LHC Project Seminar - String controls

The Control System for the LHC tunnel cryogenics

Controlling Cool AcceleratorsControle da Criogenia de Aceleradores de Partculas

Dr. Paulo Gomes

on behalf of the team CERN TE CRG

with the precious contributions of the colleagues:

Project Associates (NTU-Athens, AGH-Krakow)Industrial SupportCryogenic OperationAB CO

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009

2 460 m170 m170 m270 m270 mSector = 3.3 kmLHC : 27km proton-proton collider , 8 sectors of 3.3 km

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009

energy per beam: 7 TeVluminosity: 1034 cm-2s-1main dipoles field: 8 Tcurrent: 12 kAmain magnets superconducting: 1200 D + 400 QTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009

in all magnets +QRL:10 000 cryogenic sensors & actuators

super-fluid liquid He bath temperature: 1.9 Kcryo distribution line feeding magnets every: 107 mQRL feeds He to the superconducting magnetsTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009The arc: Most of a sector is composed of 154 dipoles and 40 quadrupoles whichare in series: dipoles in series & quads in seriesoperate at 1.9 Kthe dipoles have a huge inductance 16Hcontainfamilies of correctors in seriesdipole correctorsThe matching sections: small subsectors operating at 4.5Koften standalone magnetsvery special often unique - magnetsThe inner triplet: composed of very high gradient quadrupoles and a dipole whichoperate at 1.9Kcontains a complex electrical circuit with nested converters

support and coolCurrent Leads that power the magnets

52 DFBs5 000 instrumentsTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009

16 cavities grouped on 4 modules, on IP4200 cryo instrumentsRF superconducting accelerator cavities @ 4.5 K

tunnel - radiationsector = 3.3 kmalcoves - radiation free CERN Control Centresurface - local control roomEthernet Technical Networkpoint-to-point cables

180cryogenic CVwithout electronics100 mCIETPVSS data server

CRYO-SCADAPVSS data server

4x Profibus1.5 Mbit/s

4x WorldFIP1 Mbit/s

8 FECWorldFIP EthernetGateway500 ms cycle

architectureFieldBuses large distancesindustrial electronics protected areasCVs electronics moved into protected areasfront-end electronics radTol custom made

intelligentCV positionerswith electronics100FIP cratescustom rad-tol electronics

2 PLCSiemens S7-400500 ms cycle

100 ma few numbers (per sector)

2 000 sensors and actuators

100 FIP crates2 Siemens S7-400 PLCs500 Closed Control Loops1 100 alarms & interlocks

PLC cycle 500 ms

5 600 objects of 16 types250 000 lines of SCL source code>3 Mbytes of machine codeAND...the last 5 sectors were to be deployed at a rate of 1 new sector every 2 weeks

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 200917 055 instrumentation channels1 738 Profibus components798 FIP crates 855 cards5 000 cable numbers

specification files for manufacturing FIP Crates specifications for control software PLC , FEC, SCADA

LHC Layout DatabaseXML files for Mobile Test Bench

Databases are intensively used - LHC Controls Layout DBcabling files for connecting & inspecting cables

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009(existing) UNICOS framework (Unified Industrial Control System)provides methodology & baseline tools to program industrial control systems @ CERN

(developed) generator of process specifications extracts from DBs the list of all objects, parameters, logical relations

(written) logic templatessimilar code for objects of same family

(existing) UNICOS source code generator for PLC & SCADA

code compilation with UNICOS libraries

project deployment on field machines

(new) last 5 LHC sectors to be deployed at a rate of 1 new sector every 2 weeks

software production cycle2d1d1h0.5dSpecs*.xlsSpecs*.xlsSpecsxlsProces Logic*.xlsProces Logic*.xlsProcess LogicLayout DBsLayout DBsLayout DBsDeploymentCompilationTestTemplateTemplateTemplates Code generationCheckerTemplates Code generation(new) checker of specifications

(new) external function with common logic

(new) generator for specificities not covered by UNICOS gen (new) run/check code on test PLC with simulated inputs

full sector code generation now takes 2 daysTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 200910

SCADA : Supervisory Control & Data AcquisitionCIET for Instrumentation Experts

CRYO-SCADA for operation200 panels / sector40 synoptics, 35 bar-graphs, 60 alarms & interlocks

Repetitive panels use parameterized templatesParameters generator, directly from DBTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009Conclusions The control software production relies strongly on a set of databases and on a package of automatic generation tools, which have been developed to create codein several steps, according to a well established methodology

The UNICOS automated generation & checking tools proved to be essential for flexible and robust PLC code generation

Thanks to extensive automatic code generation, we achievedreduced software-production time and effortincreased code reliabilityminimised risk of human mistakessimplified long term maintenance

We managed to reach a deployment rate of 1 new sector every 2 weeks, while in parallel giving support and modifications on other operating sectors

AndTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 20091210 Sep 08 the first proton beams in the LHC

At 10:28, one beam of protons was steered around the machine for the 1st time

Around 15:00 the other beam circulated in the second ring (anticlockwise)

(http://cdsweb.cern.ch/journal/article?issue=39/2008&name=CERNBulletin&category=News%20Articles&number=1&ln=en)

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009In Sector 3-4, during powering tests (without beam) at high current (9 KA) for 5 TeV a fault occurred in one electrical connection between magnets, resulting in mechanical damage and release of helium from the magnets into the tunnel.

During the ramping-up of current, a resistive zone developed in the faulty connection

An electrical arc punctured the L He enclosure, leading to a release/expansion of He into the insulation vacuum of the cryostats; the pressure-relief system was not able to contain the rise of the He pressure;large pressure forces displaced some magnets;several magnets were contaminated with dust;and had their multilayer insulation blankets damaged;

(http://press.web.cern.ch/press/PressReleases/Releases2008/PR14.08E.html)The 19 Sep 08 incident

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009Why did the LHC break downhttp://cdsweb.cern.ch/record/1176912.flvTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009The measures taken Sector 3-4 was warmed and 53 magnets were taken to the surface for repair or cleaning

New systems were installed, to ensure that similar incidents will not happen again:enhanced protection system, with more sensitive measurement of resistance(early detection of high-resistance, and quench, of electrical connections)new pressure relief system, with installation of extra relief valves(avoid high pressure to build inside the magnets)the anchoring of the LHC magnets to the floor was strengthened

In all LHC sectors, 10 000 high-current superconducting electrical connections were tested:the ones with critically high resistance were repairedthe remaining ones do not pose problem for safely running below 5 TeV

(http://press.web.cern.ch/press/PressReleases/Releases2009/PR02.09E.html, PR06.09E.html, PR13.09E.html)TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009The re-start planAfter finishing cooling and electrical-tests on all sectors, the LHC beams will restart in Nov09;

During a few weeks:Inject and capture proton beams in each direction, for a few days, take data for collisions at the injection energy (0.5 TeV), gradually increase energy up to 3.5 TeV per beam (= 1/2 nominal E);

Run at 3.5 TeV to collect data and gain experiencethen, increase energy towards 5 TeV per beam;

At the end of 2010: run with lead ions

After that: shut down and do the necessary to have 7 TeV per beam in 2011

(http://press.web.cern.ch/press/PressReleases/Releases2009/PR13.09E.html)TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009

TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 200910 Sep 08 - first beams @ CERN media eventhttp://www.youtube.com/watch?v=fxJqVsQ6yjc.flvTE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. # CERN Portuguese Teachers Programme, 4 Sep 2009FIP cratesFIP segmentsProfibus segmentsPLCCCLalarmsinterlocks

average /sector1008522x250600+500

total all-sectors80068421640008800

TTCVPVQVPTLTEHtotal

average /sector10003259090653101 880

total all-sectors8 0002600720720520248015 040