Matthias Clausen DESY, Hamburg, Germany Cryogenic Controls for the European XFEL

Matthias ClausenDESY, Hamburg, Germany

Cryogenic Controls for the European XFEL


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11. October 2014, CryoOps Workshop DaresburyMatthias Clausen - DESY

How it works: a closer look at the facility Scientific instruments

for research

Undulator systems

Electron injector

Superconducting electron accelerator

Ebeling, Bernd

Improve general layout (standardize flashes, change/improve "boxes" around pictures


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Construction site DESY-Bahrenfeld

9 August 2013

Modulator hall

Entrance hallLinear accelerator

Entrance hallElectron injector

Cryogenic hall

AMTF hall


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Using X-rays to explore matter

Synchrotrons Electrons traveling in a wide

circular path, emitting light as the change directions

Light is UV or X-ray, but not coherent

Free-Electron Lasers Electrons accelerated in a straight

line and manipulated to generate light Light is coherent and intensely

bright in very short pulses, showing objects in even more detail and revealing processes


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A big facility for studying tiny objects…

Total facility length: 3.4 km


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6 XFEL-Cryoplant Production Readiness Review Meeting 11.04.2011

XFEL-Cryoplant - Requirements

Start-up: 17.5 GeV state

Spec 20 GeV 17.5 GeV Offer (one! CB)

2K 2457 1896 2010

5K 4150 3593 3030

40K 30000 23923 20175


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CM

Distribution BoxXLVB

Distribution Box XIVB

FB

FB

CM FCEC 3,9 GHz

FCEC 3,9 GHz

Injectors

XFELRefrigerator

Distribution BoxDB54

CC BoxCB44

SC SC SC

SC

CB 41

SC SC

SC

CB 43

SCXRTL

XLTL1 XLTL3XLTL2

CMSFC EC CMSFC EC CMSSCB ECCMSFC SCB

Contributions:

LINDE KRYOTECHNIK

BINP

DEMACO

XFEL Cryogenic Equipment - Overview

Option

© Tobias Schnautz


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Commissioning of XFEL Cryogenic Equipment

XFELRefrigerator


CC BoxCB44

SC SC SC

SC

CB 41

SC SC

SC

CB 43

SCXRTL

Contributions:

LINDE KRYOTECHNIK

BINP

DEMACO

Building 54

Commissioning of cryo equipment in building 54 is almost finished

© Tobias Schnautz


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XFELRefrigerator


CC BoxCB44

SC SC SC

SC

CB 41

SC SC

SC

CB 43

SCXRTL

Contributions:

LINDE KRYOTECHNIK

BINP

DEMACO

Building 54

CXRTL

Commissioning of XFEL Cryogenic Equipment

Pre-commissioning of XFEL refrigerator with CB44 in building 54

Now – November 2014

© Tobias Schnautz


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Cold Compressors and Distribution Box in the Injector Building

© Tobias Schnautz


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• 671 control valves

• 2647 temperature sensors

• 800 pressure sensors

• 212 flow sensors

• >100 level sensors

• 433 regulation loops

• > 22000 records (description of process parameters)

• > 220000 properties (set values, critical values, scanrates, calculation codes, etc.)

Signal Overview

© Tobias Schnautz


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CM

Distribution BoxXLVB

Distribution Box XIVB

FB

FB

CM FCEC 3,9 GHz

FCEC 3,9 GHz

Injectors

XFELRefrigerator


CC BoxCB44

SC SC SC

SC

CB 41

SC SC

SC

CB 43

SCXRTL

XLTL1 XLTL3XLTL2

CMSFC EC CMSFC EC CMSSCB ECCMSFC SCB

Process Controller for the Cryogenic Equipment

Option

© Tobias Schnautz


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The Cryogenic Control System

EPICS for process controls and as a SCADA system Process Controller:

EPICS IOC (Input Output Controller) PLC: Siemens (machine protection,

(partly) control functionality OPI: CSS (Control System Studio)

Operator Interface (graphic, alarm, trend, diagnostic) Configuration: graphics, Profibus, controls(signals,

loops), SNL (State Notation Language) editor Field bus: Profibus


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Where the Controls reside

Turn Key KS2/ FLASH KS1/3/ XFEL Cold Compressors XFEL Distribution

example specify implement specify implement specify implement specify implement

GUI SCADA Control System Studio Control System Studio Control System Studio Control System Studio

- Graphic DESYLinde/ DESY DESY Linde DESY DESY DESY

- Faceplates DESY DESY DESY DESY DESY

- Alarms DESY DESY DESY DESY DESY

- Trends DESY DESY DESY DESY DESY

Process Controller EPICS-IOC EPICS-IOC EPICS-IOC EPICS-IOC

-Process Control Blocks DESY DESY Linde DESY DESY DESY

- State Notation/ Sequences DESY DESY Linde DESY DESY DESY

- Communication with PLC Linde DESY Linde DESY

PLC used for Controls PLC - - Siemens -

- Process Control Blocks Linde Linde

PLC - Machine protection Siemens Siemens Siemens -

- Turbines hard wired Linde Linde

- Compressors Sulzer*Sulzer/DESY Linde

Linde/ DESY Linde Linde

… where the control resides


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Running Controls in PLCsPros and Cons

Pros: The ‘Turn Key’ aspect: Do not care/ no responsibility - as a

customer Intellectual property of the contractor (turbines/ cold

compressors) kept in the PLC as a ‘black box’

Cons: No knowledge about implementation details Change management must be organized with contractor –

or in addition - with sub-contractor Any signal in the PLC which shall be modified from outside

must be configured in communication with higher level applications (read/ write)

Complex to implement sequences


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Running Controls in EPICS IOCsPros and Cons

Pros: Any property of any control block is accessible without any

additional configuration. (read/ write) Deep knowledge about implementation on customer side Easy to add custom control blocks Change management can be organized in house Sequences/ states are implemented in SNL

Cons: Work load on customer’s staff Organize the implementation according to contractors

specification

Reliability: Is not an issue to decide between IOCs and PLCs


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Cryogenic Controls in the AMTF(Accelerator Module Test Facility)


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The Injector Building


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Equipment in the XFEL Injector Tunnel

OLM and DP/ PA GatewaysWAGO I/O and Custom

Temperature- Heater Modules

Redundant Power


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Custom Hardware for Temperature readoutand Level Measurement incl. Heater Control.

Specialized low temperature read out system designed at DESY. The system is designed to support any kind of resistive measurement over a range from 0 to 200kΩ and voltage measurements in the range from 0 to 1.17V.

The LHe level monitor supports a wide range of on the market available LHe level sensors like AMI. The bus coupler can be exchanged to support different field buses (or Ethernet).


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XFEL Installation


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XFEL Installation


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CSS

GSD

CSSI/OCFGCSS

DCT

CSS

SDS

Configuration – or:How to get a Valve to the Console

EPICS IOC

CSSSDS

XML EPICS

DB

Driver

Config

EPICSDatabase

XML

SIM

Add simulation

WinMOD


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Simulation

Simulating I/O is a powerful tool Applications:

New installations: Verify I/O configuration Test displays

Modifying existing configurations Check new logic Check sequence programs

In general: Reduce commissioning times Stable applications from the very beginning


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Cryogenic Control Room


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Screen Shot from CSS ApplicationsSDS (Synoptic Display Studio)


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Screen Shot from CSS ApplicationsSDS Correlation Plot


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Screen Shot from CSS ApplicationsTrend Plotter


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Screen Shot from CSS ApplicationsAlarms / Messages

SNL - Log

PUT - Log

ALARM

Other:

System

Diagnostic

…


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Summary

Over the last two decades we developed EPICS for cryogenic controls. It has reached a mature state which combines the reliability of PLCs with the fexibility of the open source control system EPICS.

Custom hardware for temperature readout and level controls is intergated into the control system.

Redundancy for power, process controllers and field-bus connections increases availability.

The cryogenic control system for the European XFEL is ready to go.

Documents

Matthias Clausen DESY, Hamburg, Germany Cryogenic Controls for the European XFEL