1. Cryoplant Controls Installation
Chris Scanlon
LCLS-II Cryoplant Installation PDR
October 18, 2016

2. Purpose: To detail the controls work in the Installation Specification
Outline
Purpose: To detail the controls work in the Installation Specification
Topics
Controls Installation Scope
Roles and Responsibilities
Documentation
Risks
Schedule
Summary
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

3. Controls Installation Scope
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

4. Controls Installation Scope
To be installed:
Control boxes containing PLCs
Field terminal boxes
Field instrumentation
Cable tray, conduit and electrical connections between field devices, terminal boxes and control boxes
Power to control boxes
Ethernet to control boxes, IT room and cryoplant monitoring room
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

5. Controls Installation Scope
Controls for both cryoplants are procured at the same time for each phase.
Phase 1
Gas Management System
Main Compressor System
Final Oil Removal System
Depressurization Manifold
Oil Management System
Cool Down/Clean Up System
Cooling Water System
One gas management system exists in each cryoplant.
Utility System
Oil Processor Skid
Gas Distribution System
Interface Boxes
Recovery System
Instrument Air System
Gas Storage System
N2 Distribution System
Guard Vacuum System
One utility system is shared by the cryoplants.
IT & Cryoplant Monitoring Rooms
Monitoring computers
Networking
Pressure Transducer
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

6. Controls Installation Scope
Controls for both cryoplants are procured at the same time for each phase.
Phase 2
4K Cold Box
Main Cold Box Test Heaters
LHe Storage Dewar
One 4K cold box system exists in each cryoplant.
2K Cold Box
Cold Compressors
One 2K cold box system exists in each cryoplant.
Contamination Analyzer
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

7. Roles and Responsibilities
JLab
Design control panel and terminal box assemblies
Design interconnecting wiring diagrams
Procure control panels and terminal boxes
Define interfaces between vendor designs and control system
Final testing before commissioning
SLAC
Hire installation GC
Program EPICS interface to Cryoplant
Differential Pressure Transducer
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

8. Roles and Responsibilities
Equipment Vendors
Provide transportation, delivery and rigging plan of equipment
Testing at vendor: Hi-pot, continuity GC
Provide detailed controls installation plan
Procure and install field instrumentation BOM
Install necessary conduit and cable tray
Rigging, offloading and installation of equipment
Wire between instruments, terminal boxes, PLC enclosures
Testing upon receipt: Hi-pot, continuity, motor rotation direction, phase orientation
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

9. Roles and Responsibilities
PLC Network Connections
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

10. Roles and Responsibilities
Example of EDM screen via EPICS at JLab
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

11. Requirements Documents
Documentation
Requirements Documents
Functional Requirements Documents
• LCLSII-2.7-FR-0492-R0 - Cryogenic Controls Functional Requirements Specification
• LCLSII-4.1-FR-0327-R0 - Cryogenic Systems Integration
• LCLSII-4.8-FR-0244-R0 – Cryogenic Plant Functional Requirements Specification
Interface Control Documents
• LCLSII-1.2-IC-0278-R0 - Radiation Safety System Controls to Accelerator Systems, Cryogenic Systems, Photon Systems, and Infrastructure Systems
• LCLSII-2.5-IC-0056-R3 - Accelerator Systems to Cryogenic Systems
Engineering Notes
• LCLSII-4.9-EN CDS Control Loop Functions
• LCLSII-4.9-EN-0255 – CDS and Cryomodule Failure Mode and Effects Analysis
• LCLSII-4.8-EN-0336 – Cryoplant Margin, Operability and Maintainability
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

12. Applicable Codes During Installation NEC – 2014 Edition
Documentation
Applicable Codes During Installation
NEC – 2014 Edition
NFPA 70E – 2015 Edition
SLAC Control of Hazardous Energy
SLAC Electrical Equipment Inspection Program
SLAC BIO-approval
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

13. Documentation Phase 1 Phase 2
Controls procurement specification: S1500
Drawings for phase 1 are 95% complete
Oil processor and purifier interfaces defined by vendor
Rest of phase 1 interfaces defined by JLab
Functional analyses defined by JLab
Phase 2
Drawings for phase 2 are 50% complete
4K cold box control interfaces
Physical interfaces defined by vendor at FDR, Oct 2016
Functional analysis defined by vendor at FDR, Oct 2016
2K cold compressor physical interfaces defined by vendor at FDR, Jan 2017
2K cold box control interfaces defined by JLab
BOM for loose instrumentation is 50% complete
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

14. Documentation – Examples
Example of a PLC enclosure assembly drawing
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

15. Documentation – Examples
Example of PLC input card wiring, including field terminal box
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

16. Documentation – Examples
Example of field terminal box wiring and assembly, including pressure transducers
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

17. Risks
Control panels are not delivered on time Low risk – months between planned completion of controls installation and supported system installation completion and commissioning Delay in installation completion Low risk – 5 months between planned completion of controls installation and supported system commissioning Installers exposed to high noise Low risk – Phase 1 (compressor room) installation complete before commissioning of WHCs. Phase 2 (cold box room) is isolated from the WHC noise.
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

18. Phase 1 controls equipment procurement award Nov 2016
Schedule
Phase 1 controls equipment procurement award Nov 2016
Loose instrumentation BOM complete Jan 2017
Phase 2 controls equipment procurement award Jan 2017
Phase 1 controls equipment delivery to SLAC Jul 2017
Install Phase 1 controls equipment and loose instrumentation Oct 2017
Phase 2 controls equipment delivery to SLAC Oct 2017
Install Phase 2 controls equipment and loose instrumentation Jan 2018
LCLS-II Cryoplant Installation PDR, Oct 18, 2016

19. The End
Questions?
LCLS-II Cryoplant Installation PDR, Oct 18, 2016