Elder Matias Canadian Light Source University of Saskatchewan System Integration and QA

Agenda The CLS Facility System Engineering Approach Control System Design Instrumentation Design Conclusion

Where is Saskatoon?

Why Saskatoon? 1964 Saskatchewan Accelerator Lab (SAL) was established for chemistry and nuclear physics research. Saskatoon was chosen for the CLS due to existing complement of staff and facilities

What are the CLS Objectives? m circumference 2.9 GeV DBA lattice with 12-fold period Nominal Tune: x = y = 3.26 E loss per turn: > MeV Bend magnet radiation: c = 1.6 Å E c = 7.6 keV  x = 18.1 nmrad Damping times:  x = 2.4 ms,  y = 3.8 ms,  E = 2.7 ms ~10 mm bunch length

The CLS Project –LTB1 (Transfer Line) –BR1 (Booster Ring) –BTS1 (Transfer Line) –SR1 (Storage Ring) –Diagnostic Beamlines OSR XSR –Scientific Beamline SGM, PGM (Soft-X-ray) SM Mid IR, Far IR HXMA (Hard X-ray) CMCF (PX) –Additional 7 beamlines –Additional 6 beamlines

CLS Project Structure Nine Work packages: –0. Administrative Support and Project Planning –1. Linac Refurbishment –2. LTB – Transfer Line to Booster –3. BR1 – Booster Ring –4. BTS – Transfer Line to Storage Ring –5. SR1 – Storage Ring –6. Phase 1 Beamlines –7. System Integration (Controls and Diagnostics) –8. Facility (Building and Mechanical Services)

Collaborate and Reuse Internal Collaboration/Reuse –Standardize equipment where it does not impact scientific capability to reduce development and maintenance time –Standardize Design Approach Toolkits and Methods across beamlines and accelerator –Common toolkit and tools across all projects External Collaboration/Reuse –Based on analysis of requirements versus available systems e.g., EPICS, RTEMS, IRMIS, ScienceStudio

Design Package A Design Package Includes: –PFD Drawings used by Mechanical Engineering to capture system layout and critical parameters, e.g., water flow rates etc. –P&ID Drawings used by Controls to define the inputs and outputs of the system and basic relationships Partially based on American Instrumentation Society –Wiring diagrams –Requirements Document (Developed as required) –PLC and EPICS Software

Drawings All Drawings have a unique drawing number AutoCAD, Inventor, Eagle, Visio Draft Drawings have letter numbering Approved Drawings Alpha Numbering Drawings Review and Approval Process Sketches have Sketch numbers As-built captured on master print Master print in control room, updated by CAD as time permits

PID Example

Change Control (Major Changes) Major Changes handled through ECR/ECO Process Minor changes handled through MKS Integrity database

Change Control (Minor Changes) Central Database MKS Integrity MKS Source –Includes source control –Web and IDE Based Implements the concept of “Sandboxes” and “Change Packages” Exploring options for using: –MKS Requirements –MKS Deploy

Sample Problem Report

Sample Change Package

Design for Maintainability Design systems for the long term Phase out and replace older equipment when changing standards Examples –Replacing IOC with Moxa IOCs –Linac upgrade –PS upgrade

Conventional Software Engineering Used for Web Services Projects Content Time Slide prepared by IBM for CLS CANARIE Project

Comparison with the Unified Process?

Safety Critical Software Applications: –lockup system (ACIS) –Oxygen monitoring –BMIT human studies (under development) IEC – SIL 3 based system Subject to CNSC Approval Siemens S7/400 F Redundant Second Chain Fail-safe design Independent Verification ALARP Hazard Analysis

Hazard Analysis Consequence CatastrophicCriticalMarginalNegligible Frequency 1 Frequent (10 -3 )IIIII Probable (10 -4 )IIIIIII Occasional (10 -5 )IIIIII Remote (10 -6 )IIIII IV Improbable (10 -7 )III IV Incredible (10 -8 )IV FrequencyConsequenceRisk Classification Initial RiskProbableCatastrophicI Residual RiskIncredibleCatastrophicII No.Constraint/RequirementAllocation AM4.1.1.aA lockup (search) procedure shall be developed requiring trained personnel or users to inspect the hutch prior to beam operation. Procedure AM4.1.1.bThe procedure shall define a specific configuration of the hutch perimeter doors prior to, during and after the inspection and the inspector is to follow a prescribed search patch. These controls are in place to ensure that on one may enter behind the inspector un-noticed. Procedure 1.Hutch is not Searched and Secured Prior to Beam Operation Analysis: The level of radiation present in a beamline hutch when the safety shutters are open is of a potentially lethal level and can not be easily detected by a worker in the hutch, it is conceivable that multiple workers could be harmed. To mitigate this hazard it is necessary to introduce an E/E/PE system (called the Access Control and Interlock System (ACIS)) that requires each hutch to be search and secured prior to beam operation through a lockup sequence. Mitigation:

System design based on highly distributed control. Extensive use of single board computers (originally used in SAL). Target lifetime of 15+ years. Data communication over Ethernet when possible. System must be user-friendly. The accelerator and beamline systems must be maintainable by a small team. Reliability and availability of beam are critical to the success of the facility. Building an open source control system was not the initial goal, it was the outcome. Accelerator complex must be complete by Dec and the first phase of beamlines by Dec The project must come in on budget. Control System Design Principles

Distributed Control Systems The options: (1) EPICS or (2) Isagraph/Virgo. EPICS was selected, since it had: –large built up accelerator and beamline user community; –availability of suitable drivers and utilities; –credibility with the CLS user community; and –good design. EPICS Extensions selected include: –EDM, –Accelerator Toolbox, –Gateway and –Data Archiver. EPICS extensions that were locally developed: –assortment of drivers, –IOC Auto-Save-Restore, –simple beamline scanning program, and –SQL Alarm Management Database.

Control Room/Areas Quad Headed Scientific Linux workstations in the accelerator control room and Dual Headed workstations on the beamlines. Scientific Linux (CERN/Fermilab) ( Human Factors Engineering EPICS Tools –EDM (Display Manager) –Strip Tool (Data Trending) CLS Specific –Audio Alarm Annunciation –Legacy hard-wired controls from older Linac Equipment

The Options: (1) RTEMS and (2) VxWorks. RTEMS was selected, since it had: –good experience from SAL, –additional flexibility with single board computers, and –high level of reliability. IOCs are CLS/SIL embedded controllers (approx 150) based on the MC MHz. Processor. Pros and Cons: –No dynamically loaded libraries; must be linked prior to download. –Large number of IOCs (separation of function but more points of failure) Note: EROCS now replaced with MOXA Linux computers. Selecting a Real-time OS

Moxa Transitioning from SAL single-board- computers to MOXA based IOC Linux based EPICS with the asyn driver and older CLS serial drivers Used extensively for RS-232/422/485

VME hardware connected to a Linux PC. SIS1100 PCI card fiber optic link SIS3100 VME module Maps VME backplane to IOC memory. Advantages: –PC can be physically separated from VME crate. –More than one VME crate per PC. –Multiple applications can access the same crate. –High throughput 25 to 80 Mbytes/sec block transfer. Using RTEMS Real-time operating system. ( VME

The options: (1) Matlab, (2) SciLab, or (3) root. Matlab was selected primarily because of the availability of the accelerator toolbox and staff experience. Matlab is commercial, the accelerator toolbox is open source. Software originates from ALS and SPEAR III. Augmented with other CLS specific utilities. Also being used as a commissioning tool for beamlines. Special care is required to maintain consistency with other parts of the control system. Online scripting environment

Provides fiber optic signal distribution of triggers. VXI based hardware IOC running EPICS on RTEMS. Operator Interface implemented using Glade. Glade was selected for the table and file handling capabilities. Timing System

Single board computers (EPICS/RTEMS) used for: –stepper motors, –power supply control, –vacuum equipment monitoring, –radiation monitors, and –other RS-232 devices. PLC hardware/software used for machine protection. Industrial PCs with VME used for diagnostics. Linux servers used for high- level control, network services and EPICS/PLC interface. MOXA RS-232 Computers Implementation Strategy

EPICS Profibus TCP/IP Siemens S7/300 PLC Modbus TCP/IP GPIB RS-232 Channel Access Protocol IOC State Machine Engine CA Single Board Computer CA Operator Workstation User Applications Touch Panels CA Telemecanique Momentum PLC VME IOC CA

Linac Controls Machine Protection –Telemecanique Momentum PLC RF –Hardwired + Telemecanique Momentum PLC Power Supplies –Old (20+ year) power supplies upgraded (Danfysik + Brooker) –Now being replaced (IE Power + Agilent) Diagnostics –FCT, ICT etc. (Scope) –Spill Monitors (CBLM) –Pop-up Viewers (CCTV + Line Generators) –TRM (Computer based image processing) –Isolated Beam-dumps

BR1 Controls Turn-key Danfysik booster Machine Protection (CLS Design) –Telemecanique Momentum PLC RF (Danfysik/ACCEL Design) –Siemens S7/300 –ANKA based electronics –ramped with trigger Power Supplies –Danfysik (RS-232) –Ramped Power Supplies, with trigger –Kickers PPT Diagnostics –Bergoz BPMs –Bergoz FCT, ICT, PCT –Bergoz Spill Monitors –Striplines –CLS CBLM Spill Monitors –CLS Spill Monitors –Synchrotron Light Monitors (3) –Pop-up viewers (4)

SR1 RF Amplifier (Thales) –Siemens S7/400 Cavity (ACCEL) –Siemens S7/300 Low Level RF (CLS) –Siemens S7/300 Cryo Plant (Linde) –Siemens S7/400

SR1 Machine Protection Vacuum, Water Flow, Thermal Switches –Telemecanique Momentum PLC Vacuum Chamber Temperature –National Instruments FieldPoint (should have used Momentum) Fast Orbit Protection –Custom electronics, –PLC provides thresholds for comparison –Trip when current < 10mA based on RF power

SR1 Power Supplies IE Power –Ring Lattice Power Supplies –RS-232/485 Slow Control –Special/Custom Interface for Fast Correctors Danfysik/PPT –Kicker Power Supplies –RS Trigger Significant Time Needs to be allocated to tuning new power supplies

SR1 Diagnostics Bergoz BPM Bergoz PCT CBLMs OSR & XSR Agilent VSA Agilent Remote Scopes Matlab Toolbox Envelop Detector Transient Recorder? Diagnostic Kicker (under development)

BPM Electronics Selection Studies were done on the Bergoz, and Libera Electron units This summer we will test Libera Brilliance

Beamline Controls are based on the same software and hardware as the accelerator systems. Each beamline is on a separate virtual network. The EPICS Gateway provides links between the different networks. Matlab is used for scripting. Beamlines

Remote Beamline Access Prototype Architecture

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Selecting a Scan Region

Lightpath Accelerator controls a software virtual cross-connect that commands UCLP. User Configurable Light Paths In effect, CA*Net4 is treated as a single lightpath cross-connect real device virtual device domain manager process UCLP commands

Mechanical Services Telemecanique Momentum PLCs Ring temperature stability requirement +/- 0.1 C. Geographically Distributed Legacy Systems: –Most 1960s equipment upgraded in 2005 –Most 1980s equipment upgraded in 2004 –Limited number of systems still using Invensys DMS DCS

Fire Protection Notifier System Smoke Detectors Laser Detection VESDA CO2 Near Oil RF Systems Power Trip –Two Zones Trip –Pull Station

Electrical Services MCC (Siemens) –SR1/BR V –Linac - 480V Panels –120 V, 208 V Conduit used extensively For control applications each rack cluster is on the same phase Early morning grid adjustments were problem at times for some power supplies

Grounding Grounding routed back to the main transformer yard Beamline have isolated grounds, with mixed results. Beamline have two separate transformers –Convenience (Dirty) –Isolated (Clean) Mechanical System from a Separate Transformer

The End