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2007 Downtime Readiness Review

2007 Downtime Readiness Review. Hamid Shoaee For LCLS Controls Group (in the following departments) Controls Power Conversion Klystron. Agenda. LCLS Control System Installation Readiness Objectives & Scope Schedule & the Process Cable Plant, racks and other infrastructure

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2007 Downtime Readiness Review

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  1. 2007 Downtime Readiness Review Hamid Shoaee For LCLS Controls Group(in the following departments) Controls Power Conversion Klystron

  2. Agenda • LCLS Control System Installation Readiness • Objectives & Scope • Schedule & the Process • Cable Plant, racks and other infrastructure • I&C Systems status and schedule • Issues & Concerns

  3. LCLS Installation and Commissioning Time-Line Injector Controls Installation Complete LTU/und. Install LTU/und. hall “ready” First Spont. Light Controls Checkout A S O N D J F M A M J J A S O N D J F M A M J J 2006 2007 2008 Gun/Inj./BC1 Install (8/21 – 2/20) Gun/Inj./BC1 Commissioning Inj./Linac/BC2 Commissioning linac/BC2 Install LTU/und. Commissioning Oct. 19, 2006

  4. LCLS Accelerator Regions 250 MeV 4.30 GeV 13.6 GeV 6 MeV 135 MeV Linac-X L =0.6 m Linac-0 L =6 m rf gun L0-a,b Linac-1 L 9 m Linac-2 L 330 m Linac-3 L 550 m 25-1a 30-8c 21-3b 24-6d ...existing linac 21-1 b,c,d undulator L =130 m X BC2 L 22 m BC1 L 6 m ‘Wall region’ DL2 L =275 m Nov. 1, ’07 2007 down, Sept-Nov Commission now SLAC linac tunnel research yard Down: Sep., Oct., Nov. of 2007 Run: Dec. 2007 through ~Aug. 2008 To: SL2-stopper in BSY (just past linac sector-30)

  5. Modifications in Sector-24 for BC2 (Emma) • Remove 8 RF sections (24-7, 8) • Remove quad Q24801 • Add 4 new bends in sector-24 • Add 6 new quads (3 types) • Add 1 ‘wide’ BPM • Add 1 x-collimator • Add 1 OTR screen

  6. Linac Modifications (Fall ‘07) • Remove 8 RF sections (24-7, 8) • Remove quad Q24801 • Add 4 new bends in sector-24 • Add 6 new quads (3 types) • Add 1 ‘wide’ BPM • Add 1 x-collimator • Add 1 OTR screen

  7. Linac Modifications (continued) • Add 4 new wire scanners in sector-24 • Add 3 OTR screens (1 BC1, 2 in sec-25) • Move LOLA (trans. deflector) from sec-29 to 25-2 (powered by the 24-8 klystron) • Add pulsed horizontal dipole magnet in sec-25 (BXKIK) • Move 2 LI28 Wire Scanners, 44 & 544, by 20-30 meters • BPM electronics upgraded (resolution improved) • More feedback loops (energy & bunch length)

  8. Linac Modifications (continued) • Power Systems • BC2 racks & PS (install racks and PS at sector 24) • I&C Systems • I&C racks and systems (install racks at sector 24) • Cable Plant • Sector 24 ( install new trays and cable plant from sector 24 racks into Linac; terminate at racks and at loads) • BTH West (pull cables from B005, 105, 106 through BSY into BTH West and coil cables; no loads & no racks installed yet) • B136 through BSY to BTH West • Remove cut cables from FFTB

  9. Plans & Process for BC2 Controls System Installation • Controls installation takes place in several steps: • Design, procurement and Installation of the cable plant including trays, long haul DC and I&C cables • Cables Termination and connection to beam line components (Mechanical Systems) • Procurement & preparation of electronics racks • Installation of electronics chassis and modules including crates, IOCs, timing modules in the racks • Rack installation in the field, AC & cable plant connection

  10. Controls Installation Schedule Overview

  11. Cable Plant Design & Installation Process • From the list of devices to be installed… • Develop racks layout & cable tray design • Generate rack profiles for electronics modules • Identify DC & I&C cabling requirements & document in CAPTAR • Produce installation bid package from CAPTAR and tray designs • Generate installation bid package & award contract • Procure trays, cables, connectors, etc. • Install cable plant and terminate to beam line components

  12. Typical Sector Cable List(Michael De salvo, Mario Ortega)

  13. Sector 24 Connector List First draft BC2 cable design • 13k feet • $245k (cable) • $10k (connectors)

  14. Racks will be pre-loaded in B24 before field installation

  15. BC2 Controls Sub-Systems • Cable plant • Racks, crates, IOC, etc. • Networks • Magnet power supply control • Vacuum control • Safety systems • PPS, MPS, BCS • Motion control • Wire scanners, Collimators, Chicane • Timing • Beam instrumentation and diagnostics • BPM, Toroid, OTR/YAG, Bunch length monitor • LLRF

  16. LCLS Controls systems • For each system… • Technical leads have developed a schedule covering all phases leading to installation and commissioning • The schedules include development of appropriate field documents (EI, WD), rack profile/cable plant design, procurement, installation and system checkout • Continue Interfacing with Mario Ortega, Bob Fuller, Mike DiSalvo to coordinate procurement and installation • We will be reviewing each schedule to identify bottlenecks, dependencies on other systems, resource availability

  17. Safety Systems for BC2,L2,L3 • PPS • The Linac PPS does not require modification to run LCLS beam to SL-2. • There is an AIP project to convert the Linac and BSY to the LCLS PLC-based system in 2008 • MPS • We will use the current (1553-based) MPS for BC2. • Two new ion chambers will be required • The system will include 10 LDIM inputs • OTR21 (2ea) • OTR22 (2ea) • OTR_CAV (2ea) • BC2 Mover (2ea) • CE21 (2ea) • We will need to commission AP25 (currently installed but powered down) to accommodate a new PICP module and an LDIM (already installed).

  18. BC2 MPS ScheduleCheck out 12/3

  19. Concurrently developing new LCLS MPS • Response time of less than one pulse at 120 Hz • Decoupling from Master Pattern Generator (MPG) • Fast communication and processing • Knowledge of beam rate • Integration of EVR to MPS and fault devices • New hardware extended 1.2 km past current MPS • Non-CAMAC • Ready for photon section

  20. LCLS MPS Features • Has response time low enough to protect the undulator (less than 8.3 ms) • Communicates with LCLS timing system (EVG) • Supports new beam loss monitoring hardware and rate limiting methods • Easily extendable and is designed around standards based COTS components • Flexible input and output methods

  21. Overview

  22. Core Hardware and Software Note: These are material costs only. Development labor, installation, etc. costs are not included.

  23. Other MPS Devices

  24. Milestones

  25. BCS (Beam Containment System) • We will use & extend the existing BCS for BC2 commissioning • Two possible configurations are being considered • New BCS PIC System installation in Sector-24 • A 50 conductor trunk from the Sector-28 BCS rack to a new rack in Sector-24. • Long hauls from Sector-24 BCS Rack to the beam line devices in Sector-24 (2 cables per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure Switch) • Use BCS PIC system in Sector-28(Depends on being able to drive PIC/LION HV and signal four sectors) • Long hauls from Sector-28 to the beam line devices in Sector-24 (2 cables per PIC, 1 cable per LION, 1 cable per Flow Switch or Pressure Switch) • For either configuration… • Install VME Crate and associated hardware/software/network • Install new LION Gas system. • AC Power to Sector-28 & Sector-24 racks.

  26. BC2 BCS ScheduleCheck out 11/23

  27. Magnet Power Supply Control • The software design is mature and will require little if any changes for BC2 • Procurements are well under way and orders have been placed for power supplies, racks, etc. • There is a detailed schedule covering bench testing, rack loading, wiring, pre-installation checkout, through field installation • The system will be ready 11/30

  28. 11/30/07

  29. Vacuum controls uses BC1 design, with detailed procurement list in place

  30. Vacuum controls check out by 11/20/07

  31. Wire scanners, Collimators and BC2 motion control use the same design as BC1, and will be available 11/20/07

  32. Networks will be ready early in October to allow Controls checkout

  33. Timing System • The scope is to deliver triggers and timestamp data to all subsystems requiring such. • The system can be split into two parts • Long-haul distribution of triggers from the EVG to EVRs in Linac and beyond • Short-haul back end consisting of the HW & SW to receive the EVG timing signal and generate triggers. This is well-understood and defined. • Part 1 requires some engineering development as the event system can only have a maximum link length of 300 meters. We can daisy-chain, but only for 3 hops before exceeding the jitter budget. We need a better solution • This is a tractable item and should not have a high level of risk. • Another item of concern with the long-haul distribution is timing phase error due to temperature drift – a mechanism is needed to correct for this. • This will need some R&D and we need to decide based on short- versus long-term requirements if users can live with this for now. We have to anyway since time is short • We have a procurement for the "back end" of the timing system consisting of all the HW (fan-outs, EVRs, crates, cables) to deliver triggers to the end subsystem. • The long haul procurement list is pending a design decision

  34. Timing System Schedule

  35. Beam Instrumentation & Diagnostics • Profile Monitors • There are 3 OTRs in the LINAC: OTR21, OTR22, OTR_TCAV – These use BC1 designs and electronics • Design in April, procurement in May, system test July ~ August. • Toroids • There are two toroids in linac: IMBC2I and IMBC2O • We need to re-spin the data acquisition board for small revisions to the artwork • Electronics will be ready in August for system testing • Bunch Length Monitor • BL21 and BL22, similar to BL11 and BL12 in BC1 • Procurement in April and test in May ~ June. • Dumps and Stoppers • SL2 might need some new data monitoring.

  36. Beam Position Monitors • The linac BPMs have to be upgraded for better resolution for undulator commissioning in May-June ‘08 • Do we need to upgrade for the BC2,L2,L3 commissioning? • Do the existing BPM electronics work at 200 pC? • Do they trigger reliably at low charge? • What resolution do they provide? • Test next week with A-Line beam • If we need the linac BPM upgrade • Install 20 racks • Design and install cable plant for 79 BPMs • Re-spin BPM analog front-end design • Fabricate and test 120 BPM chassis • Install 79 BPM chassis • If we can defer the upgrade • We still have to install the cable plant for all of the linac BPMs in this down time • Of the 17 BPMs in switchyard we will connect to only 2 • And one BPM in BC2

  37. LLRF Schedule

  38. BC2 Controls Risk Matrix

  39. Testing & Checkout Strategies • For each subsystem, we will use test stands to verify the complete system • Test stands currently in place include: • Timing • Vacuum • Magnet power supplies • Motion control – wire scanners, collimator, etc. • Rack loading & testing • Need to accomplish as much as possible in B024 prior to Sept. transport to field site. • In-field loading (Davis-Bacon) and intra-rack cabling is less efficient.

  40. Rack Assembly Area

  41. Issues & Concerns • Schedule & Resources • Schedule is very tight, just fits in down time • Controls is the systems “integrator” – delays in other systems directly impact our installation • Cable Plant Installation • Coordination of activities with other installation groups is very important and could jeopardize schedule • Linac BPM upgrade could be an added challenge • System Functionality • Timing System – small concern • BPM, Toroid – need verification of design

  42. Summary • Controls in general is in good shape for 2007 installation • No major design or production issues dominate the plan • The schedule is challenging with little float • While a large number of sub-systems will be installed on time, some will need attention to stay on schedule

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