NSNS Integrated Control System

1

SNS Control System EPICS Collaboration Meeting
May, 2001 Bob Dalesio
2
SNS The Spallation Neutron SourceThe Next
Large EPICS Project

• A Partnership between Six National Laboratories
• Argonne National Lab
• Brookhaven National Lab
• Lawrence Berkeley National Lab
• Los Alamos National Lab
• Oak Ridge National Lab
• Thomas Jefferson National Lab

3
The Spallation Neutron Source

• Largest civil science construction project
  1.4B
• Forefront Facility for future high beam power
  facilities
• First superconducting pulsed proton linac
• Key Parameters
• Beam Energy 1 GeV
• Beam Power 1.4 MW (can reach 2)
• Linac tunnel length 320 m
• Repetition rate 60 Hz
• Avg Macropulse Current 26 ma
• Pulse length on Target 695 ns
• Duty Cycle 6
• Projected Finish date is December, 2005

4
Spallation Neutron Source Aerial/Site Plan
5
Project Status

• Funding of 1.4B approved (incl 60M for
  Controls)
• FY01 Funding of 278M approved (and half spent!)
• (including 9.5M for Controls)
• FY02 Funding of 291M in the Presidents budget
• (including 12.5M for Controls)
• 1.4 million cu. yards of dirt moved first
  concrete poured

6
Over 168,000 Construction Hours Worked Safely

• Completed two major access roads on plan

• Moved over 1.3 million cubic yards of dirt
• Linac tunnel excavation in process
• Completed retention pond on plan

• Completed installation of three temporary
  electrical distribution centers

• Completed Target Building deep foundation
  installation on schedule

7
(No Transcript)
8
SNS Project Commissioning
9
We plan a system fullyintegrated under EPICS,
including

• Accelerator Systems
• Front End, Linac, Compressor Ring, Beamlines
• 50,000 channels, 160 IOCs
• Front End already running under EPICS (at
  Berkeley)
• Target System
• Large and complex liquid Mercury Target
• 1000 channels, 6 PLCs
• Test facility already running prototypical EPICS
  system
• Conventional Facilities
• 2500 channels, 10 PLCs, 150 screens
• To be done in EPICS by Sverdrup in Tullahoma
• Training in June

10
Controls Effort is Distributed across the Partner
Laboratories
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.4 Cryo
Front End
Linac
Ring
Target
Instruments
Facilities
Controls Dave Gurd Bill DeVan Muriel Tate
(JLAB, ORNL)
(LBNL)
(LANL)
(BNL)
(ORNL)
(ORNL, ANL)
(ORNL, CM)
1.9.3
1.9.4
1.9.5
1.9.6
1.9.7
1.9.8
1.9.9
1.9.10
Front End
Linac
Ring
Target
Instrument
Facilities
Cryo
Personnel
Controls Steve Lewis Carl Lionberger Pete
Cull
Controls Mike Thuot Bob Dalesio Karen
Collier Jeff Hill Kay Kasemir Stan Brown Pilar
Marroquin P. McGeehee Chris Tremel Chris Allen
Controls John Smith Johnny Tang Tom
Nepsee Sheng Peng Nikolay Malitsky Jennie Weng
Controls (Ron Battle) (Delphi Nypaver)
Controls J. Hammonds
Controls John Cleaves John Munro
Controls Herb Strong Richard Epps (Pam Gurd)
Safety Paul Wright Bill Stone
38 Names most full time
1.9.2 Global Controls Brian Oerter (BNL) Ron
Nelson, Paul Stein (LANL) Coles Sibley, Ernest
Williams, Delphi Nypaver, Bryan Moss (ORNL)
1.9.1 Integration Management
11
Control System Systems and Functions

• Data Acquisition and Control
• 160 distributed Input Output Controllers with
  50,000 signals
• Timing and Synchronization
• Synchronizes choppers, kickers, rf systems and
  beam diagnostics
• Time stamps all acquired data to microsecond
  accuracy
• Machine Protection
• Turns off beam in lt20usecs for beam loss) or
  equipment failure
• Control System Network
• Isolated Control system network includes gt20
  switches
• System and Application Software
• Communications, databases, EPICS core software,
  engineering applications and the human
  interface
• Control Room
• Operator Consoles, Personnel Access control,
  network hub, computer servers, timing
  distribution etc

12
Where we are now

• Controls Group Staff of 10 at Oak Ridge
• (and still hiring hint hint)
• EPICS Systems running Target Test Facility in Oak
  Ridge and Front End Systems at Berkeley
• Application Development Environment runs at ORNL
• Distributed CVS accessible by all the partners
• Prototypical Environment running
• MVME 2100 PPC, EPICS 3.13.3, Tornado II, EDM
• ControlLogix PLC
• ControlNet over EtherNet Driver

13
Some things we have agreed upon

• Site-wide Device and Signal Naming Convention
• ControlLogix PLCs (Allen-Bradley)
• ControlNet over EtherNet Driver
• Standard Cabinets
• PowerPC IOCs (MVME 2100)
• VME64x (Contract awarded)
• Including Utility Board
• Linux Environment where appropriate
• Oracle

14
Some EPICS Developments are needed

• Large Array Support
• Needed for Diagnostics
• Long PV Names
• We could bump up against the current limit
• Variable String Size
• Multipriority Channel Access
• Needed for Diagnostics and Machine Protect
• SNS will fund some of these Core developments,
  but we will need help from the community

15
Network

• Controls Network based upon Gigabit Ethernet
  backbone. High speed brought close to front ends
  (IOCs) using new Cisco switch technology.
• Private IP address space set up and tested in
  lab. This allows nearly unlimited IOCs and PLCs
  and can be used to model planned subnets. Cisco
  switch installed this will be the core switch
  for the control system network. (Currently on
  loan.)
• Redesign for network hub and temporary control
  room in the Front End Building. FDR coming up.
• PV Gateway at LBNL allows remote access to FE
  control system (from ORNL), demonstrating EPICS
  security. Will demo during DOE semi-annual
  review.

Prototype Control System network core switch.
Low cost terminal server and remote reboot device.
16
Global Timing and Synchronization

• Timing System based upon RHIC. Event link for
  synchronization operates at 16X Ring Frequency.
  Real-time Data Link distributes, time, modes,
  other data.
• System Components in design at BNL and LANL. Test
  stand set up at BNL. First articles required in
  May at LANL and LBNL (tight)

Timing test Stand at BNL
17
Machine Protection System (MPS)

• Star Configuration
• Easier for phased commissioning
• Shorter Propagation Delays
• Prototype system using PCI Mezzanine Card (PMC)
• Technobox 96 channel reconfigurable IO
• VME P2 transition module Layout in progress at
  LANL
• MPS I/O Chassis Prototype design near
  completion, PCB layout in progress at Los Alamos

18
MPS based upon BNL Beam Permit System

• Carrier loop (the permit link)
• 16 inputs (8 latched) 4 outputs/board
• (8 inputs 5 outputs/board)
• Interfaces with event system
• Time stamping of trips
• VME/PCI - based hardware (VME)
• Uses programmable logic devices
• Just one chassis to fab

Inputs
Beam Off
Master
Carrier
Slaves
19
Cryogenic Controls

• Cryo control system for cryo plant and cryo
  modules being designed at Oak Ridge in
  collaboration with JLab..
• Design is based upon Jlab Design, with PLCs
  replacing hard-wiring, and VME replacing CAMAC.
• Operator screens are based upon Jlab screens
  converted to EDM
• A prototypical Cryo control system is operating
  in lab (ORNL)

20
Testing of Power Supply Controllers and Standard
Vacuum System Interfaces
Power Supply Controller Test Bed

• Power Supply Controller (PSC) and Interface (PSI)
  under test. Controller is VME module linked to 6
  Power Supply interfaces with fiber. Supplies come
  integrated with interface.
• Vacuum controls Lab set up with prototype
  architecture to be used by all collaborators

Power Supply Test Results
Vacuum System Test Bed (BNL)
21
Application Development and Database

• A demonstration program has been set up at BNL
  to show the capability of the EPICS tools
  integrated with a commercial tool (Matlab) as a
  possible method for SNS control applications,
  such as the SNS Injection Orbit Bump Optimization
  shown here.
• Collaboration on new EPICS Display Manager (EDM)
  started with Holifield
• Technical database design ready for initial
  deployment. Derivation of EPICS distributed DB
  from Oracle demonstrated.

22
Superconducting RF Controls
Ethernet - TCP/IP
RF System
Cavity System
Control System
HPRF IOC
ControlNet
PLC
KA
KA
KB
HPRF System
KA
KB
LLRF IOCs
LLRF IOCs
KA
KB
Power Supply
KA
KB
(50 Channels)
KA
KB
PLC
PLC
X 5
X 6
Transmitter
Transmitter
(125 Channels)
(125 Channels)
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
Klystron
11 Cavities
23
Summary

• Lots going on
• Jobs available
• Many issues the EPICS Community can help us with.
• Jobs available
• SNS should become a major contributor to EPICS
• Jobs available
• We look for help and advice from this meeting
• Jobs available

24
SPARE SLIDES
25
Front End A Highly Complex System with Several
Major Subsystems and Critical Functions
The Front End has relationships with all
systems rf, high voltage, diagnostics,
alignment, controls, magnets, power supplies,
pulsed power, physics, vacuum, Cesium,
radiation.
Create 65-mA H- ion beam Ion
Source/LEBT Accelerate beam to 2.5 MeV
RFQ Chop beam into mini-pulses LEBT/MEBT Match
52-mA beam into DTL MEBT
26
Layout of Linac RF with NC and SRF Modules
DTL
RFQ
CCL
(4)
(6)
(1)
86.8 MeV
2.5 MeV
972 MeV
SRF, ß0.81
SRF, ß0.61
186 MeV
379 MeV
HEBT
(33)
(59)
(2)
from
CCL
1
59 (92 total)
1
33
27
Ring Lattice
2000P-03550/jhb
28
Ring Straight Section Functions

• Separate functions in each straight
• Four straights 12.5 m 2 x 6.85 m
• Injection modules
• Two-stage collimation
• 3 (h1)1 (h2) interchangeable RF cavities
• Beam-in-gap kicker
• Empty section for future use

29
WBS 1.9 Scope includes control of all major
subsystems as well as Personnel Safety and
Global Systems.
SNS Integrated Control System
OPIs
IOCs
(1.8.3.4)
ROUTER
FILE SERVERS (EPICS FILE SERVER, ARCHIVERS,
ETC.) (1.9.2.4)
(1.9.2.4)
(1.9.2.4)
(1.9.2.4)
(1.9.2.4)
MAIN CTRL. RM. EQUIP.
FRONT END CTRL. RM. EQUIP.
RING CTRL. RM. EQUIP.
OTHER LOCAL CNTL STNS
TIMING SYSTEM MASTER (1.9.2.2)
BEAM PERMIT SYSTEM (1.9.2.3)
CABLES (1.9.2.2) RACEWAYS (1.8.X)
1.9.2.1 CONTROL SYSTEM NETWORK (EQUIPMENT AND
NODE CABLING) 1.8.4 POWER AND COMMUNICATIONS
SYSTEMS (BACKBONE CABLING)
CABLES (1.9.2.3) RACEWAYS (1.8.X)
CONVENTIONAL FACILITIES IOCS (1.9.8).
PPS IOC (1.9.9)
FAST PROTECT OUTPUT HARDWARE (1.9.2.3)
FRONT END CONTROL SYSTEMS (1.9.3)
RING CONTROL SYSTEMS (1.9.5)
EXPERIMENT CONTROL SYSTEMS (1.7)
TARGET IOCS (1.9.6)
LINAC CONTROL SYSTEMS (1.9.4,10)
PPS PLCs (1.9.9)
C.F. PLCs (1.8.x)
RACEWAY SYSTEM (1.8.x), TYPICAL
CABLE SYS. (1.7.x)
CABLE SYS. (1.3.x)
CABLE SYS. (1.5.x)
CABLE SYS. (1.6.8)
PLCs
CABLE SYS. (1.4.x)
CABLE S (1.8.x)
CABLE S (1.8.x)
(1.9.6)
FRONT END SENSORS, CONTROL ELEMENTS, CONTROLLERS,
ETC. (1.3)
LINAC SENSORS, CONTROL ELEMENTS, CONTROLLERS,
ETC. (1.4)
RING SENSORS, CONTROL ELEMENTS, CONTROLLERS,
ETC. (1.5)
TARGET SENSORS, CONTROL ELEMENTS, CONTROLLERS,
ETC. (1.6)
EXPERIMENT SENSORS, CONTROL ELEMENTS, CONTROLLERS
, ETC. (1.7)
CONVENTIONAL FACILITIES SENSORS CONTROL
ELEMENTS, CONTROLLERS, ETC.(1.8)
PERSONNEL PROTECTION SYSTEM SENSORS CONTROL
ELEMENTS, ETC. (1.9)
EQUIPMENT PROTECTION SYSTEM HARDWARE (1.9.2.3)
TIMING SYSTEM SLAVE HARDWARE (1.9.2.2)
30
Subsystem interfaces arevaried and complex
Ethernet TCP/IP Channel Access Protocol
VXI IOC
PC IOC
VME IOC
VME IOC
PC IOC
Negotiated Exception Examples Cryoplant
Conven. Facilities
Default Interface Examples Injector
Default Interface Examples Beamlines Vac.
Sys.
PLC
Default Interface Example HPRF
Negotiated Exception Examples LLRF
Diagnostics
PLC
PLC
Packaged PLC System
Embedded PLC System
Equipment
Equipment
Equipment
Equipment
PLC
Equipment
IOC Input.Output Controller PLC Programmable
Logic Controller PC Personal Computer
31
Proposed Baseline for full operations (26)
2
Management GL Secretary
8
4
12
Hardware Design Eng Tech Pool (7)
Safety Eng (2) Techs (2)
Software EPICS System Programmers (3) Application
Engineers (7) Network, Sysadmin, Database (2)
Total is 26
APS is 29 for same scope
32
Staffing Plan for Controls
NOTE FY01 Actual FTEs represent the average
actual FTE from October 01 through March 01
33
Cost Summary for Controls