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HallDSolenoidControlsSystemand
MonitoringPlan
Ellio6WolinDirector’sReviewoftheHallDSolenoid
26‐Oct‐2010
1JeffersonLab‐HallDSolenoidDirector's
Review26‐Oct‐2010
Outline
I. SafetyandControlsII. ControlsandMonitoringStrategy
InHallD
FortheCoiltest
III. CurrentStatusIV. SummaryandConclusions
2JeffersonLab‐HallDSolenoidDirector's
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I.SafetyandControls
• Allpressure,mechanical,electricalsystemsself‐protected– Fail‐safeagainstcontrolsystemfailure
• Hard‐wiredmagnetpowersupplysafetyinterlocksystem– CaniniSatefastorslowdump,dependingonproblemdetected
• PLC‐basedcontrolsystem– NOmajorroleconcerningsafety
• tooeasilydefeated– AutomatestediousoperaSons– Putscryosysteminto“safestate”ifproblemdetected– CaniniSateslowdump– Note:slowdumpiniSatedbyinterlocksystemifPLCnotacSve
3JeffersonLab‐HallDSolenoidDirector's
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II.ControlsandMonitoringStrategy
• Fullsystem– Uniformlook‐and‐feelacrossalldevices– Designedforshi[personnel(physicists)
• Coiltestsystemissubsetoffinalsystem– Expert‐onlysystem– Nophysicistoperators– Onlyexpertdisplaysandmonitoring/archivescreens
4JeffersonLab‐HallDSolenoidDirector's
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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
6JeffersonLab‐HallDSolenoidDirector's
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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
8JeffersonLab‐HallDSolenoidDirector's
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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
• 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
12JeffersonLab‐HallDSolenoidDirector's
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III.CurrentStatus• Allchannelscheckedend‐to‐endduringconstrucSon
• Cryochannels– Allcablesinstalled– OperaSonverifiedinTestLab– CalibraSonscompleted
• Electricalchannels– Almostallareready– Somerecentlyadded/modified
• notneededforafewweeks • willbeinstalledduringmulS‐weekcooldownphase
16JeffersonLab‐HallDSolenoidDirector's
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• PLC– Programready– Alldevicesoperated– FullalgorithmfromnarraSveimplemented– somecalibraSonsmustbedoneduringoperaSons
• EPICS– CryoGroupprocessvariablesavailableasPLCtags– RelevantPLCtagsservedouttoCryoEPICSsystem– PagingandGuardShackcommunicaSonsimplemented– Everythinginfinalcheckout
• HMIandWebscreensready– WilltweakconSnuously
• Archivesystem– Testedandready
17JeffersonLab‐HallDSolenoidDirector's
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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
IV.SummaryandConclusions• SafetysystemdoesnotrelyonPLCcontrolsystem
– PLCwilltakepreempSveacSonifproblemdeveloping– Willmovesystemto“safestate”andpageexpert– IfPLCacSve,unlikelyhard‐wiredsafetysystemwilloperate
• Coiltestcontrolsystem– Implementssubsetoffinalsystem– AlmostenSremagnetcryoandelectricalcontrolsystemimplemented– OnlytestonecoilataSme– Expert‐onlyinterfaces
• CoilTestPlan– Completestep‐by‐stepplandeveloped
Coiltestcontrolsystemready!24
JeffersonLab‐HallDSolenoidDirector'sReview26‐Oct‐2010
• WetreatthePLCasanunreliable“operator”– incorrectusageofcontrolGUIbyoperators– misunderstandings,bugs– badcalibraSons– ACPowerloss,UPSfailure– damagedcables– processorfailure
• experimentwillusedual‐redundantPLCsystem
26JeffersonLab‐HallDSolenoidDirector's
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• 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)
27JeffersonLab‐HallDSolenoidDirector's
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• ExperimentControlSystem
– AFECS• AgentFrameworkforExperimentControlSystems• Javaagent‐basedcontrolsystemfromJLabDAQgroup
• usedforCODA3runcontrol• allowsintegraSonofslowcontrolswithruncontrol
– high‐levelstatemachinescripSnglanguage
– hierarchical– similartoSMI++usedatLHC
28JeffersonLab‐HallDSolenoidDirector's
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• CleardisSncSonbetweensystemsforshi[personnelandforexperts
– Verystrictrequirementsforoperators• uniformlook‐and‐feelveryimportant
– Verylooserequirementsforexperts• uniformlook‐and‐feelnotimportant
UniformpresentaSontoshi[operatorsisamajorfuncSonoftheSCADAlayer
29JeffersonLab‐HallDSolenoidDirector's
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Allen‐BradleyPLC
LinuxComputers
Ethernet
CounSngHouse
HallDControlNet
andEthernet/IP
ControlNetworkConfiguraSon
TargetControlCrate
SolenoidControlCrate
Target
Magnet
HVCrate
GoniomenterControl
FDC
GONI
TenModuleRemoteChassis
Powersupply
RemoteChassisCommunicator
DCInputModule
31
AlsousingPointI/ORemoteChassis
JeffersonLab‐HallDSolenoidDirector'sReview26‐Oct‐2010
PLCRedundantChassisLayoutSevenModuleChassis
PowersupplyPLC
RedundancyModule
CommunicaSonModule
RemoteChassisCommunicator
BlankSlots
32JeffersonLab‐HallDSolenoidDirector's
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FuncSonBlockProgram
OnePIDFuncSonblockcanhaveover160parametersinit.
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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
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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
SignalName Descrip(on Limit Response
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
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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
SignalName Descrip(on Limit Response
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