LCLS Accelerator Readiness Review Control System for Injector Commissioning

1. LCLS Accelerator Readiness ReviewControl Systemfor Injector CommissioningHamid Shoaee31 October 2006

2. Outline • Control System Scope and Organization • Control system development life-cycle • Injector Control System Installation Plan • Controls Status for commissioning • Summary

3. LCLS Control System is at WBS Level 3 John Galayda – Project Director Mark Reichanadter – Chief Engineer ----------------------------------------------------- Steve Milton – ANL Project Director Richard Bionta – LLNL Project Director e-Beam Dave Shultz Conventional Facilities Jess Albino Photon-Beam John Arthur Controls Manager Hamid Shoaee 1.5 X-Ray ODT Manager Richard Bionta 1.4 Undulator Manager Steve Milton 1.2 Injector Manager Eric Bong 1.3 LINAC Manager Eric Bong 1.6 End Station Stefan Moeller 1.2.2 Injector Controls1.3.2 Linac Controls1.4.2 Undulator Controls1.5.2 XTOD Controls 1.6.2 XES Controls There are Controls Components in every WBS Level 2

4. The Scope of LCLS Control System • The Controls scope extends from the connection to the beam line components to the Control Room (MCC), including: • Cable plant, racks, wiring, termination • Global systems • Magnet power supplies and control • Vacuum • Timing • Networks, Servers, Control Room upgrades • Safety systems • Personnel Protection • Machine Protection • Beam Containment

5. LCLS Control System Scope… • Beam Instrumentation & Diagnostics • BPM • Profile monitors and other beam imaging systems • Toroid charge monitors • Wire scanners • Bunch Length Monitor • High level applications software, physics modeling, feedback systems • Control Room Operations Software • Electronic log books • Data archiving and history buffers • Alarm management and status displays • Configuration control • Problem reporting and tracking

6. LCLS Controls Group Staffing • The control system development is performed by a matrixed group of about 50 engineers and technicians organized in two dozen engineering teams • Each multi-disciplinary team manages the full product lifecycle from specification and design to engineering development, production, installation and commissioning • Following a recent re-organization, the LCLS & SLAC controls effort have been integrated into one Controls Department • LCLS Controls Group is now fully integrated & matrixed within the SLAC Controls Department • The control system development, maintenance and sustaining engineering will be performed by the same department which has been responsible for other projects at SLAC

7. LCLS Controls is matrixed within the Controls Department

8. Control System Development Life-cycleDocuments • All documents are available on line… • Physics Requirements Document (PRD) – for each system the requirements are specified in detail by a cognizant physicist. These are reviewed and signed by relevant system managers • Engineering Specifications Document (ESD) – the specifications follow directly from the PRD and include a detailed list which will drive the implementation • Interface Control Document (ICD) – lists the interface between the system under development and all other systems interfacing with it

9. Control System Development Life-cycleReviews • Conceptual Design Review (CDR) – Review of the proposed system architecture • Preliminary Design Review (PDR) – Review of the detailed design including hardware & Software components • Final Design Review (FDR) – Review of complete system as will be implemented, including testing strategies, etc.

10. Control System Development Life-cycleProcess • PRD • ESD, ICD and high level system architecture proposal • CDR • Detailed system design, equipment specification (& prototyping if necessary) • PDR • Procurement, final engineering implementation, user interface development, test plans • FDR • Bench testing, validation and verification • Field installation • System integration tests

11. Example Process:Vacuum Controls Development Life-Cycle • Requirements • Use existing controls for linac vacuum hardware • Remote control and status in EPICS for all new hardware • Local control and status for all new hardware • Interlock gate valves with gauges • Notify MPS when a gate valve is not open • Shut off klystron modulators when waveguide pressure exceeds a threshold • Close all valves in a PPS region if that region is set to controlled or permitted access

12. Vacuum Controls Conceptual Design

13. Vacuum Controls External Interfaces • Valve status to MPS: Shut off beam when valve is not open (MPS ICD, Vacuum Controls ESD) • Waveguide vacuum status to modulator: Shut off modulator when WG vacuum is bad (Vacuum Controls ESD) • Access state from PPS: Close valves when in controlled or permitted access (Vacuum Controls ESD)

14. Vacuum Controls Design and Review Stages • Vacuum safety review – September 2005 • Safety review of all vacuum components • Audience: Vacuum experts and safety experts from several SLAC departments • Internal design review – November 2005 • Early review of vacuum controls plan • Audience: SLAC controls department • Vacuum Controls Requirements document – March 2006 • Final design review – April 2006 • Review of vacuum system controls hardware • Audience: Control system experts and vacuum experts from SLAC

15. The development life-cycle is driven by a detailed Schedule

16. Testing Program • Vacuum equipment bench testing • Pump controller load tests • Gauge controller tests • Valve control panels will be tested when delivered • Intra-rack wiring testing • Most intra-rack wiring was tested before the racks were sent to Sector 20 • Remaining wiring will be tested after PLC crates are installed • System testing to be done in December • All PLC interlocks will be tested after PLC programming is finished • Detailed testing procedures not yet developed • End to end testing in January-February

17. Vacuum Hardware Status • Date Needed: January 2007 • Progress to date: • Assembled test stand: PLC, gauge controller, pump controller, IOC • Installed all long haul cables • Procurement and bench testing of COTS vacuum controllers finished • Most equipment installed in racks in Sector 20 (exceptions: PLC crates, valve control panels) • Intra-rack wiring complete • Remaining work: • Make and install vacuum pigtail cables (in progress) • Install PLC crates in Sector 20 (when programming complete) • Fabricate valve control panels (in progress); install in Sector 20 • Install wiring to provide vacuum interlocks to RF system

18. Vacuum Software Status • Date Needed: January 2007 • Progress to date: • Software requirements determined (Vacuum Controls ESD) • EPICS device support mostly complete: • EPICS ↔ PLC: done (using ether-ip from SNS) • EPICS ↔ Vacuum Controllers: nearly done (using streamdevice from SLS) • Test stand PLC programming in progress • Test stand IOC development in progress • Remaining work: • PLC programming (in progress) • EPICS databases and EDM screens (in progress) • System testing (formal test plan to be written)

19. Magnet Power Supply Control • Final Design Review – March 30, 2006 • Documentation – drawings, wire lists, ELPs , Web site (>90% complete) • System Integration and checkout begins – Nov 13, 2006 • Injector and BC1/LI21- 2007 Commissioning • 89 new magnet ps systems • 6 Intermediate PS, 10kW or 20kW rated (5 Injector, 1 BC1) • 83 new MCOR systems (55 Injector, 28 BC1) • 6 new double-bay racks • Installed in Sector 20: Sep 24, 2006

20. Magnet Power SupplyDesign Documentation Status • DC Cables • EI (Electrical Interconnect), CAPTAR list, power supply spreadsheet – all complete • Racks, power supplies, PS controllers VME/PLC crates, modules and terminal server • Specifications, front views and manufacturer’s drawings/manuals, EPICS/VME integration documents • PLC wiring diagram undergoing some changes • Hazard analysis completed – requested labels from CEF • Manuals, cable lists • AC Power • One lines, panel-board schedules

21. Modified S21 QE System – Design Documentation Status • DC cables • On modified EI diagram • Racks and accessories • Existing – one front view needs updating • Power supplies and controllers • Bulk PS Isolation chassis and QE201/301 magnet reversing / shorting switch chassis wiring diagrams • AC power • Existing 120VAC control

22. Magnet Power Supply System Architecture EPICS IOC SLAC Ethernet PS Controller VME Crate Magnet Magnet PS Magnet Magnet Linux VMS Alpha CA Server OPI SCP Standalones Ethernet (LCLSnet) (LEBnet) SLC net SLC Micro CAMAC MCOR Protection PLC MCOR Large PS Controller SCOR PS Bulk PS Bulk PS Ext. Interlocks

23. Magnet Power SupplyPre-Installation Test - B24 • Purpose – Verify wiring, basic operation as integrated systems • Controller Power Supply- Local Mode • BX01,02 (pps) and BXH1,2,3,4 successfully tested • PLC, 3 MCOR bulk power supplies, MCOR12/30s • BXS, SOL1, SOL2 and BX11,12,13,14 • Network Integration • Ethernet Nodes • IOC, Crate PLC, Terminal Server, Intermediate PS Controllers • Terminal Server • IOC, Intermediate PS Controllers • Controller Power Supply - Remote Mode • VME, PLC, 3 MCOR bulk power supplies, MCOR12/30s • Completion September 24, 2006

24. Bench testing is accomplished with Operations software

25. Magnet Power SupplySystem Integration Field Test Plan • Three weeks needed in timeframe • Hi pot DC cables • DC cable / magnet polarity checks B and V • Run Intermediates in Local Mode to verify transductor polarity • Run Intermediates and MCORs in Remote Mode • Addressing is correct (configuration control) • Voltage and current compliance • All readbacks are functional • Klixon, water flow, ground current interlocks function and display correct status • Tune response of each system

26. Magnet Power Supply Schedule

27. 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

28. Controls will be available for Pre-Beam Checkouts • Vault and Linac Checkouts • Power on access: Check polarity of magnets • Read-backs , Motion controller: Exercise motion-control • Screen camera images: Use Alignment laser to define screen center • Pre-Beam preparation • Laser stabilization system • Fiducializing of real cathode location w.r.t virtual cathode • LLRF for Gun, L0a, L0b (Volt. feedback, Phase Lock) • Start conditioning (Gun, L0a, L0b) when PPS ready • Dark current measurement • Vacuum pumps and gauges reading available • Feedback loops for gun temperature stabilization

29. Injector Control System Installation • Almost all procurement is complete • Controls installation is taking place in several stages • Installation of cable plant. • Phase I – Injector (Apr. ’06 thru Jun. ’06) – Completed • Phase II – Linac (Aug. ’06 thru Dec. ’06) – In Progress • Installation of the electronics racks. • Installation of electronics chassis, modules, and intra-rack wiring • Installation of the Controls software on the production servers

30. Phase I Cable including Laser Room Completed in June Phase II Cable Plant Currently in progress Will be completed in December ..to BC1 Area

31. All electronics racks for injector controls have been installed

32. Injector Controls Status • Magnet power supply control hardware & software • Final Design Review conducted successfully • Hardware installation is complete • EPICS Software – almost complete and tested • System Integration on Nov 10, 2006 • Vacuum control system • all electronics installed, software nearing completion • Timing system • Procurement completed • Two test stands are equipped and available • Tasks in progress • Hardware testing – jitter, • Applications software

33. Injector Controls StatusSafety Systems • PPS • LCLS Injector PPS Reviews are Complete • The Radiation Safety Committee has approved the design based on PLC • The design is complete and installation is in progress • Injector MPS • Using existing linac infrastructure • Hardware procurement is almost complete • Installation will be completed in early December • BCS • Prevents radiation from ‘escaping’ the shielding enclosure • Protection of safety-critical collimators and stoppers • Hardware is nearing readiness for installation in November

34. Actuator A1 Laser Actuator A2 Camera B Actuator B1 Actuator B2 Camera A Spiricon Injection Laser Stabilization System • The injector laser stabilization system includes two feedback loops • The loop operates @ 1 Hz, and the camera is synced to 120Hz. • The prototype of the first loop has been tested for several months and works well.

35. Beam Instrumentation and Diagnostics • Beam profile imaging system hardware and software currently being tested • BPM electronics in fabrication • Toroid, Faraday cup – design is complete, electronics fabrication in November • Bunch length monitor – commercial electronics are on hand, SLAC designed digitizer will be available in November • Wire Scanners – Hardware Tested (without beam), Calibrated, and currently being installed, software is almost complete

36. Injection Wire Scanners after Assembly

37. LLRF Hardware Available for Injector Turn-on • Linac Sector 0 RF Upgrade • All 3 RF Chassis Installed • Sector 20 RF distribution system • equipment near completion • LLRF Control and Monitor System • most components either ready or in fabrication • Beam Phase Cavity • 3 units Complete • Phase and amplitude control and detection software is complete; feedback loops ready • RF Gun Temperature Feedback – In Design

38. High Level Applications Software • Combination of rich existing controls software and new applications developed in MATLAB

40. Injector Controls Installation Summary • A number of Injector Controls sub-systems have been successfully installed – most of the cable plant, racks, power supply controls, vacuum, most of the PPS • A large number of subsystems are ready for installation – laser control, wire scanners, profile monitors and beam imaging system • The remaining systems will be available for installation in November and early December – BCS, MPS, BPM, Toroid, Timing, applications software

41. Operation Software • The Main Control Center (MCC) software will be primarily the existing linac system which has been in use at SLAC for over 20 years • All operators are very experienced in the use of the system • In the case of new LCLS components, we have provided a bridge to make the new system available through the legacy control system • Controls engineers will be available on day shifts to assist physicists and operators during commissioning

42. Summary • The installation of the injector controls will be complete in December • All controls subsystems will be available and tested for pre-beam checkout and March commissioning • The integration of controls effort at SLAC is ensuring the availability of required expertise and resources to complete the control system development and installation • The control system development, maintenance and sustaining engineering will be performed by the same department to ensure continuity