Stephen Schuh Vacuum Controls Final Design [email protected] 6 April 2006 Injector Vacuum Controls Hardware Final Design Review 6 April 2006

Stephen Schuh

Vacuum Controls Final Design Review [email protected]

6 April 2006

Injector Vacuum Controls Hardware

Final Design Review

6 April 2006

Stephen Schuh


6 April 2006

Outline

Introduction

Vacuum system overview

Vacuum controls overview

Safety

Interlocks and Interfaces

Valve Interlocks

Pump Interlocks

Waveguide Vacuum Interlocks

Failure modes

Maintenance and spares

Budget

Schedule

Stephen Schuh


6 April 2006

Review Committee MembersKeith Kishiyama (Lawrence Livermore National Lab) - Chair

Karen Fant or Dan Wright (to be determined)

Kathleen Ratcliffe

Ron Akre

Stephen Schuh


6 April 2006

Charges to the Review Committee1. Evaluate the presented design against LCLS physics and performance requirements.

In particular:Does the proposed control system provide appropriate status and control signals to the vacuum system users (vacuum experts, physicists, operators)?

Is the PLC adequate to perform all the required interlocking functions?

Do the proposed valve interlocks adequately prevent the spread of vacuum leaks in the beam line?

Does the proposed gun waveguide vacuum interlock adequately protect the gun from vacuum-related arcing?

Do all the proposed waveguide vacuum interlocks adequately protect the klystrons from vacuum-related arcing?

Are the proposed outputs to the MPS adequate to prevent the electron beam from striking a valve?

Does the proposed plan to shut off ion pump power supplies after a smoke alarm adequately protect against fires in cable trays?

2. Identify any other technical issues not already addressed in the presented design

3. Determine if the presented schedule and plans for design, procurement, and installation are reasonable

4. Identify any safety or environmental issues that have not been addressed

5. Write a report of comments, findings, and recommendations

Stephen Schuh


6 April 2006

PersonnelControls:

Stephen Schuh (LCLS Controls) – vacuum softwareTom Porter (SLAC Controls and Power Electronics) – vacuum hardware

Mechanical:Leif Eriksson (LCLS) – beam line vacuumJose Chan (LCLS) – RF waveguide vacuumCarl Rago (LCLS) – RF waveguide vacuum

RF and Gun:Ron Akre (Klystron Dept) – klystron protection from vacuum arcsDave Dowell (LCLS) – gun protection from vacuum arcs

MPS:Stephen Norum (LCLS Controls)Arturo Alarcon (LCLS Controls)

PPS:Patrick Bong (SLAC Controls and Power Electronics)

Stephen Schuh


6 April 2006

Scope of WorkVacuum Mechanical / Vacuum Controls

Close collaboration with mechanical vacuum groupTreaty point is connector on beam line component

Mechanical is responsible for pumps, gauges, valvesControls is responsible for cables, controllers, PLC, EPICSInterface document: Vacuum Controls <-> Vacuum Mechanical (ICD 1.1-510)

Mechanical: LCLS Mechanical Vacuum Specifications (ESD 1.1-302)Beam line component specificationsPressure requirements

Controls: Vacuum Controls Requirements (ESD 1.1-326)Status and control requirementsInterlock requirementsInterface requirements

Stephen Schuh


6 April 2006

Injector Vacuum Schematic

Injector Linac Tunnel Tunnel

VVPGBL155

VVPG BL435

VVPG BL545

VVPGBL635

L0-BWaveguide

L0-AWaveguide

GunWaveguide

VPIOWG552

L0-AWaveguide

to output of 20-5 accelerating section

GunWaveguide

Window

L0-BWaveguide

VPIOWG557

VPIOWG550

VPIOWG850

VPIOWG750

VPIOWG650

VPIOWG660

VPIOWG665

VPIO WG775

VPIOWG780

VPIOWG670

VPIOWG675

VPIOWG680

VPIOBL113

VPIOBL111

VPIOBL235

VPIOBL811

VPIOBL465

VPIOBL605

VPIOBL965

VPIOBL377

VPIOWG685

VGCCBL221

CC

VGPRBL221

P

T-CavWaveguide

20-6Gun Klystron

20-7L0-A Klystron

20-8L0-B Klystron

VPIOWG600

VPIOWG610

VPIOWG620

VPIOWG635

VPIOWG625

VPIOWG615

VPIOWG605

VPIOWG700

VPIOWG740

VPIOWG720

VPIOWG800

VPIOWG820

VGCCBL605

CC

VGPRBL605

P

VGCCBL469

CC

VGPRBL469

P

VGCCBL775

CC

VGPRBL775

P

VGCCBL113

CC

VGPRBL113

P

VGHFBL111

HF

VGCPBL111

CV

HF

CV

P

CC

Hot Filament Gauge

Convectron Gauge

Pirani Gauge

Cold Cathode Gauge

Ion Pump

Pneumatic Valve

Beamline

Waveguide

KlystronGallery

VPIOWG565

String of Ion Pumps

VPIOWG640

VPIOWG630

VPIOWG555

VPIOBL705

VVPGBL915

VPIOWG760

VPIOWG765

VPIOWG860

VPIOWG865

PVGPRBL935

CCVGCCBL935

VPIOWG595

VPIOWG770

VPIOWG870

Device Count:

49 Ion Pumps29 Ion Pump Strings15 Ion Pump Power Supply Groups7 CC/ Pirani Gauge Pairs1 HF/ Convectron Gauge Pair5 Pneumatic Gate Valves

VVWGWG560

VVWGWG558

VPIOBL375

VPIOBL303

VPIOBL301

VGCCBL365

CC

VGPRBL365

P

VGCCWG685

CC

VGPRWG685

P

Stephen Schuh


6 April 2006

Linac X-Band Vacuum Schematic Laser Vacuum Schematic

XL-4 Klystron

VVMG LI21 BL195

XL-4Waveguide

VPIOLI21

WG290

KlystronGallery

Linac Tunnel

VPIOLI21

WG260

Device Count:

14 Ion Pumps6 Ion Pump Strings3 Ion Pump Power Supply Groups1 CC/ Pirani Gauge Pair2 Manual Gate Valves

P

CC

Pirani Gauge

Cold Cathode Gauge

Ion Pump

Manual Valve

Beamline

Waveguide

String of Ion Pumps VPIOLI21

KL230

VPIOLI21

KL220

VPIOLI21

KL210

VPIOLI21

KL200

Window

VGCCLI21

WG200

CC

VGPRLI21

WG200

P

VPIOLI21

WG250

VPIOLI21

WG240

VPIOLI21

WG210

VPIOLI21

WG230

M

VVMG LI21 BL175

M

M

VPIOLI21

WG220

VPIOLI21

WG270

VPIOLI21

WG280

VPIOLI21

WG200

WindowWindow

LaserRoom

Injector Vault

Device Count:

2 Pirani Gauges

P Pirani Gauge

Laser Light PipeWindow

Las

er tu

be 1

Window

VGPRIN20LR100

P

Window

Las

er tu

be 2

Window

VGPRIN20LR200

P

Window

Las

er tu

be 3

Window

Window

Las

er tu

be 4

Window

Stephen Schuh


6 April 2006

Vacuum Controls Block Diagram

to MPS

to MKSU

Beam Line or Waveguide

GateValve

IonPump

CC P

Cold Cathodeand PiraniGauges

Hot Filamentand Convectron

Gauges

A-B PLC Two Valve

Control Panel

Gamma DigitelMultiple Pump

Controller

MKS 937AGauge

Controller

Granville-Phillips 307

Gauge Controller

Allen-Bradley ControlLogix

PLC

Terminal Server

IOC

Ethernet

Devices

Controllers

PLC

EPICS IOC

HF CP

from VESDA

from PPS

Stephen Schuh


6 April 2006

Vacuum Controls ArchitecturePLC

Primary means of vacuum control system input and outputDirect connection (24V digital or 0-10V analog) to gauge, pump, valve controllersInterlocksConnections to MPS, PPS, MKSU, VESDA, EthernetPrecedent: Same PLC used for SNS Vacuum System

IOCInterface to LCLS global control system: archiving, remote controlConnected to PLC by EthernetEther-IP driver to read and write PLC tagsAuxiliary input/output with RS-232No critical control functions

Stephen Schuh


6 April 2006

Allen-Bradley ControlLogix PLCProgramming

Ladder logic formatRSLogix software on Windows computerLogic stored in nonvolatile memory – won’t lose logic on power failure

“Master” crate PLC Processor: model 1756-L61, 2MB nonvolatile memoryEthernet connection to global control systemControlNet connection to other cratesInputs from PPS, VESDAOutputs to MPS, RF System 24V digital and 0-10V analog connections to gauge controllersUninterruptible Power Supply (UPS)

“Slave” cratesControlNet connection to master crate24V digital and 0-10V analog connections to pump and valve controllers

Stephen Schuh


6 April 2006

Valve ControlEPICS

Remote control and statusPLC

Interlock LogicValve status to MPSPPS access state from PPSSolenoid control

A-B PLC Two Valve Control PanelNo logic, sends signals to PLCValve control mode switch

EPICS: Commands from EPICSLocal: Buttons on panelJ-Box: Key switch on J-Box – Interlocks bypassedClosed: locked closed

Local valve status and control (only in Local mode)Interlock status

Tunnel valve hardwareSolenoid valveAir supply, air reservoir, pressure regulator, air switchJ-Box provides local status and control (only in J-Box mode)

Beam Enclosure

to MPS

Beam Line

GateValve

A-B PLC Two Valve

Control Panel

Control Mode SwitchValve Status

Interlock Status

Allen-Bradley ControlLogix PLC

Interlock LogicValve Solenoid Control

EPICSIOC

Remote Status and Control

Ethernet

from PPS

J-Box

Valve StatusValve Control (Experts only)

I&C Racks

Stephen Schuh


6 April 2006

Gamma Digitel Multiple Pump ControllerController Configuration

Two high voltage channels5.6kV output, “Medium” supply: 100mA maxPositive polarity for noble diode type pumps

PLC Status/ControlProcess set point status (4 per controller)Analog pressure and voltage signalsPump on/off control

RS-232 Status/ControlDiagnostic info about suppliesRead and change set points

CablesNo SafeConn cablesCables and connectors rated for 10 kVSome controllers support multiple pumps on one channel

One long haul cable per pumpCable junctions in control racks

Stephen Schuh


6 April 2006

MKS 937A Gauge Controller

Controller configuration2 cold cathode gauges and 2 convection enhanced Pirani gauges“Fast response” cold cathode gauges – 15 msec instead of 100 msec standardInternal interlock to shut off cold cathode gauge based on pressure read by Pirani

PLC Status/ControlOne process set point per gaugeAnalog pressure signals

RS-232 Status/ControlView and change set point configuration

Stephen Schuh


6 April 2006

Granville-Phillips 307 Gauge Controller

Controller configuration1 hot filament gauge and 1 Convectron gauge

SLAC modifications for input/output card

PLC Status/ControlProcess set points (4 per controller)

Gauge on/off control

Analog pressure signals

Stephen Schuh


6 April 2006

SafetyVacuum safety issues addressed at LCLS Vacuum Safety Review (September 28, 2005). Safety review materials posted on the web:

https://www-lcls-internal.slac.stanford.edu/slaconly/Injector-Linac-Meeting-Minutes/Injector-Linac-Vacuum/LCLS_Inj_Mech_Vac_FDR/LCLSVacuumSafetyReview/

Electrical Equipment Inspection Program (EEIP) approval for vacuum controllers:

Gamma Digitel ion pump controller: LLNL AHJ certification being entered into SLAC’s EEIP databaseMKS 937A: EEIP approval not yet obtainedGranville-Phillips 307 gauge controller: EEIP approval not yet obtainedAllen-Bradley ControlLogix PLC: All components are UL-listed

Ion pump high voltage cable plantPower supplies will be configured for 5.6 kV. Output of 7 kV is possible with internal power supply hardware changesAll connectors and cables rated for 10 kVPump cables will be type C coaxial cables. Gamma SafeConn cables will not be used

SafeConn interlock cannot be relied on, per SLAC electrical safety officerEven with SafeConn cables, lock-and-tag would still be required for disconnecting cablesSafeConn cables more expensive (factor of 10), take more tray space (factor of 2)Gamma SafeConn cable not low smoke, non-halogenated; type C cable is

Stephen Schuh


6 April 2006

Valve InterlocksRequirements:

Automatically close valves to isolate regions with bad vacuumAutomatically close valves in controlled or permitted accessNotify MPS when valve is closed to prevent beam from hitting valve100 msec response time (valves are slow valves with ~500 msec closing time)

Solution:Set points stored in gauge controllers and pump controllersPLC receives set point status from controllers (24V digital inputs)PLC receives access state from PPS (24V digital inputs)PLC controls valve solenoid (24V digital output)PLC sends valve state to MPS (24V digital output)Interlock logic is a PLC ladder logic routine: monitor inputs, close valve if an input is faulted

Stephen Schuh


6 April 2006

Pump Interlocks

Requirements:Turn off injector vault ion pumps if injector vault or laser room VESDA smoke detector asserts alarm

Injector vault cables run over laser room ceiling

Solution:PLC receives status of injector and laser room VESDA systems (24V digital inputs)

PLC controls pump controller high voltage (24V digital outputs)

Interlock logic is a PLC ladder logic routine: monitor VESDA status, turn off pumps if VESDA system sends alarm

Stephen Schuh


6 April 2006

Waveguide Vacuum InterlocksPurpose:

Inhibit RF output from klystron if vacuum pressure in RF waveguide is high, in order to avoid arcing. Arcing could damage RF windows or the RF gun.

Background:Existing waveguide vacuum interlock for linac klystrons:

Measure pressure at output of klystron

If pressure exceeds set point, send fault signal to Modulator Klystron Support Unit (MKSU)

MKSU inhibits RF output from klystron

Features of existing interlock:Fast: gauge controller wired directly to MKSU

Simple: one gauge per klystron

Some existing interlocks are more complicated: Positron source, PEP injectorMultiple gauges and pumps are interlocked to each klystron

Stephen Schuh


6 April 2006

Existing Waveguide Vacuum Interlocks

Cold Cathode / Pirani

Gauge Controllers

Ion PumpPower Supplies

Waveguide Vacuum Interlock

Summary Box(analog hardware)

Modulator Klystron Support

Unit (MKSU)

CC gauge set points

Ion

pum

p

curr

ent

se

t po

ints

Waveguidepressuresummary

WaveguideVacuum Gauge

Controller


Unit (MKSU)


Controller

Wav

egu

ide

gaug

ese

t po

int

Existing Interlock for Typical Klystron

Existing Interlockfor Positron Source Klystrons 20-3c, 20-4a

Waveguide gaugeset point

NewWaveguideIon Pumps

NewWaveguide

Gauges

WaveguideGauge

WaveguideGauge

Stephen Schuh


6 April 2006

LCLS Waveguide Vacuum Interlock Requirements

Modify waveguide vacuum interlocks for the following klystrons:20-6: New waveguide directs RF output to LCLS Gun

20-7: New waveguide directs RF output to L0-A in LCLS injector

20-8: New waveguide directs RF output to L0-B in LCLS injector

20-5: New waveguide directs RF output to TCAV0 in LCLS injector

21-2: New waveguide directs RF output to X-Band section in Sector 21

Goals for modified interlocks: Monitor pressure everywhere in waveguide, not just at klystron output

Response time: at most 8 msec slower than existing system (8 msec is 1 beam pulse at 120 Hz)

Stephen Schuh


6 April 2006

Proposed Changes to Waveguide Vacuum Interlocks


Gauge Controllers


ProgrammableLogic Controller

(PLC)


Unit (MKSU)

CC gauge set points

Ion

pum

p cu

rren

t se

t poi

nts


Controller


Unit (MKSU)


Controller

Wav

egui

de

gau

gese

t poi

nt

Existing Interlock for Klystrons20-5, 20-6, 20-7, 20-8, and 21-2

Proposed New Interlocks for Klystrons 20-5, 20-6, 20-7, 20-8, and 21-2


NewWaveguide

Gauges

WaveguideGauge

WaveguideGauge

Wav

egui

de

gau

gese

t poi

nt

Waveguide Vacuum

Summary

Stephen Schuh


6 April 2006

Wiring Diagram: Waveguide Vacuum Input to MKSU

Flt -24V OK

WaveguideVacuum

Input

A

MKSU

B CJ6

OK

FaultA

B

C

WaveguideVacuumGauge

Controller

Open

Closed

WaveguideSwitch

OK

Fault

PLC WGVacuum

SummaryExternal

Relay

ground

in

MKSU Waveguide Vacuum Input

with PLC Waveguide Vacuum Summary added

MKSU Waveguide Vacuum Input

Original Configuration

out

+

PLC BinaryOutputModule

+24V

ground

24VDCPowerSupply

Flt -24V OK

WaveguideVacuum

Input

A

MKSU

B CJ6

OK

FaultA

B

C

WaveguideVacuumGauge

Controller

Open

Closed

WaveguideSwitch

Stephen Schuh


6 April 2006

Response Time of New InterlockGauge controller or pump Controller:

Cold cathode gauge controller response time is 15 msecPump controller response time is 650 msec

PLC logic: <4 msecResponse time estimate of 3.6 msec per Allen-Bradley worksheet (see Design Report, Appendix G)Response time <3 msec measured for ControlLogix PLC at SNS (see Design Report, Appendix F)

External Relay: 2 msec (see Design Report, Appendix H)

Total: 6 msec + gauge/pump response time. Meets requirement of 8 msec + gauge/pump response time.

Stephen Schuh


6 April 2006

Alternative: Use Hardware Summary Box Instead of PLC


Gauge Controllers


PLCModulator

Klystron Support Unit (MKSU)

CC gauge set points

Ion

pum

p

curr

ent

se

t po

ints

Waveguidepressuresummary


Controller


Unit (MKSU)


Controller

Wav

egu

ide

gaug

ese

t po

int

Existing Interlock for Typical Klystron

Alternative Interlock:Installation Hardware Interlock Summary Box

Waveguide gauge

set point


NewWaveguide

Gauges

WaveguideGauge

WaveguideGauge

InterlockSummary

Box(analog hardware)

Stephen Schuh


6 April 2006

PLC vs Hardware Summary BoxPLC

AdvantagesNo additional gauge / pump wiring needed. All gauges & pumps already wired to PLCPLC hardware well suited to interlockingEasy to modify interlock logic if desired

DisadvantagesPLC adds ~5 msec to response timeRely on vacuum PLC for RF interlock

Hardware Summary BoxAdvantages:

Faster interlockProven to work at positron source klystronsRF interlock independent of vacuum PLC

DisadvantagesAdditional hardware summary box neededAdditional gauge and pump wiring required Difficult to change interlock logic

Stephen Schuh


6 April 2006

Vacuum Controls Hardware Failure ModesSystem Power Failure

Valves close, pumps turn off, interlock outputs go to safe states

PLC Power FailureMaster crate powered by UPSSlave crates can safely be powered off. Interlock outputs go to safe states.

Disconnected PLC Cable:Set point cables appear as faults when disconnectedOutputs to other subsystems appear as faults when disconnected

24V Power Supply FailureValves close, set points appear faulted, interlock outputs go to safe states

Component Power Failure:Interlock outputs go to safe states

Network Failure:PLC performs all interlocks without need for network

Loss of Site Compressed Air PressureAir reservoirs hold enough air to close each valve once

Stephen Schuh


6 April 2006

Installation, Maintenance, SparesSLAC Mechanical Fabrication Department (MFD) maintains mechanical hardware and pigtails

SLAC Controls & Power Engineering (CPE) installs, tests, and maintains controls equipment

All work is performed by qualified CPE personnel

Installation, testing, and maintenance of vacuum equipment will follow established CPE procedures

Work on high voltage equipment or cables will follow CPE high voltage procedures

CPE determines need for spares; most components are commercial off-the-shelf devices with short lead times

Stephen Schuh


6 April 2006

BudgetAvailable Money for Injector and Linac up to Undulator

WBS Injector: $128kWBS Linac and Linac-to-Undulator (LTU): $174k

Money Needed for Injector and Linac through BC1

Item Count Unit Cost Total Cost

Gamma Digitel Multiple Pump Controller 20 $3686 $73724

MKS 937A Gauge Controller 7 2048 14336

Granville-Phillips 307 Gauge Controller 1 2545 2545

Valve Control Hardware: Air supply, J-Box, A-B PLC Two Valve Control Panel

5 2000 10000

Injector PLC Hardware 40000 40000

EPICS IOC 1 5000 5000

Terminal Server 2 2100 4200

Total $149805

Stephen Schuh


6 April 2006

Schedule: Design, Prototype, Software

ID Task Name Start Finish Duration20062005

Oct AprDec JanSep JulNov MarFeb May Jun

3 151d30-Mar-200601-Sep-2005Determine Requirements; Write Vacuum Controls ESD

1d28-Sep-200528-Sep-2005Vacuum System Safety Review

64d30-Mar-200602-Jan-2006Develop Final Design

1d06-Apr-200606-Apr-2006Final Design Review5

7

4

1 156d06-Apr-200601-Sep-2005Design and Reviews

2

9

8

130d31-May-200601-Dec-2005Prototype

44d31-Jan-200601-Dec-2005Acquire Prototype Components

85d28-Apr-200602-Jan-2006Assemble Prototype Hardware

10 108d31-May-200602-Jan-2006Develop Prototype Software

6

11

90d01-Sep-200601-May-2006Software Development and Testing

67d01-Aug-200601-May-2006Write PLC Ladder Logic

67d01-Aug-200601-May-2006Create EPICS Databases

24d01-Sep-200601-Aug-2006Test Software

Aug Sep Oct Nov Dec

12

13

14

15

Stephen Schuh


6 April 2006

Schedule: Hardware Installation, TestingID Task Name Start Finish Duration

20062005Oct AprDec JanSep JulNov MarFeb May Jun

12d30-Jun-200615-Jun-2006SLAC A-B PLC Two Valve Control Panel

2 87d15-Mar-200615-Nov-2005Design Long Haul Cable Plant for Injector through BC1

102d15-Sep-200627-Apr-2006Long Haul Cable Installation: Injector and Klystron Gallery Sector 20

9 33d31-May-200617-Apr-2006Allen-Bradley Programmable Logic Controller

55d30-Jun-200617-Apr-2006Pneumatic Valve Hardware and J-Box

5d07-Jun-200601-Jun-2006Pre-Load Controllers Into Racks, Building 24

21d15-May-200617-Apr-2006Granville-Phillips 307 Gauge Controller

10

11

23

3

20

14

44d15-May-200615-Mar-2006Gamma Digitel Ion Pump Controllers

12

5

33d28-Apr-200615-Mar-2006Design Inter- and Intra-Rack Cables for Injector through BC1

6

7

15

18

19

8

14d01-Jun-200615-May-2006Pre-Installation Testing of Controllers

34d15-Sep-200601-Aug-2006Install Valve Control Hardware, Pigtails, etc in Injector Tunnel21

13d23-Jun-200607-Jun-2006Inter- and Intra-Rack Wiring, Building 24

1 119d28-Apr-200615-Nov-2005Cable Plant

78d30-Jun-200615-Mar-2006Hardware Procurement

21d15-May-200617-Apr-2006MKS 937A Gauge Controllers

55d30-Jun-200617-Apr-2006Pigtails, Junction Boxes, Miscellaneous Hardware

156d30-Nov-200627-Apr-2006Hardware Installation and Testing

4d29-Jun-200626-Jun-2006Move Loaded Racks to Klystron Gallery

11d29-Sep-200615-Sep-2006Connect Controls Hardware to Vacuum Mechanical Hardware

56d15-Sep-200630-Jun-2006Test Controls Prior to Connection to Vacuum Hardware

17

22

33d15-Nov-200602-Oct-2006Test Controls After Connecting to Vacuum Mechanical Hardware

16 88d30-Nov-200601-Aug-2006Long Haul Cable Installation: Linac Tunnel and Klystron Gallery Sector 21

4

13

24

Aug Sep Oct Nov Dec

Documents

Stephen Schuh Vacuum Controls Final Design [email protected] 6 April 2006 Injector Vacuum Controls Hardware Final Design Review 6 April 2006