Transcript Cryogenic Controls for the European XFEL

Cryogenic Controls for the
European XFEL
Matthias Clausen
DESY, Hamburg, Germany
Cryogenic Controls for the European XFEL
How it works: a closer look at the facility
Scientific instruments
for research
Electron injector
Undulator
systems
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Superconducting
electron accelerator
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Cryogenic Controls for the European XFEL
Construction site DESY-Bahrenfeld
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AMTF hall
Cryogenic hall
Entrance hall
Electron injector
Modulator hall
Entrance hall
Linear accelerator
9 August 2013
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Cryogenic Controls for the European XFEL
Using X-rays to explore matter
Synchrotrons
 Electrons traveling in a wide
circular path, emitting light as the
change directions
 Light is UV or X-ray, but not
coherent
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Free-Electron Lasers
 Electrons accelerated in a straight
line and manipulated to generate light
 Light is coherent and intensely
bright in very short pulses, showing
objects in even more detail and
revealing processes
Cryogenic Controls for the European XFEL
A big facility for studying tiny objects…

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Total facility length: 3.4 km
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Cryogenic Controls for the European XFEL
XFEL-Cryoplant - Requirements
Spec
20 GeV
17.5 GeV
Offer (one! CB)
2K
2457
1896
2010
5K
4150
3593
3030
40K
30000
23923
20175
Start-up: 17.5 GeV state
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XFEL-Cryoplant Production Readiness Review Meeting
11.04.2011
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Cryogenic Controls for the European XFEL
XFEL Cryogenic Equipment - Overview
SC
XRTL
Distribution Box
DB54
SC
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SC
SC
SC
SC
SC
CB 41
CB 43
SC
Contributions:
LINDE KRYOTECHNIK
CC Box
CB44
BINP
DEMACO
XFEL
Refrigerator
Distribution Box
XLVB
FB
EC 3,9 GHz CM FC Distribution Box
XIVB
FB
Injectors
Option
EC 3,9 GHz CM FC
XLTL1
XLTL2
FC CMS EC
XLTL3
FC CMS EC FC CMS SCB
SCB CMS EC
© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
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Cryogenic Controls for the European XFEL
Commissioning of XFEL Cryogenic Equipment
XRTL
Building 54
Distribution Box
DB54
SC
SC
SC
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SC
SC
SC
SC
CB 41
CB 43
SC
Contributions:
LINDE KRYOTECHNIK
CC Box
CB44
BINP
DEMACO
XFEL
Refrigerator
Commissioning of cryo equipment in building 54 is almost finished
© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
Matthias Clausen - DESY
Cryogenic Controls for the European XFEL
Commissioning of XFEL Cryogenic Equipment
XRTL
Building 54
Distribution Box
DB54
Contributions:
DEMACO
SC
SC
SC
SC
SC
SC
CB 41
CB 43
SC
CXRTL
LINDE KRYOTECHNIK
BINP
SC
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CC Box
CB44
XFEL
Refrigerator
Now – November 2014
Pre-commissioning of XFEL refrigerator
with CB44 in building 54
© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
Matthias Clausen - DESY
Cryogenic Controls for the European XFEL
Cold Compressors and Distribution Box
in the Injector Building
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© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
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Cryogenic Controls for the European XFEL
Signal Overview
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• 671 control valves
• 2647 temperature sensors
• 800 pressure sensors
• 212 flow sensors
• >100 level sensors
• 433 regulation loops
• > 22000 records (description of process
parameters)
• > 220000 properties (set values, critical values,
scanrates, calculation codes, etc.)
© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
Matthias Clausen - DESY
Cryogenic Controls for the European XFEL
Process Controller for the Cryogenic Equipment
SC
XRTL
Distribution Box
DB54
CC Box
CB44
SC
SC
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SC
SC
SC
SC
CB 41
CB 43
SC
XFEL
Refrigerator
Distribution Box
XLVB
FB
EC 3,9 GHz CM FC Distribution Box
XIVB
FB
Injectors
Option
EC 3,9 GHz CM FC
XLTL1
XLTL2
FC CMS EC
XLTL3
FC CMS EC FC CMS SCB
SCB CMS EC
© Tobias Schnautz
11. October 2014, CryoOps Workshop Daresbury
Matthias Clausen - DESY
Cryogenic Controls for the European XFEL
The Cryogenic Control System
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

EPICS for process controls and as a SCADA system
 Process Controller:
EPICS IOC (Input Output Controller)
 PLC: Siemens (machine protection,
(partly) control functionality
OPI: CSS (Control System Studio)
 Operator Interface (graphic, alarm, trend, diagnostic)
 Configuration: graphics, Profibus, controls(signals,
loops), SNL (State Notation Language) editor
Field bus: Profibus
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Cryogenic Controls for the European XFEL
Where the Controls reside
Turn Key
GUI
KS2/ FLASH
KS1/3/ XFEL
implement specify
SCADA
Control System Studio Control System Studio Control System Studio Control System Studio
- Trends
DESY
EPICS-IOC
DESY
DESY
DESY
DESY
Process Controller
-Process Control Blocks
- State Notation/ Sequences
- Communication with PLC
Linde/
DESY
DESY
DESY
DESY
DESY
DESY
DESY
DESY
EPICS-IOC
Linde
DESY
Linde
DESY
EPICS-IOC
DESY
Siemens
hard wired
Sulzer*
Siemens
Linde
Linde
Sulzer/DE
SY
Linde
Linde/
DESY
-
Linde
Siemens
Linde
EPICS-IOC
DESY
DESY
DESY
DESY
DESY
Siemens
Linde
… where the control resides
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Linde
-
- Process Control Blocks
- Compressors
Linde
implement
DESY
DESY
DESY
-
DESY
DESY
DESY
implement specify
DESY
DESY
DESY
Linde
PLC
implement specify
XFEL Distribution
specify
DESY
DESY
DESY
PLC - Machine protection
- Turbines
Cold Compressors
example
- Graphic
- Faceplates
- Alarms
PLC used for Controls
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Linde
-
Cryogenic Controls for the European XFEL
Running Controls in PLCs
Pros and Cons
Pros:
 The ‘Turn Key’ aspect: Do not care/ no responsibility - as a
customer
 Intellectual property of the contractor (turbines/ cold
compressors) kept in the PLC as a ‘black box’
Cons:
 No knowledge about implementation details
 Change management must be organized with contractor –
or in addition - with sub-contractor
 Any signal in the PLC which shall be modified from outside
must be configured in communication with higher level
applications (read/ write)
 Complex to implement sequences
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Cryogenic Controls for the European XFEL
Running Controls in EPICS IOCs
Pros and Cons
Pros:
 Any property of any control block is accessible without any
additional configuration. (read/ write)
 Deep knowledge about implementation on customer side
 Easy to add custom control blocks
 Change management can be organized in house
 Sequences/ states are implemented in SNL
Cons:
 Work load on customer’s staff
 Organize the implementation according to contractors
specification
Reliability: Is not an issue to decide between IOCs and PLCs
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Cryogenic Controls for the European XFEL
Cryogenic Controls in the AMTF
(Accelerator Module Test Facility)
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Cryogenic Controls for the European XFEL
The Injector Building
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Cryogenic Controls for the European XFEL
Equipment in the XFEL Injector Tunnel
OLM and DP/ PA Gateways
Redundant Power
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WAGO I/O and Custom
Temperature- Heater Modules
Cryogenic Controls for the European XFEL
Custom Hardware for Temperature readout
and Level Measurement incl. Heater Control.
Specialized low temperature read out system designed at DESY. The system is
designed to support any kind of resistive measurement over a range from 0 to
200kΩ and voltage measurements in the range from 0 to 1.17V.
The LHe level monitor supports a wide range of on the market available LHe level
sensors like AMI. The bus coupler can be exchanged to support different field
buses (or Ethernet).
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Cryogenic Controls for the European XFEL
XFEL Installation
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Cryogenic Controls for the European XFEL
XFEL Installation
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Cryogenic Controls for the European XFEL
Configuration – or:
How to get a Valve to the Console
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Add simulation
CSS
CSS
CSS
I/OCFG
SDS
SDS
DCT
GSD
XML
XML
SIM
EPICS
IOC
EPICS
Database
Driver
Config
Win
MOD
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EPICS
DB
Cryogenic Controls for the European XFEL
Simulation
Simulating I/O is a powerful tool
 Applications:
 New installations:
 Verify I/O configuration
 Test displays
 Modifying existing configurations
 Check new logic
 Check sequence programs
 In general:
 Reduce commissioning times
 Stable applications from the very beginning
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Cryogenic Controls for the European XFEL
Cryogenic Control Room
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Cryogenic Controls for the European XFEL
Screen Shot from CSS Applications
SDS (Synoptic Display Studio)
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Cryogenic Controls for the European XFEL
Screen Shot from CSS Applications
SDS Correlation Plot
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Cryogenic Controls for the European XFEL
Screen Shot from CSS Applications
Trend Plotter
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Cryogenic Controls for the European XFEL
Screen Shot from CSS Applications
Alarms / Messages
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SNL - Log
PUT - Log
ALARM
Other:
System
Diagnostic
…
11. October 2014, CryoOps Workshop Daresbury
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Cryogenic Controls for the European XFEL
Summary

Over the last two decades we developed EPICS for
cryogenic controls. It has reached a mature state which
combines the reliability of PLCs with the fexibility of the
open source control system EPICS.
 Custom hardware for temperature readout and level
controls is intergated into the control system.
 Redundancy for power, process controllers and field-bus
connections increases availability.
 The cryogenic control system for the European XFEL is
ready to go.
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