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1

SPS RENOVATION

Final design and status

R.Mompo, P.Dahlen, Y.Bastian, I.Romera, M.Zerlauth

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SPS LAYOUT and Magnet Powering

• SPS (7 kms) composed of 6 sextants

• Main dipole and quad magnets powered in series, power converters located in respective BA

• Auxiliary (corrector) magnets powered individually (some exceptions) from respective BA

• Ring-line magnets (quadrupole, octupoles, sextupoles) powered in series in whole SPS ring from BB3

• Current interlock system built in 1974 (mains) 1980 (Aux)

BB3

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SUMMARY Description Cost Manpower PRO CON

ConsolidationOption #1

- - - Risk of lengthy failure

Option #2 (Boolean PLC)

180kCHF 0.5 FTE (MS) + 0.1 FTE (ICE)

Simple + standard, no cabling, diagnostic

Ring line remains, no remote test, info only by sextants/ring

Option #3 (Boolean PLC +

cable)

300kCHF 0.75 FTE (MS) + 0.1 FTE (ICE)

Simple + standard, diagnostic per demi-sextant

Additional cabling + patches, no remote test

Option #4 (Boolean PLC + PLC

comms)

300kCHF 0.75 FTE (MS) + 0.1 FTE (ICE)

Simple + standard, diagnostic per demi-sextant

Special (non-safety part in PLC, no remote test

Option #5 (Analogue I/Os)

400kCHF 1.5 FTE (MS) + 0.4 FTE (ICE)

Diagnostic per magnet without major

Completely new SW projects, no remote test

Option #6 (Profibus)

>1.2MCHF 2 FTE (MS) + 0.1 FTE (ICE)

Full Monty Considerable investment, validation time for rad tolerant

I/Os, feasibility?

During last MPE-TM meeting, we concluded that they were 2 realistic options (#3 or #4) to renovate the SPS interlock system !

Finally, we have chosen option #3 ! I will explain why in the following slides...

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4

Main Dipole and Quadrupole Magnets

Ring-Line Magnet

Auxiliary Magnet

SPS Magnet families

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Principle of the SPS interlock system

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Principle of the SPS interlock system

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Principle of the SPS interlock system

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Principle of the SPS interlock system

Each magnet has an interlock box to collect signals from thermo-switches and for visual indication («trefle»)

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PLC architecture (1/2)

• Configuration of WIC PLC for the “Mains” and “Aux. circuits.

• In BA1 * , BA2, BA3, BA4, BA5 and BA6:

• * In BA1, there is no “Aux.” crate (circuits combined with TT10 transfer line not renovated during LS1).

Ethernet

Crate 1: Type 1 Power supplies

Profibus

SITOP Modular power

supply

6EP1 334-3BA00

SITOP Modular power

supply

6EP1 334-3BA00

SITOP SelectDiagnostics

module 6EP1 961-

2BA00

Redu

ndan

cy m

odul

e6E

P1 9

61-3

BA21

From PLC power suppliesMagnets and

PCs statusTo Power

converters To BIC

Remote test

From Magnets

PCsstatus

To Power converters

SITOP Modular power

supply

6EP1 334-3BA00

SITOP Modular power

supply

6EP1 334-3BA00

SITOP SelectDiagnostics

module 6EP1 961-

2BA00

Redu

ndan

cy m

odul

e6E

P1 9

61-3

BA21

Mod

ule

32 D

O

6ES

7 32

2-1B

L00-

0AA0

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

ET 200 M

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Crate 2: Type 2PLC for SPS main circuits

Crate 3: Type 1Power supplies for deported unit

Crate 4: Type 3Deported unit for SPS aux. circuits

Impedance adaptation crates

CP 343-1 IT

P L C

3 1 5 F -

2 D P

Mod

ule

8 DI

/ 8

DO6E

S7 3

23-1

BH01

-0AA

0

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

32 D

O

6ES

7 32

2-1B

L00-

0AA0

6 “new” racks

5 existing racks =

cohabitation

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PLC architecture (2/2)• Configuration of WIC PLC for the Ring-Line located in BB3:

Ethernet

Crate 1: Type 1 Power supplies

Profibus

SITOP Modular power

supply

6EP1 334-3BA00

SITOP Modular power

supply

6EP1 334-3BA00

SITOP SelectDiagnostics

module 6EP1 961-

2BA00

Redu

ndan

cy m

odul

e6E

P1 9

61-3

BA21

CP 343-1 IT

P L C

3 1 5 F -

2 D P

Mod

ule

8 DI

/ 8

DO6E

S7 3

23-1

BH01

-0AA

0

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

8 DO

(rel

ay)

6ES

7 32

2-5H

F00-

0AB0

Mod

ule

32 D

O

6ES

7 32

2-1B

L00-

0AA0

From PLC power supplies

PCs status To Power converters

To BIC

From Magnets

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

ET 200 M

Mod

ule

24 D

I Saf

ety

6E

S7 3

26-1

BK02

-0AB

0

Crate 2: Type 2PLC for SPS Ring Line circuits

Crate 3: Type 4Deported unit for SPS Ring line circuits

Impedance adaptation crates

1 existing rack =

cohabitation

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Powering scheme of the main dipoles

EDMS: 681304

• If a dipole magnet overheats (or any powering failure):

Þ All 14 PCs must be switched off!

• If we put a WIC in each BA (to protect 1 sextant), how do we propagate the info to the PCs located in the other BAs?

• Do we need to introduce a PLC-PLC communication between the WICs ??? (=> use of non- safety PLCs ).

• Long distances: Issues on reliability/ dependability/ reaction time?

• How do we send a «Beam Dump» signal to the BICs?

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Powering scheme of the main quadrupoles

EDMS: 681372

• In a way simpler, as all PCs are located in 1 BA (BA3).

• But the WIC installed in BA3 must also receive the info from all other sextants?

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Powering scheme of the “Ring-Line”

• The “Ring-Line” is composed of:

o Quadrupole, sextupole, octupole magnets

o Divided in 4 circuits (166 magnets, 8 PCs)

o All PCs are in BB3

• One of the main objective of this renovation (despite replacing the old electro-mechanical crates) is to split the “Ring-Line” in half sextants

o In 2012, we lost 24h to identify the origin of a problem in the Ring-Line (impedance of the line changing due to ageing of the TS).

From the WIC side, it is seen as:

4 x (6 x 2) = 48 circuits !

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Powering scheme of the “Ring-Line”• Since we had to put in place patch panels for the «Ring-Line», it became obvious

that we could also centralise all the quadrupole signals in BA3 (where the PCs are located)

=> Advantage: Avoid using crates belonging to EPC

BA4

BA1

BA2

BA3 BA5

BA6

SPS-RING

NE48 (2x24p) cable

Ring line as is today (4 circuits = 4x NE4 cables going around the machine)

NER48 «Radiation-tolerant» cable

«Bouchons» to cut the Ring Line:4 «bouchons» on each side

2x4 NE4 per sextant

Patch in pos. 62250

Patch in pos. 11310

Patch in pos. 12100

Patch in pos. 21450

Patch in pos. 22100

Patch in pos. 31482

Patch in pos. 32100

Patch in pos. 41450

Patch in pos. 42250

Patch in pos. 51450

Patch in pos. 52250

Patch in pos. 61450

Dedicated PLC in BB3RA 8518

Dipole & Quadrupole interlock line(Split by ½ sextant)

x2

+ 2x1 NE4 per sextant Dedicated PLC in BA3

RA 1777

+

+

+

+

+

+

-

-

-

-

-

-

Patch in PA3 RA2301

This doesn’t solve our communication pbm for the dipoles!

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Communication between BAs

EDMS: 682971

Interlock crate (present in each BA)

Centralisation crate for the mains Quads

Around year 2000, EPC introduced some major changes:1. Local PLCs to pilot each PC.2. A Master_PLC.3. A Hardware Interlock Loop (HIL)!

Crates named «chassis CO» and “CISBOX” are used to distribute signals between «BAs».

Overview of the layout of all BAs (for the mains):

Water interlock crate (EN/CV)

Dipole & Quads PC’s

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Communication between BAs

EDMS: 682971

Overview of the layout of all BAs (for the mains):

• Modifications after LS1:

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Hardware Interlock Loop (HIL)

EDMS: 684948

• 3 current loops• Red: main dipole• Green: main quadrupole• Blue: Sextupole PCs of the

Ring-Line

• If a loop is open, all PCs of the same loop will trip and send a beam dump signal to the BIC in BA3.

• HIL loop and functionality remains under the responsibility of TE/EPC

Thanks to this HIL loop, our WIC PLCs in each BA do not need to communicate between them!

=> In case of a fault in 1 sextant, the WIC sends a «FPA» to the 2 PCs of the corresponding BA. This will cause the opening of the HIL loop and the trip of the other PCs!

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Beam Dump (Current Situation)• The Beam Dump Request:

o The beam dump requests are centralized in BA3.

o 3 input signals (Dipole, Quads, Sextupoles).

o + 1 input from the ROCS system (that checks the consistency between the output of the PCs and the loaded functions)

o + Other PCs are interlocked via the Software Interlock System (SIS).

o ... + inputs for all other systems.

CIB.BA3.S3.Beam Dump Control.

In the future, we could think of replacing this crates (EPC) by a FM352 PLC (High speed Boolean Processor).

Our proposal:1. Keep those inputs as is.2. Add a signal sent by the WIC to the BIC in

each respective BA.

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Status of the renovation

• Functional Specification (EDMS 1295506): o A first version is being circulated to gather comments from all groups involved with detailed

explanation of all changes (What will stay, what will be removed, cabling convention etc...).

• Underground work:o EN/EL has installed the cables for us in BA3 and BA5 (2/6 sextants).o 13 patch panels are in place in the tunnel.

• Surface work:o 5/6 “new” racks installed in each BA. UPS and UTP installation scheduled.o 15/31 PLC crates are cabled, remaining ones should be ready by end of August 2013 (Spie).o Patch panels (x17) are ordered, need to be cabled (+ control cables) .

• PLC/PVSS programming:o David Willeman’s (EN/ICE) contract ends in Feb. 2014 o We depend on David to get the PLC programs (… true as well for Booster, Linac4 etc...)

We agreed on deadlines to get the programs before!

• HWC:o Discussion started to optimize the strategy, given the little time dedicated to the powering tests

before the SPS restart (planned for July-Aug. 2014).• For the final checks, we need the PC to be «déconsigné».

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Conclusions

• In the case of a renovation, to design an efficient magnet interlock system, one has to know in details how a machine is operated... (Machine layout, naming convention, interaction with other systems, standard operation mode as well as non standard operation modes i.e. MD, different people). o “Each machine at CERN is a different Kingdom”, dixit Karel Cornelis

• In «old» machines (same issues for the «Booster» and the «PS») the optic of the machine is often modified, therefore some flexibility must be anticipated at the level of our WIC configuration (to avoid hardware & software modifications at every changes).

• Production of hardware and cable installation is going on as scheduled.

• Potential issue with David Willeman’s contract ???

• During LS1, our colleagues from EN/EL will replace all cables in sextant 1.o Part of the standard procedure to replace periodically cables exposed to radiation

=> We are impacted.

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Thank you for your attention!