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XFEL Refrigerator Controls A basic Overview

XFEL Refrigerator Controls A basic Overview. XFEL Refrigerator Review April 27, 2010 Matthias Clausen - DESY. Cryogenic Control for the XFEL. Historic Review Cryogenic Controls Principles EPICS Basics XFEL Cryogenic Controls For the Cryogenic Plant For the XFEL Accelerator.

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XFEL Refrigerator Controls A basic Overview

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  1. XFEL Refrigerator ControlsA basic Overview XFEL Refrigerator Review April 27, 2010 Matthias Clausen - DESY

  2. Cryogenic Control for the XFEL • Historic Review • Cryogenic Controls Principles • EPICS Basics • XFEL Cryogenic Controls • For the Cryogenic Plant • For the XFEL Accelerator

  3. … how everything started • Cryogenic Controls for HERA • The Cryogenic Plant and the Cryogenic Distribution in the HERA tunnel needed a reliable and scalable process control system • The D/3 system was chosen because of its • Flexibility • Scalability • Redundancy for process controllers

  4. The D/3 Sysem • For the Cryogenic Plant • Redundant Process Controller • Native – centralized - D/3 hardware • For the HERA Cryogenic Distribution • Single Processor • EPICS as an intermediate system (gateway) to ‘talk’ to the DESY SEDAC field bus • The D/3 System is a Distributed Controls System (DCS) similar to the ABB System – Which is (was) in operation at CERN

  5. Cryogenic Controls Principles for HERA • All analogue control loops in the process controller • All digital controls in the process controller • Machine safety implemented in • Hardware (relay) for turbine over speed shut off • PLCs for basic compressor safety • PLCs also used as data concentrator for multiple digital signals from compressors • Due to high costs for the D/3 I/O hardware, signals were indirectly connected to the D/3 system

  6. EPICS Basics • Experimental Physics and Industrial Control System • Is following the same controls principles like the D/3 • Open Source • Developed in an international collaboration • Introduced at DESY as a gateway between the D/3 and the SEDAC field bus • Used for all cryogenic systems following after the HERA plant • Used for utility controls at DESY as a SCADA system(MKS-2 provides technical support) • Used for machine controls for most HEP accelerators and light sources world wide. • Selected as the main machine control system for ITER • The EPICS community is continuously growing

  7. EPICS Technical Background • Running on real-time operating system (VxWorks) • VxWorks based process controller (called Input Output Controller (IOC)) can run continuously for many years without reboot • The functional control blocks (called ‘records’) are running in several thousand instances world wide • The primary functional blocks are well tested and reliable • EPICS ‘databases’ are configuring instances of the functional blocks. The source code stays untouched • New developments are driven by the requirements of the EPICS collaborators • They are distributed either as part of the core distribution • Or as an additional distribution package from the developer

  8. EPICS EPICS (Experimental Physics and Industrial Control System) Client (Configuration- and Operator Interfaces) Channel Access IP based Communication Protocol I/O Controller is independent from clients I/O Controller (control loops, Sequence programs) I/O System (Field bus) P T

  9. Application Development Adding new databases for supported devices Integrating new I/O devices Hardware Engineer Process Engineer Programmer Get driver from EPICS site Configure Profibus Configure Database Prepare new IOC Load Image Profibus Configuration Tool Database Creation Tool Write text file to load directory Load IOC with -Operating System -EPICS core -Database

  10. EPICS Developments at DESY - I • Extensions for process control • A ‘real’ PID record • Digital Logic record – providing a basic –PLC like-functionality (derived from the D/3 system) • Temperature record – for calibrated temperature sensors • Archive record – to keep a local history on the IOC • Extensions for Redundant IOCs • Redundancy Monitor Task • Support to synchronize • Continuous Control Data • Sequence Programs • Field-bus DPM buffers

  11. EPICS Developments at DESY - II • Field-Bus driver for • SEDAC • CAN • Profibus (FMS, DP) • Modbus-TCP • Siemens-H1 • Siemens-TCP

  12. EPICS Developments at DESY - III • Control System Studio (CSS) • Java based Eclipse Rich Client Platform (RCP) application • Operator Interface (Graphic, Alarm, Trend, Diagnose) • Process Engineer Interface (Tool-set to configure the control system) • Management Interface to manage CSS installations • Core part of a variety of server based services

  13. New Cryogenic Controls for the HERA Plant • In March 2010 we finished the modification of the cryogenic control system of one third of the former HERA cryo plant to be used for FLASH, CMTB, XMTS and the AMTF • Replacing the D/3 System with EPICS • Replacing all the centralized I/O hardware with decentralized – field-bus based I/O( Profibus is used as the primary field-bus) • Replacing old PLCs with Siemens PLCs – integrated into the control system • Replacing the D/3 continuous controls blocks with EPICS records • Replacing the D/3 sequence programs with EPICS State Notation Language (SNL) programs • Replacing D/3 alarms with a new – JMS based – alarm system • Introducing the new operator interface: CSS • ( JMS: Java Message Service)

  14. Using EPICS for the FLASH Cryo Plant • New EPICS Control Blocks • Compressors and Coldbox: ~2250 • Valve box, dewar, low temp cleaner…: ~1600 • New EPICS SNL Programs • 6/ 2 Files (Compr. Coldb./ Valve box) • 9600/ 4750 Lines of code (Compr. Coldb./ Valve box)(converted from ??sequence programs ??lines of code)

  15. Impact on the controls for the XFEL Refrigerator • Continuous Controls • The Database Creation Tool (DCT – as part of CSS) was used to create the EPICS databases. This is based on a component based approach. • Control loops for the FLASH cryo plant can be used for the XFEL cryo plant • Logic implemented for actually one compressor street is prepared to handle three streets • State Notation Language Programs • Start/ stop and supervisory control programs for compressors and cold boxes (incl. turbines) may be also used for the XFEL plants with minor modifications

  16. Cryogenic Controls Principles for XFEL • All* analogue control loops in the process controller • All* digital controls in the process controller • Machine safety implemented in • PLCs whenever possible • Hardware (relay) if not avoidable • PLCs are used for ‘turn key’ systems which do not require external access to control loops/ parameters • Vacuum Compressors • Cold Compressors • New Turbines in Cold Boxes?? • Current optimization implemented in SNL programs • How to handle new optimization strategies? • *If not part of a PLC for a turn key system

  17. EPICS based control structure

  18. Redundant IO-Controller

  19. DP Config F P T IOC Profibus DP Master Device-DB GSD Profibus Configuration Profibus Configurator Sensors & actuators

  20. Profibus Infrastructure in the Cryo Building (54)

  21. Profibus Communication in the XFEL Tunnel

  22. DTM Diagnose Signal Conditioning Asset-Management Configuration Profibus FDT/DTMCondition Monitoring Integrated Engeneering Tool Pactware (openSource) Fieldcare (Endress+Hauser) Field Device Tool FDT Device Tool Manager DTM

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