1. Cryogenic Plant Controls - Configuration
Chris Scanlon
Cryoplant Controls Hardware FDR
September 13, 2017 1

2. Configuration - Charges
Is the overall Control Architecture defined and approved?
Are the control cabinets adequately tagged, identified, and mapped?
Are Instruments, Wires, Inputs/Outputs identified (tagged, labeled) and listed?
Is the number of installed spares commensurate with the magnitude of the project? (this includes installed spare: I/O cards, Terminals, …)
Is the equipment listed adequate? (this includes type of: PLCs, I/O modules, terminal blocks, cabinets, …)
Is the hardware assembly adequate and safe? This includes: Cabinet internal lay-out, cables and wires in and out, ferrules, touch-safe contacts, breakers, racks, mounting/back panel, internal lights, internal sockets, front panel lights and panel, etc… 2
Cryoplant Controls Hardware FDR, September 13, 2017

3. Is the overall Control Architecture defined and approved?
Configuration
Is the overall Control Architecture defined and approved?
Control architecture is defined by:
P&IDs
Functional Requirements Documents
Interface Control Documents
Engineering Notes
All are approved and released. 3
Cryoplant Controls Hardware FDR, September 13, 2017

4. Control Architecture Document Number Document Title LCLSII-2.7-FR-0492
Cryogenic Controls Functional Requirements Specification
LCLSII-4.1-FR-0327
Cryogenic Systems Integration
LCLSII-4.8-FR-0244
Cryogenic Plant Functional Requirements Specification
LCLSII-1.2-IC-0278
Radiation Safety System Controls to Accelerator Systems, Cryogenic Systems, Photon Systems, and Infrastructure Systems
LCLSII-2.5-IC-0056
Accelerator Systems to Cryogenic Systems
LCLSII-4.9-EN-0289
Cryogenic Distribution System Control Loop Functions
LCLSII-4.9-EN-0255
Cryogenic Distribution System and Cryomodule Failure Mode and Effects Analysis
LCLSII-4.8-EN-0336
Cryoplant Margin, Operability and Maintainability
000-PFP-0011
Cryogenic Distribution System P&ID F
Cryomodule P&ID
LCLSII-4.8-EN-0803
LCLS-II Cryoplant Flowmeter Sizing
LCLSII-4.8-EN-0754
LCLS-II Cryoplant Interface Box Control Functions
Cryoplant Controls Hardware FDR, September 13, 2017

5. Control Architecture Document Number Document Title Status
Technical Specification for the Fabrication of Enclosed Industrial Control Panels
Rev -
Various
Cryogenics Plant Phase 1 Controls Drawings
Rev A Submitted to document control
Cryogenics Plant Phase 2 Controls Drawings
Rev - Submitted to document control
JLab produced documentation supporting the procurement of the cryoplant controls enclosures.
LCLS-II Cryo Controls Integration Workshop, February 8, 2017

6. Control Architecture Document Number Document Title Status 79120-C6003
Cryogenics Plant Utility System Software
Rev 0
79120-C6002
Cryogenics Plant Gas Management System Software
79120-C6001
Cryogenics Plant Warm Helium Compressor Software
Rev -
C1303 NT 400
Cryogenics Plant 4K Cold Box Software
Rev 1
79222-C6001
Cryogenics Plant 2K Cold Box Software
Various
Cryoplant P&IDs
Various revisions
LCLS-II Cryo Controls Integration Workshop, February 8, 2017

7. Control Architecture: Systems
Cryoplant control ends at the interface of the building to the CDS and cooling water.
The cryoplant is split into 7 main systems, each controlled by one PLC. Each warm compressor is controlled by its own PLC.
PLC Systems: Utility / Gas Mgmt / 4K CB / 2K CB / Warm Comps
Cryoplant Controls Hardware FDR, September 13, 2017

8. Control Architecture: Systems
7 PLC systems total in both cryoplants.
21 total PLCs in the cryoplants.
Each PLC has an HMI in the same enclosure
45 enclosures being purchased in this procurement
Each warm compressor is controlled by its own PLC. These are already purchased and were delivered on each compressor.
One per cryoplant of each of:
Gas Management System
4K Cold Box
2K Cold Box
One utility system is shared by both cryoplants and covers the shared subsystems.
Cryoplant Controls Hardware FDR, September 13, 2017

9. Control Architecture: Systems
Each PLC has an HMI in the same enclosure
The HMI screens will close as possible to the SLAC EDM screens and PFDs
JLab gas management system screen
Cryoplant Controls Hardware FDR, September 13, 2017

10. Control Architecture: Systems P&IDs
Utility
System
P&ID
Gas Management
4K Cold Box
2K Cold Box
LP Compressor
MP Compressor
HP Compressor
Cryoplant Controls Hardware FDR, September 13, 2017

11. Control Architecture: PLC Network
Hardware interface: Gigabit/Fast Ethernet at IT room switch
Software interface: Produced/consumed tags, IOCs to EPICS
To Cooling Towers
(SLAC scope)
To CP2
Fiber To CDS and CMs
(SLAC scope)
Cryoplant Controls Hardware FDR, September 13, 2017

12. Control loop examples by system
Control Architecture
Control loop examples by system
Gas Management Controls
Warm compressor inlet/outlet pressures (via bypass valves)
Mass in/out valves
Utility System Controls
Recovery compressor bypass valve
Recovery compressor inlet valve
LN2 valve to purifier heat exchanger
Overarching integrated control is SLAC scope and is not part of this review.
Cryoplant Controls Hardware FDR, September 13, 2017

13. Adsorber regeneration heaters Turbine bearing and brake pressure
Control Architecture
4K Cold Box Controls
LN2 level
HP flow partitioning
Adsorber regeneration heaters
Turbine bearing and brake pressure
Turbine speed control
Dewar levels
Shield temperatures and pressures
2K Cold Box Controls
Cold compressor speeds
Outlet and bypass valves
Cryoplant Controls Hardware FDR, September 13, 2017

14. Control Architecture: 4K Cold Box
Proposed cryoplant hardware provides for the above cold box operation
Cryoplant Controls Hardware FDR, September 13, 2017

15. Configuration
Are the control cabinets adequately tagged, identified, and mapped?
Yes, they are tagged and identified in assembly drawings. 15
Cryoplant Controls Hardware FDR, September 13, 2017

16. Configuration
Control cabinets are mapped in installation drawings. This design was approved in the installation FDR. 16
Cryoplant Controls Hardware FDR, September 13, 2017

17. Configuration
Are Instruments, Wires, Inputs/Outputs identified (tagged, labeled) and listed?
Yes, I/O are located, tagged and labeled in the wiring drawings.
Field cables are labeled in the wiring drawings. 17
Cryoplant Controls Hardware FDR, September 13, 2017

18. Configuration Field cables are labeled in the CAPTAR list.
The CAPTAR list included in the GC’s installation package 18
Cryoplant Controls Hardware FDR, September 13, 2017

19. Configuration Field cables are labeled in the installation drawings. 19
Cryoplant Controls Hardware FDR, September 13, 2017

20. Configuration
Instruments and field cables are labeled in the installation drawings. Field cables labeled starting with L2CP. This design was approved in the installation FDR. 20
Cryoplant Controls Hardware FDR, September 13, 2017

21. Configuration
Is the number of installed spares commensurate with the magnitude of the project? (this includes installed spare: I/O cards, Terminals, …)
Yes, there are spare I/O on each type of I/O, but additional installed spares are not provided. Space is available to install additional I/O cards and terminal blocks if that is necessary, in addition to open I/O on existing cards. Available card space allows for 20% spares per I/O type for future expansion, if needed. 5% of spares are provided on the shelf. 30% additional spare wire pairs are provided in cable runs. 21
Cryoplant Controls Hardware FDR, September 13, 2017

22. Configuration
Extra space is available in the PLC enclosures to install additional terminal blocks, if needed. 22
Cryoplant Controls Hardware FDR, September 13, 2017

23. Configuration
Is the equipment listed adequate? (this includes type of: PLCs, I/O modules, terminal blocks, cabinets, …)
Filtered cooling fans are provided with each PLC cabinet to cool internal components and prevent dust buildup 23
Cryoplant Controls Hardware FDR, September 13, 2017

24. Configuration
Controllogix PLCs are more than adequate for controlling the cryoplants. PLC controller has a large margin on processing power.
JLab 4K Cold Box PLC Scan Time (5560 controller)
Normal: 22ms
Maximum: 75ms
5580 has a minimum performance boost of 10x
Expected scan time with 5580 controller
Normal: 2.2ms
Maximum: 7.5ms
Air Liquide requires a maximum scan time of 120ms.
Cryoplant Controls Hardware FDR, September 13, 2017

25. Configuration The chose PLC controllers have a large margin on memory
JLab 4K Cold Box PLC RAM (L62, 4MB)
19% used
LCLS-II 4K Cold Box PLC RAM (L81, 3MB)
Expected maximum used: 0.75MB (25%)
Cryoplant Controls Hardware FDR, September 13, 2017

26. Configuration
The L81 controllers have a large margin on I/O capabililty
JLab 4K Cold Box PLC I/O
16% used
LCLS-II 4K Cold Box PLC I/O
Digital I/O: 34 of 128,000 maximum
Analog I/O: 190 of 4,000 maximum
Cryoplant Controls Hardware FDR, September 13, 2017

27. Configuration
Terminal blocks are cage clamp type to eliminate the possibility of screws loosening and are rated for the appropriate current 27
Cryoplant Controls Hardware FDR, September 13, 2017

28. Software specifications match the P&IDs and wiring drawings.
Configuration
Electrical enclosures are of the appropriate NEMA rating (NEMA 12 or 4)
I/O modules, TBs, cabinets cover all I/O in cryoplant, according to P&IDs.
Software specifications match the P&IDs and wiring drawings.
Digital output (relay) cards can drive loads of up to 2A and each output is individually fused.
Analog input and output cards have 16/15 bit resolution, respectively, providing plenty of resolution for precise process control. 28
Cryoplant Controls Hardware FDR, September 13, 2017

29. CP controls hardware same as JLab CHL2 Examples:
Configuration
CP controls hardware same as JLab CHL2
Examples:
Controllers and I/O cards – Allen Bradley Controllogix
Pressure Transducers – GE Unik 5000
Differential Pressure Transducers – Rosemount 3051CD
Platinum RTDs – Rosemount Fed into Cryocon
Temperature Diodes – Lakeshore - Fed into Cryocon
Gauges
Signal from these instruments are compatible with the enclosed hardware, including CANbus for the cold compressors
Subsystems have been approved and purchased. 29
Cryoplant Controls Hardware FDR, September 13, 2017

30. Standardized hardware was chosen to reduce the spares need
Configuration
Standardized hardware was chosen to reduce the spares need
One I/O card per type
Two PLC controllers
Three terminal blocks
Two pressure transducer models with four pressure ranges
Differential pressure transmitters in three pressure ranges
Subsystem specifications have already been approved and purchased
Cryoplant Controls Hardware FDR, September 13, 2017

31. Configuration
Is the hardware assembly adequate and safe? This includes: Cabinet internal lay-out, cables and wires in and out, ferrules, touch-safe contacts, breakers, racks, mounting/back panel, internal lights, internal sockets, front panel lights and panel, etc…
All components in the PLC cabinets >49 Volts are finger safe and are concentrated in the upper left hand corner of the PLC cabinets. This allows hazardous voltages to be more easily avoided. 31
Cryoplant Controls Hardware FDR, September 13, 2017

32. Large electrical enclosures are seismically rated.
Configuration
Large electrical enclosures are seismically rated.
The PLC enclosure floor anchoring design was performed by SmithGroup and was BIO approved.
Anchoring requirements 32
Cryoplant Controls Hardware FDR, September 13, 2017

33. Configuration
Low voltage cables exiting cabinets are specified in the CAPTAR list. (See slide 17)
Internal and external wire gauges are specified on the controls enclosure drawings and are coordinated with breaker sizes per Article 310 of the NEC 2014.
Each enclosure containing >49 Volts will have an LED voltage indicator on the door. 33
Cryoplant Controls Hardware FDR, September 13, 2017

34. Is the hardware assembly adequate and safe?
The PLC cabinets each include a power strip to power the Cryocons with additional space for additional devices 34
Cryoplant Controls Hardware FDR, September 13, 2017

35. Is the hardware assembly adequate and safe?
The PLC cabinets each include two overhead, 400 Lumen LED fixures 35
Cryoplant Controls Hardware FDR, September 13, 2017

36. Configruation
Heat generated inside the cabinet is removed by fans and filter grilles. These fans are sufficient to reject the ~500W of heat generated inside the cabinet and keep the temperature inside below 50°C. 36
Cryoplant Controls Hardware FDR, September 13, 2017

37. I/O Breakdown System/IO type Analog Input Analog Output Digital Input
Digital Output
Temperatures (Pt&Diode)
Warm He Comp 11 3 24 9 33
Gas Mgmt 34 4 7 12
Utility 89 21 52 42
4K Cold Box 85 45 60
2K Cold Box 19
Many valves and pressure transducers have HART communication. This provides
Remote configuration
Advanced diagnostics
Access to additional variables (i.e. valve readback without additional input)
Cryoplant Controls Hardware FDR, September 13, 2017

38. Summary The cryoplant control architecture is defined and approved.
The control cabinets are tagged, identified and mapped as shown in the assembly and installation drawings.
All instruments, wires and I/O are tagged, labelled and listed as shown in the wiring and installation drawings.
Adequate spares are included as operational, installed and on the shelf spares. The provided mix reduces the cost and wear of operational spares which may never be used, while still allowing room for expansion.
The equipment specified is adequate. All of the instruments have been accounted for. Equivalent equipment has been running at JLab for years.
The hardware assembly is adequate and safe. UL and NEC guidelines were followed. Requests from SLAC have been added to the JLab design such as internal lighting and voltage indicators.
Cryoplant Controls Hardware FDR, September 13, 2017