2007 Downtime Readiness Review
Hamid Shoaee
For
LCLS Controls Group
(in the following departments)
Controls
Power Conversion
Klystron
3/16/2007
Control System Installation Readiness
1
Hamid Shoaee
hamid@slac.stanford.edu
Agenda
LCLS Control System Installation Readiness
Objectives & Scope
Schedule & the Process
Cable Plant, racks and other infrastructure
I&C Systems status and schedule
Issues & Concerns
3/16/2007
Control System Installation Readiness
2
Hamid Shoaee
hamid@slac.stanford.edu
LCLS Installation and Commissioning Time-Line
Injector Controls
Installation Complete
LTU/und.
Install
LTU/und.
hall “ready”
Controls
Checkout
First Spont.
Light
A SOND J FMAM J J A SOND J FMAM J J
2006
2007
2008
Gun/Inj./BC1
Install
(8/21 – 2/20)
Gun/Inj./BC1
Commissioning
linac/BC2
Install
Oct. 19, 2006
3/16/2007
Control System Installation Readiness
Inj./Linac/BC2
Commissioning
3
LTU/und.
Commissioning
Hamid Shoaee
hamid@slac.stanford.edu
LCLS Accelerator Regions
6 MeV
rf
gun
250 MeV
135 MeV
Linac-1
L 9 m
21-1
b,c,d
X
Linac-2
L 330 m
Linac-3
L 550 m
21-3b
24-6d
25-1a
30-8c
BC1
L 6 m
‘Wall region’
Commission now
BC2
L 22 m
2007 down, Sept-Nov
SLAC linac tunnel
Down:
Run:
To:
13.6 GeV
Linac-X
L =0.6 m
Linac-0
L =6 m
...existing
linac
4.30 GeV
undulator
L =130 m
DL2
L =275 m
Nov. 1, ’07
research yard
Sep., Oct., Nov. of 2007
Dec. 2007 through ~Aug. 2008
SL2-stopper in BSY (just past linac sector-30)
Modifications in Sector-24 for BC2 (Emma)
Remove 8 RF
sections (24-7, 8)
Remove quad
Q24801
Add 4 new bends in
sector-24
Add 6 new quads
(3 types)
Add 1 ‘wide’ BPM
Add 1 x-collimator
Add 1 OTR screen
Linac Modifications (Fall ‘07)
Remove 8 RF sections (24-7, 8)
Remove quad Q24801
Add 4 new bends in sector-24
Add 6 new quads (3 types)
Add 1 ‘wide’ BPM
Add 1 x-collimator
Add 1 OTR screen
3/16/2007
Control System Installation Readiness
6
Hamid Shoaee
hamid@slac.stanford.edu
Linac Modifications (continued)
Add 4 new wire scanners in sector-24
Add 3 OTR screens (1 BC1, 2 in sec-25)
Move LOLA (trans. deflector) from sec-29 to 25-2
(powered by the 24-8 klystron)
Add pulsed horizontal dipole magnet in sec-25 (BXKIK)
Move 2 LI28 Wire Scanners, 44 & 544, by 20-30 meters
BPM electronics upgraded (resolution improved)
More feedback loops (energy & bunch length)
3/16/2007
Control System Installation Readiness
7
Hamid Shoaee
hamid@slac.stanford.edu
Linac Modifications (continued)
Power Systems
BC2 racks & PS (install racks and PS at sector 24)
I&C Systems
I&C racks and systems (install racks at sector 24)
Cable Plant
Sector 24 ( install new trays and cable plant from sector 24 racks
into Linac; terminate at racks and at loads)
BTH West (pull cables from B005, 105, 106 through BSY into
BTH West and coil cables; no loads & no racks installed yet)
B136 through BSY to BTH West
Remove cut cables from FFTB
3/16/2007
Control System Installation Readiness
8
Hamid Shoaee
hamid@slac.stanford.edu
Plans & Process for BC2 Controls System
Installation
Controls installation takes place in several steps:
Design, procurement and Installation of the cable plant
including trays, long haul DC and I&C cables
Cables Termination and connection to beam line
components (Mechanical Systems)
Procurement & preparation of electronics racks
Installation of electronics chassis and modules
including crates, IOCs, timing modules in the racks
Rack installation in the field, AC & cable plant
connection
3/16/2007
Control System Installation Readiness
9
Hamid Shoaee
hamid@slac.stanford.edu
Controls Installation Schedule Overview
Cable Plant Design & Installation Process
From the list of devices to be installed…
Develop racks layout & cable tray
design
Generate rack profiles for electronics
modules
Identify DC & I&C cabling requirements
& document in CAPTAR
Produce installation bid package from
CAPTAR and tray designs
Generate installation bid package &
award contract
Procure trays, cables, connectors, etc.
Install cable plant and terminate to
beam line components
Typical Sector Cable List
(Michael De salvo, Mario Ortega)
DATE
SYSTEM
3/12/2007
SECTOR 24
MEAN LENGTH WIRE SCANNER (4) VAC GAUGE (0) VAC PUMP (13)
RG214
LMR400
1/4" HELIAX
220
170
170
2.0HEL
TYPE C
3C18OS
18PR 22 GA
9C18TLN
4PR18TLN
RG58
32C18TLN
12C18TLN
85
220
170
170
170
170
170
170
220
4PR22TLN
RG59
FIBOPT11
FIBOPT9
50C18TLN
36PR16OS
COAX TRUNK
220
170
170
170
1500
170
170
TOTALS
4675
BCS (2)
TOTAL MATERIAL COST $39,070
BPM (2)
4
8
2
4
13
2
4
4
4
1
TOTAL
4
10
0
2
19
2
2
2
0
4
1
4
4
1
1
1
2
1
10
IC
60
41
HV
CV
4
Control System Installation Readiness
14
TOTAL
880
1700
0
$2.89
$2,543
$1.20
$2,040
$0.90
$0
$13.04
$2,217
$0.26
$1,087
$0.70
$238
$1.96
$666
$2.75
$935
1
4
170
4180
340
340
340
0
680
170
880
4
1
1
1
2
1
10
10
19
2
2
2
4
19
8
TOTAL FT
3/16/2007
CABLE FT Ft COST
$1.36
$0
$0.85
$578
$9.04
$1,537
$3.09
$2,719
880
170
170
170
3000
170
1700
$1.20
$1,056
15940
15940
Hamid Shoaee
hamid@slac.stanford.edu
$0.53
$90
$6.00
$1,020
$2.00
$340
$2.49
$7,470
$2.49
$423
$8.30
$14,110
TOTAL
$39,070
Sector 24 Connector List
CAPTAR
NUM
N214
8
N400
20
1/4HELSF
0
N-PLIC
4
SHV-C
38
4
AMP36,DIN96
4
TT19P
2
TT8P,S & PLB6P,S
0
BNC58
8
2
8
8
BNC59
2
2
2
4
2
20
120
CONNECTOR TYPE
COST EA TOTAL
N214 MALE PLUG
$26.95
$215.60
FEMALE-N BULKHEAD
$14.30
$286.00
1/4" HELIAX SF FR
$0.00
1 5/8" N-Female H7PNF
$243.24 $972.96
SHV TYPE C TEFLON
$34.30 $1,303.40
$0.00
AMP HIGH DENSITY CAMAC
$26.00
$464.00
$0.00
$37.39
$0.00
BNC 58 MALE PLUG
$2.52
$20.16
$0.00
$0.00
$0.00
BNC 59 MALE PLUG
$2.44
$4.88
$0.00
$0.00
$0.00
$0.00
COAX TRUNK
$5.00
$100.00
TOTAL $3,367.00
3/16/2007
Control System Installation Readiness
15
First draft BC2 cable
design
 13k feet
 $245k (cable)
 $10k (connectors)
Hamid Shoaee
hamid@slac.stanford.edu
Racks will be pre-loaded in B24 before field installation
BC2 Controls Sub-Systems
Cable plant
Racks, crates, IOC, etc.
Networks
Magnet power supply control
Vacuum control
Safety systems
PPS, MPS, BCS
Motion control
Wire scanners, Collimators, Chicane
Timing
Beam instrumentation and diagnostics
BPM, Toroid, OTR/YAG, Bunch length monitor
LLRF
3/16/2007
Control System Installation Readiness
18
Hamid Shoaee
hamid@slac.stanford.edu
LCLS Controls systems
For each system…
Technical leads have developed a schedule covering all
phases leading to installation and commissioning
The schedules include development of appropriate field
documents (EI, WD), rack profile/cable plant design,
procurement, installation and system checkout
Continue Interfacing with Mario Ortega, Bob Fuller, Mike
DiSalvo to coordinate procurement and installation
We will be reviewing each schedule to identify
bottlenecks, dependencies on other systems, resource
availability
3/16/2007
Control System Installation Readiness
19
Hamid Shoaee
hamid@slac.stanford.edu
Safety Systems for BC2,L2,L3
PPS
The Linac PPS does not require modification to run LCLS beam to SL-2.
There is an AIP project to convert the Linac and BSY to the LCLS PLCbased system in 2008
MPS
We will use the current (1553-based) MPS for BC2.
Two new ion chambers will be required
The system will include 10 LDIM inputs
OTR21 (2ea)
OTR22 (2ea)
OTR_CAV (2ea)
BC2 Mover (2ea)
CE21 (2ea)
We will need to commission AP25 (currently installed but powered down) to
accommodate a new PICP module and an LDIM (already installed).
3/16/2007
Control System Installation Readiness
20
Hamid Shoaee
hamid@slac.stanford.edu
BC2 MPS
Schedule
Check out 12/3
Concurrently developing new LCLS MPS
Response time of less than one pulse at 120 Hz
Decoupling from Master Pattern Generator (MPG)
Fast communication and processing
Knowledge of beam rate
Integration of EVR to MPS and fault devices
New hardware extended 1.2 km past current MPS
Non-CAMAC
Ready for photon section
3/16/2007
Control System Installation Readiness
22
Hamid Shoaee
hamid@slac.stanford.edu
LCLS MPS Features
Has response time low enough to protect the
undulator (less than 8.3 ms)
Communicates with LCLS timing system (EVG)
Supports new beam loss monitoring hardware and
rate limiting methods
Easily extendable and is designed around
standards based COTS components
Flexible input and output methods
3/16/2007
Control System Installation Readiness
23
Hamid Shoaee
hamid@slac.stanford.edu
Overview
3/16/2007
Control System Installation Readiness
24
Hamid Shoaee
hamid@slac.stanford.edu
Core Hardware and Software
Hardware and
Software
Completion Date
Quantity
04/16/2007
30
700
Done
4
700
MVME 6100
08/31/2007
27
3000
EVR
05/31/2007
1
2500
Reflective Memory
04/02/2007
25
2000
Reflective Memory
Hub
04/02/2007
5
2500
Digital Input Card
Digital Output Card
Cost per Unit
Note: These are material costs only. Development labor, installation, etc. costs are not included.
Total
3/16/2007
Control System Installation Readiness
169800
25
Hamid Shoaee
hamid@slac.stanford.edu
Other MPS Devices
Hardware and Software
Completion Date
Quantity
Beam Loss Monitors
05/01/2008
52–154
Beam Loss Monitor ADC
(Argonne)
05/01/2008
10–25
PLIC Scope Card
05/01/2008
3
3/16/2007
Control System Installation Readiness
26
Hamid Shoaee
hamid@slac.stanford.edu
Milestones
Task
Completion Date
User Interface
11/01/2007
Linac Installation
11/01/2007
BC2 Commissioning
12/03/2007
LTU-Undulator Commissioning
05/01/2008
Preliminary Design Review
04/16/2007
Final Design Review
09/03/2007
Readiness Review
10/17/2007
3/16/2007
Control System Installation Readiness
27
Hamid Shoaee
hamid@slac.stanford.edu
BCS (Beam Containment System)
We will use & extend the existing BCS for BC2 commissioning
Two possible configurations are being considered
1. New BCS PIC System installation in Sector-24
A 50 conductor trunk from the Sector-28 BCS rack to a new rack in Sector24.
Long hauls from Sector-24 BCS Rack to the beam line devices in Sector-24
(2 cables per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure
Switch)
2. Use BCS PIC system in Sector-28
(Depends on being able to drive PIC/LION HV and signal four sectors)
Long hauls from Sector-28 to the beam line devices in Sector-24 (2 cables
per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure Switch)
For either configuration…
Install VME Crate and associated hardware/software/network
Install new LION Gas system.
AC Power to Sector-28 & Sector-24 racks.
3/16/2007
Control System Installation Readiness
28
Hamid Shoaee
hamid@slac.stanford.edu
BC2 BCS
Schedule
Check out
11/23
Magnet Power Supply Control
The software design is mature and will
require little if any changes for BC2
Procurements are well under way and orders
have been placed for power supplies, racks,
etc.
There is a detailed schedule covering bench
testing, rack loading, wiring, pre-installation
checkout, through field installation
The system will be ready 11/30
3/16/2007
Control System Installation Readiness
30
Hamid Shoaee
hamid@slac.stanford.edu
11/30/07
Vacuum controls uses BC1 design, with
detailed procurement list in place
3/16/2007
Control System Installation Readiness
32
Hamid Shoaee
hamid@slac.stanford.edu
Vacuum controls check out by 11/20/07
Wire scanners, Collimators and BC2 motion
control use the same design as BC1, and will
be available 11/20/07
Networks will be ready early in October to
allow Controls checkout
Timing System
The scope is to deliver triggers and timestamp data to all subsystems requiring
such.
The system can be split into two parts
1. Long-haul distribution of triggers from the EVG to EVRs in Linac and beyond
2. Short-haul back end consisting of the HW & SW to receive the EVG timing signal and
generate triggers. This is well-understood and defined.
Part 1 requires some engineering development as the event system can only have a
maximum link length of 300 meters. We can daisy-chain, but only for 3 hops before
exceeding the jitter budget. We need a better solution
This is a tractable item and should not have a high level of risk.
Another item of concern with the long-haul distribution is timing phase error due to
temperature drift – a mechanism is needed to correct for this.
This will need some R&D and we need to decide based on short- versus long-term
requirements if users can live with this for now. We have to anyway since time is
short
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.
The long haul procurement list is pending a design decision
3/16/2007
Control System Installation Readiness
36
Hamid Shoaee
hamid@slac.stanford.edu
Timing System Schedule
Beam Instrumentation & Diagnostics
Profile Monitors
There are 3 OTRs in the LINAC: OTR21, OTR22, OTR_TCAV –
These use BC1 designs and electronics
Design in April, procurement in May, system test July ~ August.
Toroids
There are two toroids in linac: IMBC2I and IMBC2O
We need to re-spin the data acquisition board for small revisions to
the artwork
Electronics will be ready in August for system testing
Bunch Length Monitor
BL21 and BL22, similar to BL11 and BL12 in BC1
Procurement in April and test in May ~ June.
Dumps and Stoppers
SL2 might need some new data monitoring.
3/16/2007
Control System Installation Readiness
38
Hamid Shoaee
hamid@slac.stanford.edu
Beam Position Monitors
The linac BPMs have to be upgraded for better resolution for undulator
commissioning in May-June ‘08
Do we need to upgrade for the BC2,L2,L3 commissioning?
Do the existing BPM electronics work at 200 pC?
Do they trigger reliably at low charge?
What resolution do they provide?
Test next week with A-Line beam
If we need the linac BPM upgrade
Install 20 racks
Design and install cable plant for 79 BPMs
Re-spin BPM analog front-end design
Fabricate and test 120 BPM chassis
Install 79 BPM chassis
If we can defer the upgrade
We still have to install the cable plant for all of the linac BPMs in this down time
Of the 17 BPMs in switchyard we will connect to only 2
And one BPM in BC2
3/16/2007
Control System Installation Readiness
39
Hamid Shoaee
hamid@slac.stanford.edu
LLRF Schedule
BC2 Controls Risk Matrix
System
Risk
Magnet Power Supply control
Racks, Crates, IOC
Vacuum Control
MPS, PPS, BCS
Motion Control
OTR/YAG
Networks
LLRF
Timing
Toroids
BPM
Cable Plant
3/16/2007
Control System Installation Readiness
In good shape
No issues
In good shape
Existing systems
In good shape
In good shape
Large amount of work
Large amount of work
Design issues
New design
New design
Tight Schedule, BPM Upgrade
41
Hamid Shoaee
hamid@slac.stanford.edu
Testing & Checkout Strategies
For each subsystem, we will use test stands to
verify the complete system
Test stands currently in place include:
Timing
Vacuum
Magnet power supplies
Motion control – wire scanners, collimator, etc.
Rack loading & testing
Need to accomplish as much as possible in B024 prior to Sept.
transport to field site.
In-field loading (Davis-Bacon) and intra-rack cabling is less
efficient.
3/16/2007
Control System Installation Readiness
42
Hamid Shoaee
hamid@slac.stanford.edu
Rack Assembly Area
3/16/2007
Control System Installation Readiness
43
Hamid Shoaee
hamid@slac.stanford.edu
Issues & Concerns
Schedule & Resources
Schedule is very tight, just fits in down time
Controls is the systems “integrator” – delays in other
systems directly impact our installation
Cable Plant Installation
Coordination of activities with other installation groups is very
important and could jeopardize schedule
Linac BPM upgrade could be an added challenge
System Functionality
Timing System – small concern
BPM, Toroid – need verification of design
3/16/2007
Control System Installation Readiness
44
Hamid Shoaee
hamid@slac.stanford.edu
Summary
Controls in general is in good shape for 2007
installation
No major design or production issues
dominate the plan
The schedule is challenging with little float
While a large number of sub-systems will be
installed on time, some will need attention to
stay on schedule
3/16/2007
Control System Installation Readiness
45
Hamid Shoaee
hamid@slac.stanford.edu