to a “signed off” test plan. • Alarm Handler, Archiver, autosave/channelWatcher, Channel Access Security, and SCORE ready to support pre-beam checkout and commissioning • Software has been installed following the LCLS software RELEASE procedure.
Issues & Concerns • Schedule & Resources • Controls is the systems “integrator” – delays in other systems directly impact our installation. This has been the case in the Injector and BC2 installation phases • Support of operations while completing final installation and pre-beam checkout of LTU/UND/EDMP • System Functionality • The new MPS – pre-beam checkout will be tight
Summary • Controls in general is in good shape for 2008 installation • No major design or production issues dominate the plan • There are concerns about the transfer of systems from ANL to SLAC. • We will use BLMs from PEP (Thanks to Alan Fischer) • We have received a draft “HandOver” and a draft “Detailed Software Design Document” plan from ANL • A large number of sub-systems have been installed and pre-beam checkout is the major activity before Dec. 1, 2008