Controls Global Group Report John Carwardine ANL Presentation to GDE Bangalore Meeting, 10 March, 2006

Carwardine, GDE Meeting, March 2006 Outline Controls Group scope Progress with RDR tasks High Availability Beam-based feedback Controls R&D program

Carwardine, GDE Meeting, March 2006 The ILC Integrated Control System Control system needs to be flexible, nimble, and easy to use, eg -Avoid users having to know details of the large machine. -Allow rapid prototyping of machine physics experiments. Provide a high degree of automation, eg -Strong scripting tools to streamline operations tasks. -Framework for implementing train-by-train and intra-train feedback loops. Provide seamless integration with accelerator physics models. Operate and support the machine from “anywhere.” Be ready to support system commissioning and machine start-up. Some of these requirements impact the technical systems designs too!

Carwardine, GDE Meeting, March 2006 Scope of Controls Global Group task Global level -Computers, control rooms, networks, archiving, high level controls infrastructure, feedback infrastructure, timing, RF oscillator, etc Local (area/technical system) level -LLRF, MPS logic, PPS logic, front-end/real-time controls, beam-based feedback, control system cable plant, etc Develop costs for each area, and global system costs -Cost roll-up for global controls goes under Global Controls WBS. -Cost roll-ups for controls for individual technical systems go under accelerator areas. Design all hardware and software systems for High Availability, as tasked by the Commissioning/Ops Global Group.

Carwardine, GDE Meeting, March 2006 Control System functional diagram (work in progress) Global Controls Local Controls

Carwardine, GDE Meeting, March 2006 Interfaces and treaty points… Still have to work out details of treaty points… -(Technical systems in general) -HLRF, LLRF, and Controls. -Cryo system, Conventional Facilities -MPS, PSS (assume Controls owns only the logic). -Beam-based feedback systems. -Installations and Operations Groups. Layout issues -Need space for control rooms, computers, relay racks in tunnels, etc -Need to establish a hierarchy for main linac (how big is a linac ‘sector’?) -Need geographical/civil layout for several accelerator areas, eg DR.

Carwardine, GDE Meeting, March 2006 Control System WBS outline Global Control System (first draft is done) - - RF System - - (first draft for linac from DESY) - Develop Global Controls WBS to granularity of ~$5M.

Carwardine, GDE Meeting, March 2006 Global Controls WBS structure (first draft)

Carwardine, GDE Meeting, March 2006 Controls POCs: Area Groups CONTROLS GG POINTS OF CONTACTPOC w/ CTL GG ControlsLLRF AREA GROUPS E- SourceFNALSLACBrachmann/SLAC E+ SourceClarke/DLSLAC Damping Ring Saunders/ANL (Lenkszus/ANL) SLACGuiducci/INFN-LNF RTMLRehlich/DESY Simrock/DESY (Rehlich/DESY) (Nagaitsev/FNAL) (Michizono/KEK) Main LinacRehlich/DESY Simrock/DESY (Rehlich/DESY) (Nagaitsev/FNAL) (Michizono/KEK) Larsen/SLAC BDS Carwardine/ANL (Saunders/ANL)

Carwardine, GDE Meeting, March 2006 Controls POCs: Global & Technical Groups CONTROLS GG POINTS OF CONTACTPOC w/ CTL GG ControlsLLRF GLOBAL GROUPS CF CryoPatrick/FNAL Operations Installation Asiri/SLAC TECHNICAL GROUPS Vacuum Magnets Tartaglia/FNAL Cryomodule Cavity Package RF PowerLarsen/SLAC InstrumentationRoss/SLAC Dumps/Collimators Physics

Carwardine, GDE Meeting, March 2006 Controls POCs: GDE Boards, Other CONTROLS GG POINTS OF CONTACTPOC w/ CTL GG ControlsLLRF GDE BOARDS DCBCarwardine/ANL Terunuma/KEK (Enomoto/KEK) RDBCarwardine/ANL Ross/SLAC CCBCarwardine/ANL Toge/KEK OTHER MDI

Carwardine, GDE Meeting, March 2006 Costing methodology Collect numbers of devices and locations from each accelerator area, list by device type (eg ps, bpms, etc) Guesstimate number of data channels for each device type, eg -Large PS, RF system: Ethernet port + timing + MPS -Small PS, vacuum pump: discrete analog and binary I/O -BPM: Ethernet port or ATCA mezzanine + timing Send our guesstimates back to technical groups for review. Guesstimate numbers of relay racks and cables based on standardized packaging arrangements. Goal is to reduce the costing effort by reducing the number of technical interfaces into a small set of generic interface types. Data from USTOS, TTR, etc will be used where appropriate.

Carwardine, GDE Meeting, March 2006 Costing methodology: standardization Standardize how we will treat interfaces for each device type... -Number and types of I/O connections for a given device type. -Packaging arrangements - Number of I/O per crate by I/O type - Number of crates per relay rack -General guidelines about layout (eg max distance between relay racks) Cost book... -Develop & maintain a list of standard parts/building blocks. - Standard I/O channel by type (some fraction of relay rack capacity). - Controls crate (ATCA). - Relay racks and associated stuff. - Standard cable types. -Include standard labor costs for each component (EDIA, construction)

Carwardine, GDE Meeting, March 2006 Controls Interfaces with technical systems Three generic “standard” interfaces assumed: Ethernet: -Default interface for most custom technical equipment. -Assume equipment is specified to have Ethernet spigots built in. Discrete analog or digital I/O: -Standard interface electronics to be specified and costed by Controls Global Group. Embedded electronics: -ATCA Mezzanine card or full-blown ACTA card. -Interface to controls via the serial link backplane. -Examples might include instrumentation, LLRF, etc Controls interfaces to technical systems should be included in the area systems Inventory & cost roll-up.

Carwardine, GDE Meeting, March 2006 Requirements gathering exercise Primary broad-scope information required for each accelerator: -Number of I/O points and DAQ channels, and their data rates - Intra-train (captured locally at 3MHz, collected at 5Hz). - Train to train (collected at 5Hz). -Geographical layout. -LLRF. -Beam-based feedback. Secondary information required for each accelerator -Timing. -MPS logic. -Personnel Protection System.

Carwardine, GDE Meeting, March 2006 Progress with requirements gathering exercise Requirements spreadsheets (being) developed for -Damping Ring. -Beam Delivery System. -E- and E+ Sources. Initial block diagrams developed for: -Main Linac LLRF -E- and E+ sources LLRF Still need (to develop) controls device lists and layouts for: -RTML, Main linac, cryomodule, cavity package -Cryo system, conventional facilities. -Beam-based feedback, MPS, timing, etc

Carwardine, GDE Meeting, March 2006 Requirements Spreadsheet example (snip) Claude Saunders

Carwardine, GDE Meeting, March 2006 Channels & Cables roll-up example (snip) Claude Saunders

Carwardine, GDE Meeting, March 2006 Packaging roll-up example (DRs + BDS) Claude Saunders

Carwardine, GDE Meeting, March 2006 LLRF front-end crate layout (option)

Carwardine, GDE Meeting, March 2006 Linac LLRF Top-Level Block Diagram B. Chase et al /

Carwardine, GDE Meeting, March 2006 “No electronics in the accelerator tunnel…” LLRF cable plant could be substantially reduced by putting front-end ADCs in the accelerator tunnel. But there are major issues… -Radiation damage (single event upsets, lifetime) -Lack of access to electronics in the accelerator tunnel. Baseline for RDR puts all electronics in the service tunnel (with exception of perhaps mixer components). Serious study would be needed before changing the baseline and opting to put front-end ADCs in the accelerator tunnel.

Carwardine, GDE Meeting, March 2006 Linac LLRF Software Functional Diagram S. Simrock (Carwardine)/

Carwardine, GDE Meeting, March 2006 Redundant Phase Reference Distribution Need to decide on number of fan- outs & local distribution nodes.

Carwardine, GDE Meeting, March 2006 Personnel Access Control System Engineered safety systems to control access to tunnels. Safety reliability design -No unsafe conditions due to single failure. Baseline design -Meet requirements of ISA Safety Integrity Level 2 (SIL-2). -Two separate (redundant) interlock chains. -Dual (redundant) industrial PLCs. -Alternate: safety-rated (TMR) PLCs. Level of compliance rigor will depend on: -Classification of facility. -Regional regulatory requirements.

Carwardine, GDE Meeting, March 2006 Personnel Access Control System Interfaces Controls Group: -Provides PLCs, indicators, control panels, etc Conventional Facilities: -Provides secure access doors, gates, shielding, etc -Divide accelerator tunnels into manageable zones (should be consistent with RF layout, control system layout, etc) Technical & Accelerator Groups -Need at least two means to kill the radiation source, eg - Rings: main dipole ps, RF system, intercepting dumps. - Linacs: RF systems, electron gun, intercepting dumps.

Carwardine, GDE Meeting, March 2006 High Availability Control System… Control system itself must be highly available -Redundant and hot-swap hardware platform (baseline ATCA). -Redundancy functionality in control system software. In many cases, redundancy and hot-swap/hot-reconfigure can only be implemented at the accelerator system level, eg -Rebalance RF systems if a klystron fails. -Modify control algorithm on loss of critical sensor. Control System will provide High Availability functionality at the accelerator system level. Technical systems must provide high level of diagnostics to support remote troubleshooting and re-configuration.

Carwardine, GDE Meeting, March 2006 HA means doing things differently… ILC must apply techniques not typically used at an accelerator, particularly in software -Development culture must be different this time. -Cannot build ad-hoc with in-situ testing. -Build modeling, simulation, testing, and monitoring into hardware and software methodology up front. Reliable hardware -Instrumentation electronics to servers and disks. -Redundancy where feasible, otherwise adapt in software. -Modeling and simulation (T. Himel). Reliable software -Equally important. -Software has many more internal states – difficult to predict. -Modeling and simulation needed here for networking and software.

Carwardine, GDE Meeting, March 2006 Beam-based feedback systems Feedback will be a fundamental part of ILC operations. -5Hz (train-to-train) systems -Intra-train systems Control system should implement feedback infrastructure to -Provide “real-time” access to all potential sensors and actuators. -Allow rapid prototyping of new feedback algorithms. There is a growing list of feedback loops that needs review.

Carwardine, GDE Meeting, March 2006 Train-to-Train feedback loops (5Hz) Positron Source: -Beam energy at undulator -Trajectory at undulator Damping Ring: -Injection trajectory control -Extraction orbit control Ring to Main Linac: -Pre- and post- turnaround emittance correction. -Beam energy at bunch compressor (two stages) Main Linac: -Trajectory Feedback (several cascaded loops) -Dispersion measurement and control -Collision timing. -Final beam energy and energy gradient Beam Delivery System: -Trajectory feedback

Carwardine, GDE Meeting, March 2006 Intra-train feedback loops Damping ring (at revolution frequency): -Orbit correction -Transverse and longitudinal bunch-by-bunch feedback. Ring to Main Linac (at 3MHz): -Turnaround trajectory feed-forward. Main Linac (at 3MHz): -RF cavity fields. -Collision timing. -Energy feedback. Beam delivery (at3MHz): -Trajectory control These lists are surely not complete! We need input from accelerator areas.

Carwardine, GDE Meeting, March 2006 Feedback work related to RDR (cost impact) Need to ensure we have a complete list of anticipated beam- based feedback loops and their performance parameters. Need to determine redundancy and robustness schemes, especially for vital feedback loops -Over-specify the number of bpms and correctors. -Back-up schemes for essential feedback loops. Must ensure locations of actuators & sensors are included as part of the machine design to ensure good sensitivity and robustness of feedback algorithms.

Carwardine, GDE Meeting, March 2006 Highest priority R&D topics LLRF Timing / RF phase distribution Control system / High Availability Beam-based feedback Several of the controls R&D tasks are ILC performance drivers. We plan to utilize various test facilities (ILC-TA, etc) as much as possible for development demonstrations.

Carwardine, GDE Meeting, March 2006 Major immediate tasks for RDR Finish gathering requirements from AS, TS, and GGs Need WBS breakdown for the area and technical systems Need a recipe/procedure for the costing model. Settle on the architecture and scale of global control system. Develop standard packaging models and cost book. “Rewrite” BCD controls content.

Carwardine, GDE Meeting, March 2006 Controls wrap-up We are making progress, but there is much to do! We are still in requirements gathering mode, and need input from several accelerator and global areas. Controls RDR resources are limited, but are increasing. A system-level review is requested of the beam-based feedback strategies and sensor/actuator needs. LLRF performance specs are very challenging and need to be fully developed and agreed, system wide.