controls system installation status

Ernest Williams

FAC November 2008

Control Systems Software Section1

Controls SystemInstallation Status

Ernest Williams

for

Controls Department

Ernest Williams

FAC November 2008


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

Ernest Williams

FAC November 2008


Project StaffDedicated 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.

Ernest Williams

FAC November 2008


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 cablesCables termination and connection to beam line components (Mechanical Systems)Procurement & preparation of electronics racksInstallation of electronics chassis and modules including crates, IOCs, networks & timing modules in the racksRack 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 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

The readiness status of each Controls Subsystem is tracked weekly

SYSTEM System EngineerRack

ProfileEI

DiagramCable

CodingProcure-

ments

MAGNET Bellomo, De Lira 100% 99% 99% 85%

FEE SYSTEMS Bill Abraham 99% 40% 45% ?%

VACUUM Boyes 100% 75% 98% 90%

BEAM LOSS MON. Krejcik 100% 100% 100% 0%

OTR, YAG, TDUND Peng 100% 70% 100% 100%

COLL, WIRE SCAN Alarcon 100% 40% 99% 90%

BPM Johnson 90% 90% 99% 90%

TOROID Peng 100% 90% 100% 100%

TIMING Krejcik, Dusatko 80% 10% 95% 100%

NETWORKS Lahey 100% 40% 100% 65%

ADS Peters, Gassner 80% 50% 100%

MPS Norum, Tilgman 100% 100% 100% 60%

BCS Bennett 100% 60% 100% 90%

LION Tilghman/ Bennett 100% 0% 100% 100%

PPS P. Bong 100% 100% 100% 75%

TCs, TRP Tilghman 100% 100% 100% 95%

Flow SWITCHES (general)

ALL 50% 50% 50%

TRUNKS Di Salvo 100% 100%

I&C CABLE PLANT DiSalvo 100%

ConnectorsDC CABLES, TRAYS Rodriguez/RogersRACKS Di Salvo 100%

CRATES Di Salvo 100%

IOCS Alarcon 100%

MAJOR PROCUREMENTS

LCLSControls System Installation

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 Installation

Overview

Ernest Williams

FAC November 2008


Control System Cable Plant & Racks

Nearly 100% of cable plant is installed and terminated.All Instrumentation Racks are installed and operational

Ernest Williams

FAC November 2008


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.

Ernest Williams

FAC November 2008

Control Systems Software Section

IOCs

Large number of IOCs running reliably for LCLS Accelerator

136 Coldfire-based embedded IOCsMainly used for BPM and LLRF front-end processors

104 MVME6100 IOCs33 MVME3100 IOCs

Beamlines will also use some number RTEMS-based IOCs for Slow controls

Ernest Williams

FAC November 2008


Magnet Power Supply Control

Magnet Control System ready to support end-to-end checkout

Alarm Handler, SCORE, ChannelWatcher and Archiver configs are ready

Ernest Williams

FAC November 2008


Safety SystemsSeparate talks later today on Safety Systems

BCSMature designProject is on schedule

PPSThe Initial Acceptance Test of the Undulator Complex has been executed.New documentation control process in place

Ernest Williams

FAC November 2008


MPS Systems

MPSConcurrently developing new LCLS MPSResponse time of less than one pulse at 120 HzNew hardware extended 1.2 km past current MPS

Non-CAMACReady for photon section

Pre-beam checkout will begin mid November

Ernest Williams

FAC November 2008


NetworksAccelerator Network Infrastructure supports I&C Ethernet and MPSThe project consists of:

Network architecture designCable Plant Davis Bacon Phase IV & Phase V ContractsFiber Termination Contract

e-Controls networks Integrate with other networks:Undulator Alignment Diagnostics System NetworkConventional FacilitiesPhoton SectionsSLAC Scientific Computing and Computing Services (SCCS) centralized networking groups are helping with all networksNew network tech hired on to support Terri Lahey

Ernest Williams

FAC November 2008


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-loadThe network consists of Cat6 long hauls between service building patch panels and cat6 boxes at racksTunnel walkup stations: one each COW and wireless accessOther IOCs are located in service buildings: MPS, BPM, etc.Fiber Trunks support Ethernet switches and MPS

Ernest Williams

FAC November 2008


Davis Bacon & Fiber Contracts

Phase IV: install and test cat6 long hauls

Phase V: fiber pull

Fiber Termination Contractterminate and test fibers for e-beam, photon, & timing

SCCS/Lahey created contract using knowledge/process learned from BC2 fiber termination contract

Ernest Williams

FAC November 2008


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)

Ernest Williams

FAC November 2008


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 beyondShort-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.

Ernest Williams

FAC November 2008


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)

Ernest Williams

FAC November 2008


Beam Diagnostics (Cont’d)

BPMsAll new Stripline BPMs controls pre-beam checkout completeCavity BPM controls pre-beam checkout in progress.Cavity BPM Calibration software is now in development.

Ernest Williams

FAC November 2008


Beam Diagnostics (Cont’d)

Alignment Diagnostic System (ADS)Interface to EPICS in good shape undergoing checkout

Ernest Williams

FAC November 2008


Facilities

HVACEPICS Interface complete and undergoing checkout.

Chiller/BoilerEPICS Interface complete and undergoing checkout

LCWEPICS Interface complete and undergoing checkout

Ernest Williams

FAC November 2008


Vacuum

Vacuum Pump ControllersVacuum Guage ControllersVacuum Valve ControllersPLCs for interlocks and controlCabling and ConnectorsDrawing and documentation in progress and in good shape.

Ernest Williams

FAC November 2008


Controls Subsystem Risk Matrix

System Risk

Magnet Power Supply control In good shapeRacks, Crates, IOC CompleteVacuum Control In good shapePPS, BCS In good shapeMotion Control In good shapeOTR/YAG In good shapeNetworks CompleteCavity BPM ADC New designMPS New designBPM New designUndulator Control Handover ConcernsCable Plant Complete

Ernest Williams

FAC November 2008


Test Plan and Risk Analysis

Ernest Williams

FAC November 2008


Testing & Checkout Strategies

Rack loading & testingWill 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

Ernest Williams

FAC November 2008


Rack Assembly Area (B024 )

B913 & B921 PS racks

B911 & B912 PS racks

Ernest Williams

FAC November 2008


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).

ProcedureIdentify/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.

Ernest Williams

FAC November 2008


PP-7 After Contractor Turn-over & LCLS Safety Lockout

PP-6 After Contractor Turn-over & LCLS Safety Lockout

Ernest Williams

FAC November 2008


Rear of Racks LKG-03 thru LKG-10 (12/05/06)

Ernest Williams

FAC November 2008


Software Installation StatusAll 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 commissioningSoftware has been installed following the LCLS software RELEASE procedure.

Ernest Williams

FAC November 2008


Issues & Concerns

Schedule & ResourcesControls 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/EDMPSystem Functionality

The new MPS – pre-beam checkout will be tight

Ernest Williams

FAC November 2008


Summary

Controls in general is in good shape for 2008 installation No major design or production issues dominate the planThere 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 ANLA large number of sub-systems have been installed and pre-beam checkout is the major activity before Dec. 1, 2008

controls system installation status

Documents