Hall D Solenoid Controls System and Monitoring Plan · PDF fileHall D Solenoid Controls System...

HallDSolenoidControlsSystemand

MonitoringPlan

Ellio6WolinDirector’sReviewoftheHallDSolenoid

26‐Oct‐2010

1JeffersonLab‐HallDSolenoidDirector's

Review26‐Oct‐2010

Outline

I.  SafetyandControlsII.  ControlsandMonitoringStrategy

  InHallD

  FortheCoiltest

III.  CurrentStatusIV.  SummaryandConclusions



I.SafetyandControls

•  Allpressure,mechanical,electricalsystemsself‐protected–  Fail‐safeagainstcontrolsystemfailure

•  Hard‐wiredmagnetpowersupplysafetyinterlocksystem–  CaniniSatefastorslowdump,dependingonproblemdetected

•  PLC‐basedcontrolsystem–  NOmajorroleconcerningsafety

•  tooeasilydefeated–  AutomatestediousoperaSons–  Putscryosysteminto“safestate”ifproblemdetected–  CaniniSateslowdump–  Note:slowdumpiniSatedbyinterlocksystemifPLCnotacSve



II.ControlsandMonitoringStrategy

•  Fullsystem– Uniformlook‐and‐feelacrossalldevices– Designedforshi[personnel(physicists)

•  Coiltestsystemissubsetoffinalsystem– Expert‐onlysystem– Nophysicistoperators– Onlyexpertdisplaysandmonitoring/archivescreens



ExperimentControlSystem(ECS)

SupervisoryControlandDataAcquisiSonSystem(SCADA)

DetectorControlSystem(DCS)

HallDThree‐TierControlsArchitecture

Allen‐BradleyPLC

Solenoid Target Gas Cooling

HVSystem

LVSystem

OtherSystems

UsesAFECSforhigh‐levelstatemachinesandoperatorGUI’s.

Integra(onlayer

UsesEPICSforcommunicaSon,archiving,alarms,display.

Providesuniformlook‐and‐feel

Autonomousdetectorcontrol,low‐levelstatemachines.

(PLC,Ethernet,OPC,CAN,SMB)

Nogeneral‐purposecomputersusedinthislayer!

•  DetectorControlSystem

– 24x7autonomousoperaSon

– Adjuncttopersonnelandmachinesafetysystem

– AllPIDandcontrolloopsresidehere

– Nogeneralpurposecomputers

– Allen‐BradleyPLC•  prefersimpleanalogsensors/actuators•  can’tavoidserial(e.g.RS232)devices



Type NumberofDevices

ControlPointsperDevice

ChannelCount ControlMechanism

FDCcoolingsystem 20 1 20 PLC

Cryogenictarget 40 1 40 PLC

Solenoidmagnet 200 1 200 PLC

Gassystems 40 1 40 PLC

Misc 50 1 50 PLC

Tagger/beamline 200 1 200 Ethernet

Goniometer 6axes 10 60 Ethernet

VXS,VME,HV,LVcrates 80 15 1200 OPC?SNMP?

HV,LVchannels 2300 4 9200 OPC?SNMP?

Discriminators 2800 1 2800 Ethernet

Cockro[‐Waltonbases 2800 5 14000 CAN

Boardtemperatures 1575 1 1575 SMB(I2C)

Misc 200 1 200 Ethernet

So[wareChannels 200 1 200 Ethernet

TOTAL 29785

ChannelTypesandCounts

7

Mecha

nical~60

0chan

nels

Electrical~29

000chan

nels

JeffersonLab‐HallDSolenoidDirector'sReview26‐Oct‐2010

SolenoidControlSystem

•  PLC‐based– ChoseAllen‐Bradley

•  reputaSon•  extensiveselecSonofcomponentsandI/Omodules

•  experienceandexperSseatJLab(HallC,Cryogroup)•  reviewin2009confirmedPLCchoice

– SinglePLCprocessorforcoiltest•  extremelyreliableinpracSce•  dual‐redundantsystemforfinalexperiment



Measurement/Control

SolenoidFinalSystem(es(mated)

SolenoidCoilTest

NotesforCoilTest

Temperature 75 27 Analog(Sidiode,Pt)andRS232(C‐glassandC‐resistor,LakeshoreCryotronics)

Pressure 10 4 Analog

Vacuum 8 2 Analog,KurtLesker

Strain 30 8 Analog,4axial+2radialHeimcolumns,2Hevesselhead

ValveposiSon 14 9 Analog,JLabdesignandcommercial

LiquidLevel 2 2 Analog,CryomagneScs,LN2andLHe

Flow 6 2 RS232,Teledyne/HasSngs

Voltage 40 12 RS232(powersupply)andanalog(voltagetaps,quenchdetector)

Current 4 4 AnalogandRS232,set+3readback

Relay 2 2 Analog,UPSandPLCheartbeat

BField 6 2 HallProbeandpickupcoil

AllsignalsarecondiSoned/isolatedbeforeconnecSontoPLC

26‐Oct‐2010JeffersonLab‐HallDSolenoidDirector's

Review 11

•  UseAllen‐Bradley(expert)tools– Displayscreens– Alarms– Archive

•  alltagsfast(1Hz),slow(0.1‐0.2Hz)oron‐change•  selectedtagsspecialrunsveryfast(10Hz)

–  forturn‐to‐turnshortdetecSon

•  EPICSusage–  InteroperatewithCryoGroupEPICSsystem

•  cross‐postrelevantprocessvariables– PagingandGuardShacknoSficaSon

CoilTestControlSystem




Review 14

WebAccessible(readonly)


Review 15

WebAccessible(readonly)

III.CurrentStatus•  Allchannelscheckedend‐to‐endduringconstrucSon

•  Cryochannels–  Allcablesinstalled–  OperaSonverifiedinTestLab–  CalibraSonscompleted

•  Electricalchannels–  Almostallareready–  Somerecentlyadded/modified

•  notneededforafewweeks •  willbeinstalledduringmulS‐weekcooldownphase



•  PLC–  Programready–  Alldevicesoperated–  FullalgorithmfromnarraSveimplemented–  somecalibraSonsmustbedoneduringoperaSons

•  EPICS–  CryoGroupprocessvariablesavailableasPLCtags–  RelevantPLCtagsservedouttoCryoEPICSsystem–  PagingandGuardShackcommunicaSonsimplemented–  Everythinginfinalcheckout

•  HMIandWebscreensready–  WilltweakconSnuously

•  Archivesystem–  Testedandready




Review 18

Legend Response=1 FastDump Response=2 SlowDump–PLCAcSvated Response=3 SlowDump–HardWired Response=4 NoSfyOperatorviaHMIScreenIndicaSon Response=4.1 DoResponse2,4,ANDalerton‐calloperator

StrainGauges

SignalName Descrip(on Limit Response SC1_SG_B StrainGauge,CoilFace,Top None NA SC1_SG_T StrainGauge,CoilFace,Bo6om None NA SC1_SG1 StrainGauge,AxialHeimColumn#4 ‐10,000lb≤F≤10,000lb 2 SC1_SG2 StrainGauge,RadialHeimColumn2O'Clock ‐7,500lb≤F≤7,500lb 2

‐10,000lb≤F≤10,000lb 3

SC1_SG3 StrainGauge,AxialHeimColumn#9 ‐10,000lb≤F≤10,000lb 2 ‐12,500lb≤F≤12,500lb 3

SC1_SG4 StrainGauge,AxialHeimColumn#16 ‐10,000lb≤F≤10,000lb 2 SC1_SG5 StrainGauge,RadialHeimColumn10O'Clock ‐7,500lb≤F≤7,500lb 2

‐10,000lb≤F≤10,000lb 3 SC1_SG6 StrainGauge,AxialHeimColumn#21 ‐10,000lb≤F≤10,000lb 2

CoilTemperatures

SignalName Descrip(on Limit Response SC1_TCR1 LHeCoilTemperature(Top) T≤4.2K 3 SC1_TCR2 LHeCoilTemperature(Center) 4.2K≤T 4 SC1_TCR3 LHeCoilTemperature(Bo6om) 4.2K≤T 4 SC1_TCR4 LHeCoilTemperature(Bo6om) 4.2K≤T 4 SC1_TCR5 LHeCoilTemperature(Center) 4.2K≤T 4 SC1_TCR6 LHeCoilTemperature(Top) 4.2K≤T 3 SC1_TSD_FT CoilFlangeTemperature(Top) 3K≤T≤7K 4 SC1_TSD_FB CoilFlangeTemperature(Bo6om) 3K≤T≤7K 4

ControlsChannelsLimits


Review 19


Review 20


Review 22


Review 23

IV.SummaryandConclusions•  SafetysystemdoesnotrelyonPLCcontrolsystem

–  PLCwilltakepreempSveacSonifproblemdeveloping–  Willmovesystemto“safestate”andpageexpert–  IfPLCacSve,unlikelyhard‐wiredsafetysystemwilloperate

•  Coiltestcontrolsystem–  Implementssubsetoffinalsystem–  AlmostenSremagnetcryoandelectricalcontrolsystemimplemented–  OnlytestonecoilataSme–  Expert‐onlyinterfaces

•  CoilTestPlan–  Completestep‐by‐stepplandeveloped

Coiltestcontrolsystemready!24


Backup



•  WetreatthePLCasanunreliable“operator”–  incorrectusageofcontrolGUIbyoperators– misunderstandings,bugs– badcalibraSons– ACPowerloss,UPSfailure– damagedcables– processorfailure

•  experimentwillusedual‐redundantPLCsystem



•  SCADA(SupervisoryControlandDataAcquisiSon)– EPICS(ExperimentalPhysicsandIndustrialControlSystem)

•  JLabhasextensiveexperiencewithEPICS–  acceleratorcontrolbasedonEPICS–  allthreehallsuseEPICS–  canreadeachother’scontrolsinformaSon–  acSvecollaboraSon,manynewdevelopments

• WilluseLinux‐onlyEPICS,noVxWorks–  possiblyJava‐onlyEPICS

•  ControlSystemStudio(CSS)orLabviewforgraphics•  ChannelAccess(CA)foundaSonforcommunicaSons•  ManytoolsinEPICStoolkit

–  alarmsystem(SNS)–  archiver(SNS)–  stripcharttool(Labview,CSS,others)–  save‐and‐restorefacility(SNS)



•  ExperimentControlSystem

–  AFECS•  AgentFrameworkforExperimentControlSystems•  Javaagent‐basedcontrolsystemfromJLabDAQgroup

•  usedforCODA3runcontrol•  allowsintegraSonofslowcontrolswithruncontrol

–  high‐levelstatemachinescripSnglanguage

–  hierarchical–  similartoSMI++usedatLHC



•  CleardisSncSonbetweensystemsforshi[personnelandforexperts

– Verystrictrequirementsforoperators•  uniformlook‐and‐feelveryimportant

– Verylooserequirementsforexperts•  uniformlook‐and‐feelnotimportant

UniformpresentaSontoshi[operatorsisamajorfuncSonoftheSCADAlayer



Allen‐BradleyPLC

LinuxComputers

Ethernet

CounSngHouse

HallDControlNet

andEthernet/IP

ControlNetworkConfiguraSon

TargetControlCrate

SolenoidControlCrate

Target

Magnet

HVCrate

GoniomenterControl

FDC

GONI

TenModuleRemoteChassis

Powersupply

RemoteChassisCommunicator

DCInputModule

31

AlsousingPointI/ORemoteChassis


PLCRedundantChassisLayoutSevenModuleChassis

PowersupplyPLC

RedundancyModule

CommunicaSonModule

RemoteChassisCommunicator

BlankSlots



LadderLogicProgram

FuncSonBlockProgram

OnePIDFuncSonblockcanhaveover160parametersinit.




Review 37

Legend Response=1 FastDump Response=2 SlowDump–PLCAcSvated Response=3 SlowDump–HardWired Response=4 NoSfyOperatorviaHMIScreenIndicaSon Response=4.1 DoResponse2,4,ANDalerton‐calloperator

StrainGauges

SignalName Descrip(on Limit Response SC1_SG_B StrainGauge,CoilFace,Top None NA SC1_SG_T StrainGauge,CoilFace,Bo6om None NA SC1_SG1 StrainGauge,AxialHeimColumn#4 ‐10,000lb≤F≤10,000lb 2 SC1_SG2 StrainGauge,RadialHeimColumn2O'Clock ‐7,500lb≤F≤7,500lb 2

‐10,000lb≤F≤10,000lb 3

SC1_SG3 StrainGauge,AxialHeimColumn#9 ‐10,000lb≤F≤10,000lb 2 ‐12,500lb≤F≤12,500lb 3

SC1_SG4 StrainGauge,AxialHeimColumn#16 ‐10,000lb≤F≤10,000lb 2 SC1_SG5 StrainGauge,RadialHeimColumn10O'Clock ‐7,500lb≤F≤7,500lb 2

‐10,000lb≤F≤10,000lb 3 SC1_SG6 StrainGauge,AxialHeimColumn#21 ‐10,000lb≤F≤10,000lb 2

CoilTemperatures

SignalName Descrip(on Limit Response SC1_TCR1 LHeCoilTemperature(Top) T≤4.2K 3 SC1_TCR2 LHeCoilTemperature(Center) 4.2K≤T 4 SC1_TCR3 LHeCoilTemperature(Bo6om) 4.2K≤T 4 SC1_TCR4 LHeCoilTemperature(Bo6om) 4.2K≤T 4 SC1_TCR5 LHeCoilTemperature(Center) 4.2K≤T 4 SC1_TCR6 LHeCoilTemperature(Top) 4.2K≤T 3 SC1_TSD_FT CoilFlangeTemperature(Top) 3K≤T≤7K 4 SC1_TSD_FB CoilFlangeTemperature(Bo6om) 3K≤T≤7K 4

ControlsChannelsLimits


Review 38

ShieldTemperatures

SignalName Descrip(on Limit Response SC1_TP1 NitrogenOuterShieldTemperature(Right) 75K≤T≤85K 4

SC1_TP2 NitrogenCenterShieldTemperature(Right) 75K≤T≤85K 4

SC1_TP3 NitrogenInnerShieldTemperature(Right) 75K≤T≤85K 4

SC1_TP4 NitrogenOuterShieldTemperature(Le[) 75K≤T≤85K 4

SC1_TP5 NitrogenCenterShieldTemperature(Le[) 75K≤T≤85K 4

SC1_TP6 NitrogenInnerShieldTemperature(Le[) 75K≤T≤85K 4

SC1_TP7 LN2SupplyLineTemperature(Chimney) 75K≤T≤85K 4.1

SC1_TP8 LN2ReturnLineTemperature(Chimney) 75K≤T≤85K 4.1

VoltageTaps

SignalName Descrip(on Limit Response

QD1 Quenchdetectorchannel1,voltageacrossupstreamcoolinglead V≥80mVDC 1

QD2 Quenchdetectorchannel2,voltageacrossdownstreamcoolinglead V≥80mVDC 1

QD4U Quenchdetectorchannel4upper,VoltageacrossCoil1 V≥50mVDC 1

AllVTT’s Voltageacrossanysub‐coilorsplice V≥30mVDC 4

CanTemperatures


SC1_TP_DSCLW DownstreamCurrentLeadWarmEnd 275K≤T≤300K 4

SC1_TP_USCLW UpstreamCurrentLeadWarmEnd 275K≤T≤300K 4

SCC_TP_NR LN2Return 75K≤T≤100K 4

SCC_TP_NS LN2Supply 75K≤T≤85K 4

SCC_TCG_HT LHeTank 3K≤T≤6K 4

SCC_TCG_HCD LHeCooldown 3K≤T≤6K 4

SCC_TCG_HS LHeSupply 3K≤T≤6K 4

SCC_TCG_HR LHeReturn 3K≤T≤6K 4

SCC_TCG_WH WarmHe(GAS) T≤5K 4

SC1_TCG_USCLC UpstreamCurrentLeadColdEnd 3K≤T≤5K 1

SC1_TCG_DSCLC DownstreamCurrentLeadColdEnd 3K≤T≤5K 1


Review 39

CanPressures

SignalName Descrip(on Limit Response SCC_PI_A VacuumA 1E‐5Torr≤P 1 SCC_PI_B VacuumB 1E‐5Torr≤P 1

SCC_PI_HT TeemountoffLiquidHeLevelprobe P≤1.5Atm 3 SCC_PI_HS HeliumSupplyPressure P≤4Atm 4 SCC_PI_HR HeliumReturnPressure P≤1.5Atm 2

SCC_PI_NT TeemountoffLiquidN2Levelprobe P≤2Atm 4

LiquidLevels

SignalName Descrip(on Limit Response SCC_LLH HeLiquidLevel L≤35% 4.1 SCC_LLN N2LiquidLevel L≤35% 4.1

FlowIndicators


SC1_FI_DSCL DownstreamCoolingLeadFlowIndicator V≤10.6SLPM 1

SC1_FV_DSCL DownstreamCoolingLeadFlowValvePosiSon 0%≤L≤100% N/A*

SC1_FI_USCL UpstreamCoolingLeadFlowIndicator V≤10.6SLPM 1

SC1_FV_USCL UpstreamCoolingLeadFlowValvePosiSon 0%≤L≤100% N/A* *RequiresnoacSonaslongassufficientflowexists

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