performance of rhic vacuum instrumentation and control

April 11-12, 2005OLAV I, Geneva, Switzerland

RHIC Vacuum I&CHseuh & Smart 1

Performance of RHIC Vacuum Instrumentation and Control

H.C. Hseuh and L.A. Smart

Collider-Accelerator Department

Brookhaven National Laboratory

April 11, 2005

Outline:

• Description of RHIC Vacuum I & C

• Performance and Reliability

• Summary



3.8 km x 2, <10-10 Torr

800m, ~1x10-8 Torr

200m, ~2x10-11 Torr

BNL Collider-Accelerator Vacuum Systems

~900m, ~10-10 Torr

150m, 10-8 Torr

~500m, 10-9 Torr



RHIC Vacuum Instrumentation(Excludes ~ 800 vacuum devices for the injector chains)

~ 1600 Vacuum Devices w/ remote control and monitoring

Beam Vacuum Systems (Warm + Cold)

420 CCGs, 150 TCGs, 15 RGAs w/ E-M 170 SIPs, 320 TSPs 133 Sector Gate Valves

Insulating Vacuum Systems

130 CCGs, 230 TCGs, 76 RGAs w/ FC ~ 42 TMPs (with isolation valves, TCG, CCG, …)

Control and Monitoring

8 PLCs 4 FEC (VME Power PC) CLC (Control Level Consoles)

~140 CCG Analog Signals to MADC (for fast logging)



Control Architecture

Based on Programmable Logic Controller (PLC)

8 Allen-Bradley PLC 5-40E or 5-20E processors

2 Co-processor + expander sets in each PLCOS-9 real-time operating systemRS-485 multi-drop serial interface ports for GC, IPC,

RGA, TMP < 5-second update time with ≤ 32 devices at each

port

Inputs from GC and IPC set points

Outputs for valve interlock (thru 2 out of 3 set point voting scheme), Beam Permit Link (any valve closed), RF & Kicker interlocks

PC GUI at two locations w/ Data Highway links to all PLCs for diagnostics and downloading programs (independent of CLC)



Control Architecture –cont’d

Distributed PLC ControlRelieves CLC of low-level tasks - simpler software & hardware

Front-end computer (FEC)

4 VME based Power PC processors100 Mb/s Ethernet links to CLC and PLC co-processors

Console Level Consoles (CLC)

Control & monitoring via spreadsheets, graphics, alarmsData Logging and LogViewElog for machine operations Elog (e.g. Vacuum Elog) with each subsystem



CLC

PC

FEC: Front End ComputerMMI: Man-Machine InterfacePLC: Programmable Logic Controller

Warm SectionCryostat

Cry

osta

t

RS-485 Networks

FEC

IPCs

PLC

Cryostat

Cryostat

PLC DataHighway

GCs

GCTMP StationPPA

RHIC Tunnel

GC: Gauge ControllerIPC: Ion Pump Controller

PPA: Partial Pressure AnalyzerTMP: Turbomolecular Pump

Service Building 1004B

Ethernet Network

RS-485 Networks

Warm Section

PLC

MMI

Cry

osta

t

Cryostat

IPCs GCs

Service Building 1006B

RHIC Vacuum I&C System with RS485 Networks

CLC High Level Application Software

~ 640m

RHIC Vacuum I&C System with RS-485 Networks



PLC, Co-Processors, I/O Modules

TMP w/ GC, SLC w/ RS485 serial link

GC, IPC, TSP, PLC, PC/GUI, …

At service buildings

TMP, CCG, TCG & Valves on Cryostats



Most useful applications for Vacuum

Spreadsheets Live monitoring and control, open architecture, no password

Logging & View from minutes to 720 Hz with synchronized time stamps; compare ∆P with other machine variables with ~msec resolution

Vacuum ELog Vacuum maintenance and operation details entered by technicians and staff for diagnostics and archives

Graphic Display 2-D, 3-D, waterfall…

Fill 5160

IR2 Pressure rise

IR10 Pressure rise

Bunch Length

LogView for diagnostics…

e.g. ∆P vs. I & bunch length



Spreadsheet for Turbopump Operation

Spreadsheet for RGA Operation



8 PLC, Processors & BPL – very reliable for machine operation, device I/L…PLC and GC are backed by UPS, IPC backed by Generators

14 Co-processors - hung several times a week, but does not affect beamCommunication errors? Resulted in no logged data, Remote soft reset (close/open ports)Some required local manual resetMust be checked daily

Common software for all subsystems at control consoleSpreadsheet, Graphic Display, Alarm…LogView allows comparison with other machine parameters Machine ELog and Vacuum ELog – detailed archives for

diagnostics

Performance and Reliability of Vacuum PLC and Controls Interfaces



GC, CCG - < 3% failure per yrHV cards (thermistors ➱ abnormal readings)CC gauges (neon bulbs, ➱ no ion current)

IPC - ~ 5% failed in 2003, less in 2004HV cards, chassis

TMP - In-house designed Station Logic Controller Possible radiation–induced errors ~ once a week (FIV,

PIV closed) Some need ring access for reset

RGA - Single filament, custom software, 6 masses only ~ 5% filament failure per yr Hardware and software are no longer supported by

vendor

TSP - In-house design to accommodate long cable runWith local step-up (I) transformer, manual operationRemote capable, but not implemented

SGV - ~ 5% faulted (momentarily) in 2004, resulted in BPL faults Stuck open due to corrosion in solenoid

Performance and Reliability of Vacuum Devices



Reliability of RHIC Vacuum Instrumentation are much better than other sub-systems over the last five years

PLC based control has worked reliably for vacuum and machine protection

Coprocessor RS485 interface is susceptible to communication errorsResults in lost dataUpdate time of > seconds per port

Augmented with analog signals to MADC for fast (msec) logging

Identical GC, CCG and TCG for beam and insulating vacuumsCCG neon bulb disconnected during bakeout

Conversion kit is available but expensive

IPC works relatively wellRepair delays due to custom products

Summary



CCG - Buy gauges designed for operation at bakeout temperatures

IPC, GC - Buy off-the-shelf controllers to avoid repair delays for custom units

PLC - Include analog inputs for fast gauge monitoring

TMP – Any commercial turn-key stations with integrated valves and gauges?

RGA – Dual filaments Avoid custom software and interfaces

TSP - Any commercial units for long cable run (with local transformer?) With remote control?

SGV – Corrosion resistant solenoids?

Considerations for the Future

performance of rhic vacuum instrumentation and control

Documents