Post on 21-Dec-2015
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
How it works: a closer look at the facility Scientific instruments
for research
Undulator systems
Electron injector
Superconducting electron accelerator
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Construction site DESY-Bahrenfeld
9 August 2013
Modulator hall
Entrance hallLinear accelerator
Entrance hallElectron injector
Cryogenic hall
AMTF hall
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
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
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
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
A big facility for studying tiny objects…
Total facility length: 3.4 km
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
6 XFEL-Cryoplant Production Readiness Review Meeting 11.04.2011
XFEL-Cryoplant - Requirements
Start-up: 17.5 GeV state
Spec 20 GeV 17.5 GeV Offer (one! CB)
2K 2457 1896 2010
5K 4150 3593 3030
40K 30000 23923 20175
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
CM
Distribution BoxXLVB
Distribution Box XIVB
FB
FB
CM FCEC 3,9 GHz
FCEC 3,9 GHz
Injectors
XFELRefrigerator
Distribution BoxDB54
CC BoxCB44
SC SC SC
SC
CB 41
SC SC
SC
CB 43
SCXRTL
XLTL1 XLTL3XLTL2
CMSFC EC CMSFC EC CMSSCB ECCMSFC SCB
Contributions:
LINDE KRYOTECHNIK
BINP
DEMACO
XFEL Cryogenic Equipment - Overview
Option
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Commissioning of XFEL Cryogenic Equipment
XFELRefrigerator
Distribution BoxDB54
CC BoxCB44
SC SC SC
SC
CB 41
SC SC
SC
CB 43
SCXRTL
Contributions:
LINDE KRYOTECHNIK
BINP
DEMACO
Building 54
Commissioning of cryo equipment in building 54 is almost finished
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
XFELRefrigerator
Distribution BoxDB54
CC BoxCB44
SC SC SC
SC
CB 41
SC SC
SC
CB 43
SCXRTL
Contributions:
LINDE KRYOTECHNIK
BINP
DEMACO
Building 54
CXRTL
Commissioning of XFEL Cryogenic Equipment
Pre-commissioning of XFEL refrigerator with CB44 in building 54
Now – November 2014
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Cold Compressors and Distribution Box in the Injector Building
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
• 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.)
Signal Overview
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
CM
Distribution BoxXLVB
Distribution Box XIVB
FB
FB
CM FCEC 3,9 GHz
FCEC 3,9 GHz
Injectors
XFELRefrigerator
Distribution BoxDB54
CC BoxCB44
SC SC SC
SC
CB 41
SC SC
SC
CB 43
SCXRTL
XLTL1 XLTL3XLTL2
CMSFC EC CMSFC EC CMSSCB ECCMSFC SCB
Process Controller for the Cryogenic Equipment
Option
© Tobias Schnautz
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
The Cryogenic Control System
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
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Where the Controls reside
Turn Key KS2/ FLASH KS1/3/ XFEL Cold Compressors XFEL Distribution
example specify implement specify implement specify implement specify implement
GUI SCADA Control System Studio Control System Studio Control System Studio Control System Studio
- Graphic DESYLinde/ DESY DESY Linde DESY DESY DESY
- Faceplates DESY DESY DESY DESY DESY
- Alarms DESY DESY DESY DESY DESY
- Trends DESY DESY DESY DESY DESY
Process Controller EPICS-IOC EPICS-IOC EPICS-IOC EPICS-IOC
-Process Control Blocks DESY DESY Linde DESY DESY DESY
- State Notation/ Sequences DESY DESY Linde DESY DESY DESY
- Communication with PLC Linde DESY Linde DESY
PLC used for Controls PLC - - Siemens -
- Process Control Blocks Linde Linde
PLC - Machine protection Siemens Siemens Siemens -
- Turbines hard wired Linde Linde
- Compressors Sulzer*Sulzer/DESY Linde
Linde/ DESY Linde Linde
… where the control resides
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Running Controls in PLCsPros 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
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Running Controls in EPICS IOCsPros 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
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Cryogenic Controls in the AMTF(Accelerator Module Test Facility)
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
The Injector Building
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Equipment in the XFEL Injector Tunnel
OLM and DP/ PA GatewaysWAGO I/O and Custom
Temperature- Heater Modules
Redundant Power
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Custom Hardware for Temperature readoutand 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).
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
XFEL Installation
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
XFEL Installation
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
CSS
GSD
CSSI/OCFGCSS
DCT
CSS
SDS
Configuration – or:How to get a Valve to the Console
EPICS IOC
CSSSDS
XML EPICS
DB
Driver
Config
EPICSDatabase
XML
SIM
Add simulation
WinMOD
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
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
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Cryogenic Control Room
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Screen Shot from CSS ApplicationsSDS (Synoptic Display Studio)
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Screen Shot from CSS ApplicationsSDS Correlation Plot
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Screen Shot from CSS ApplicationsTrend Plotter
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
Screen Shot from CSS ApplicationsAlarms / Messages
SNL - Log
PUT - Log
ALARM
Other:
System
Diagnostic
…
Cryogenic Controls for the European XFEL
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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY
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.