SPX Controls System WBS U1.02.01.03.04 (R&D) WBS U1.03.03.04

SPX Controls System WBS U1.02.01.03.04 (R&D)

WBS U1.03.03.04

Ned ArnoldComputer Systems EngineerAES Division/Computer Systems

DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

Outline

Science / Technical Significance WBS Scope of this system Staff / Org Chart Requirements Design Interfaces Value Engineering ES&H Cost Schedule

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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3

Channel Access Protocol

(over ethernet) Input / Output Controllers (IOC)

Tim

ing

& S

ynch

roni

zatio

n

SPX DiagnosticsReal-time Control

Fast Acquisition & HistoryStatistics

Post Mortem Fault Capture

Existing OAGTools

InteractiveGraphicalDisplays

AlarmHandler

Distributed Control System (based on EPICS)

NewNewApplicationApplication

#2#2

ExistingAcceleratorSubsystems

LLRF (& Tuners)(Downstream Cryo)

LLRF (& Tuners)(Upstream Cryo)

Interface(s) to Technical Equipment

SPX

Inte

r-sy

stem

Inte

rlock

s

SPX Cryogenics System

SPX Cryo-moduleInstrumentation

SPX WaveguideInstrumentation

SPX HLRF(Klystrons & HVPS)

SPX Controls System Technical Significance & Scope NewNew

ApplicationApplication#2#2

NewApplications

Scope:•Operator Interface panels•New application programs•Tools for engineers and operators (Matlab/SDDS scripts, calibration tools, Post Mortem Fault Analysis, etc.)•Data acquisition (primarily for LLRF systems)•Input/Output Controller (IOC) Hardware•EPICS Databases/Sequence Programs in IOC•Subsystem Interface Hardware


SPX Controls Scope WBS U1.02.01.03 and U1.03.03

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Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 2,276 361 228 506 3,373 U1 02.01.03 - SPX R&D 724 130 11 159 1,024

02.01.03.04 - Controls R&D 724 130 11 159 1,024 U1 03.03 - SPX Production 1,552 232 217 347 2,348

03.03.04 - Controls System 1,552 232 217 347 2,348

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)


SPX Controls System Org Chart

Controls is a part of the Systems / Signals / Integration (SSI) Group led by Frank Lenkszus

Contributors– Ned Arnold (Lead)– Sinisa Veseli (Software Services Group)– Nick DiMonte (Controls Group)– Tony Scaminaci (Controls Group)– Jim Stevens (Controls Group)– Josh Stein (Controls Group)

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SPX Controls System Requirements The entire SPX system must be thoroughly integrated with

the existing APS storage ring controls, timing, and diagnostics. Since any instability in the operation of the SPX cavities will impact all APS users, thorough instrumentation and diagnostics will be required to detect any operational abnormalities. The primary responsibilities for SPX controls are as follows:

– Provide remote monitoring and control to all SPX subsystems consistent with APS standards and existing OAG tools

– Provide the necessary interfaces between the SPX and other APS systems as required by the SPX needs (e.g. RTFB, MPS, Event System, etc.)

– Provide a real-time data processing environment for the SPX control algorithms to ensure they can be executed at the necessary rate

– Provide thorough diagnostic information and tools to assist in quick determination of SPX performance and post-mortem fault analysis (required for maintaining high availability)

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SPX Controls System

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SPX Subsystems - Control/Monitor Parameters

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Subsystem Devices toInterface

Interfaceto IOC

Parameters toMonitor / Control

Default Rate

LLRF LLRF Controller (x8)

Real-time Data Link

RF Monitor: 10 I/Q pairs (x8)

RF Control: 2 I/Q pairs (x8)

Parameters: 200 / 200 (x8)

272 KHz20 KHz10 Hz

HLRF PLCs (x8) Ethernet 200 / 50 (x8) 5 Hz

Cavity / Cryomodule

PLCs (x8) + Numerous

Instruments

Ethernet 200 / 100 (x8) 10 Hz

Fault/Timestamp Recorder

VME Module VME 32 Fault Inputs / Module On Demand

Cryomodule Vacuum

MM200, MPC, VVC210

Ethernet 50 / 20 (x2) 5 Hz

Cryo Distribution PLC (x3) Ethernet 150 / 30 5 Hz

Cryo Plant PLC Ethernet 500 / 50 5 Hz

Phase Stabilized Timing

LBL LLRF4(or equivalent)

USB 50 / 10 (x5) 5 Hz


SPX Controls System Design

Most subsystem control requirements are quite nominal and many similar interfaces already exist.

Support for the SPX LLRF will require substantial effort in data

acquisition, real-time processing, and extensive fault response algorithms to ensure proper operation and minimal effect on user beam.

Beam availability to users is paramount and will drive many aspects of the Controls System design.

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SPX Controls Conceptual Design (LLRF)

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Prudent Operating Constraints

( software interlocks )

Fault / Exception Response

Fast Automated Sequences

Filtering / Statistics

Fast History Buffer

Save / Compare / Restore

Data Logging (long term)

Graphical Displays

Deflection Control

High Level Tools

Automation (PEM)

SPX Diagnostic Tool

Real-time Signal Correlations(RF Power/Phase, HVPS Voltage,

BPMs, temperature)

Single Cavity LLRF Control

Sector LLRF Control

(4 cavities)

Real-time Functions

Post Mortem Fault Capture (including

History Buffer)

Alarm Tools

Phase Control

Amplitude Control

CalibrationsCavity Tuning

Vector Sum Phase/Amplitude

DS Sector Adjust to Minimize Residual Tilt

(differential amplitude)

Orbit Feedback SystemUS Sector Adjust to Achieve Desired Tilt

(phase/amplitude)

Deflected Tilt Monitor

Residual Tilt Monitor

Fault Response

Sector Adjust to Minimize orbit/emittance Disturbance

(differential phase)

Intra-sector control(for lattice tuning)

Beam Arrival Time Monitor

S35 Residual Effects Diagnostics

• How are these functions partitioned into hardware?

• At what rate must each process data?

• At what rate must each transmit/receive data? By what method?

• What is the best computing architecture for each (e.g. DSP, FPGA, multi-core CPUs, etc)

FFTs/NAFF on RF, BPM, actuator signals

Identify end-to-end functions


SPX Controls Preliminary Design (LLRF)

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SPX0 Controls (A subset of SPX Controls)

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X

XX

X

X

XX

XX

X


SPX0 Controls (LLRF)

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Interfaces

The Controls System interfaces to almost every other subsystem, including existing APS subsystems such as Timing, Event Link, etc.

Details of these interfaces (communication mechanism, number of parameters to be monitored and/or controlled, etc.) are described in the Engineering Specification Documents and additional details in the Interface Control Documents.

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Integrated Safety Management System (ISMS)– APS-U Project following Argonne’s ISMS program requirements – Argonne Integrated Safety Management System (ISMS) Description recently

revised and submitted to DOE ASO• Describes framework for integrating ESH requirements with mission objectives• References Argonne LMS procedures which implement specific portions of the

ISMS

Identify General Safeguards and Security Requirements– No special materials or project specific security requirements– APS-U Project required to follow Argonne’s Operations Security Program

(OPSEC) Master Plan General Safety Requirements for Controls

– All equipment must be approved for electrical safety by a NRTL or re-inspected by ANL

– Controls System hardware and software is not responsible for any personnel or equipment protection

SPX Controls System ES&H


SPX Controls System Value Engineering

Where feasible, use commercial or existing hardware and software to avoid redundant solutions– IOC Hardware– Existing EPICS device support for many devices– Area detector data acquisition framework (used on beamlines)– SDDS (File Format & Tools)– APS Standard Valve Controller

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Cost Drivers– Labor– Server-grade Workstations: 5 * $6300 = $31.5K (existing purchase order)– Network Switch + Operator Workstations: $24500 + (4 * $3000) = $36.5K (vendor quote

+ engineering est.)– VME-based Input Output Controller: 3 * $14000 = $14K (existing purchase orders +

custom modules)– Deflection Controller; Prototype + Production: 2 * $16,700 = $33.4K (engineering est.

based on similar devices)

Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 2,276 361 228 506 3,373 U1 02.01.03 - SPX R&D 724 130 11 159 1,024

02.01.03.04 - Controls R&D 724 130 11 159 1,024 02.01.03.04 - ACWP 136 17 - 27 180 02.01.03.04.01 - Support R&D Activities of LLRF - Timing & Synchronization 216 31 2 40 290 02.01.03.04.02 - Demonstrate Intersystem Communication Requirements 40 16 0 8 65 02.01.03.04.03 - High Level Software - Evaluate Tools - Identify Necessary Enhancements212 15 7 52 286 02.01.03.04.04 - Support R&D Activities for other Major Assemblies 119 51 2 31 204

U1 03.03 - SPX Production 1,552 232 217 347 2,348 03.03.04 - Controls System 1,552 232 217 347 2,348 03.03.04 - ACWP 105 - 0 20 125 03.03.04.01 - Controls Support for Test Stands & Prototypes 193 15 29 43 280 03.03.04.02 - Control System Infrastructure & Tools 452 107 75 101 735 03.03.04.03 - Controls for Production Subsystems 472 65 69 110 716 03.03.04.04 - Deflection Controls 330 45 43 73 491

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)

SPX Controls Scope WBS U1.02.01.03 and U1.03.03


SPX Controls Obligation Profile U1.02.01.03 & U1.03.03

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SPX Controls BOE Contingency U1.02.01.03 & U1.03.03

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SPX R&D and Production Milestones U1.02.01.03 & U1.03.03

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u START: Preliminary Design - SPX0 4/10

u START: Preliminary Design - SPX 2/12

u COMP: PDR - SPX0 7/12

u COMP: PDR - SPX 1/13

u SHIP: SPX0 Cryomodule to ANL 4/14

u COMP: SPX0 Cryomodule Test 6/14

u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)

u COMP: SPX0 Installation 10/14

u AVAIL: SPX0 Ready for Operation 1/15

u START: Final Design - SPX 6/14

u COMP: Final Design 9/15

u START: Major Procurement 10/15

u AWARD: Cryoplant Contract 10/15

u START: Cryoplant Installation 9/17

u COMP: Cryoplant 3/18

SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u

COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u

SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u

COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u

SPX SYSTEM

FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17


SPX Controls Milestones U1.02.01.03 & U1.03.03

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q Support Horizontal Cavity Test at ATLAS - SPX0 12/12

q COMP: SPX0 Control System Design 4/13

q AVAIL: SPX0 Controls Ready for Installation 2/14

q Support In-ring Test - SPX0 8/14

q START: Final Design 6/14

q COMP: Final Design 9/15

q START: Gateway Development - Deflection Control 10/15

q COMP: Deflection Controls 6/17

q Support Cryom #1 Testing at COLT 7/17

COMP: Controls System Installation 12/18 q

FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15

CONTROLS

FY16 FY17 FY18


Work After CD-2

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Ongoing R&D Activities– Support R&D Activities of LLRF, Timing, and Synchronization (Test Stands and SPX0)– Demonstrate Intersystem Communication Requirements– High Level Software; Evaluate Tools, Identify Necessary Enhancements– Support R&D Activities of Other Major Subsystems (HLRF, Cavity, etc.) (Test Stands and

SPX0)

Begin design of …– Deflection Controller Hardware– Deflection Controller Gateware– Real-time Processing Algorithms– Real-time Processing Benchmarks


Summary

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This system provides the hardware, software, and tools to integrate the SPX subsystems into the existing APS controls infrastructure.

The design has progressed substantially from the Conceptual Design. Control functions are now mapped into hardware components.

Controls requirements for many SPX subsystems are typical of existing designs and require no special development.

A "Deflection Controller" has been added to orchestrate the control and monitoring of the 8 LLRF systems. This is a substantial addition since the CDR.

Cost is $3,373K Installation

SPX0 Ready for Installation: 02/14 Production: Tracks subsystem installations

We are ready for CD-2 ….


Backup Slides

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SPX0 Controls Installation & Checkout

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SPX Controls Installation & Checkout

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SPX Controls Summary Schedule U1.02.01.03 & U1.03.03

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SPX Controls System WBS U1.02.01.03.04 (R&D) WBS U1.03.03.04

Documents

review of aps

aps upgrade project

aps systems

aps standards

aps users

spx controls system

spx needse

spx cavities