1 BROOKHAVEN SCIENCE ASSOCIATES Integrated Testing George Ganetis Integrated Testing ASAC Review...

1 BROOKHAVEN SCIENCE ASSOCIATES

Integrated Testing

George GanetisIntegrated Testing

ASAC Review October 14-15, 2010


Outline

• Definition of Integrated Testing• Power Supplies• Electrical & Mechanical Utilities• Fast Orbit Feedback• Other Systems• Conclusions


Definition of Integrated Testing

• We have defined integrated testing as operating the various sub-systems through the control system.

• We plan to perform integrated testing pentant-wise in parallel to installation in other pentants

• This testing is done without beam. • Hardware sections of the controls system has to be fully functional –

network, IOCs and some servers.• Monitoring, logging, alarming, and some control applications are required

for all sub-systems.• Some sub-systems will have applications software for verification of

correct operation and location of devices. • Quality Assurance features will be incorporated in these applications.

Reports of tests stored in a easily accessible central location.


Summary Table – Storage Ring Power Supplies

Power Supply-Model

Qty Max. Voltage

Max Current

Configuration Stability /Resolutionppm of max I

Operation

Main Dipole 1 1200 V 450 A Unipolar Switch-Mode , Digital Regulatorcenter point tied to GND

25 3.8

DC 1 Quadrant

Quadrupole -A -B -C -D

601206060

16 V22 V30 V30 V

175 A175 A175 A200 A

Unipolar Switch-ModeAnalog Curr. Regulator – 2 DCCTs1 PS per Magnet

503.8

DC1 Quadrant

Sextupole -A -B -C

40512

40 V60 V16 V

120 A165 A120 A

Unipolar Switch-ModeAnalog Curr. Regulator- 2 DCCTsModel A & B = 1 PS per 6 MagnetsModel C = 1 PS per 2 Magnets

10015 (3.8)

DC1 Quadrant

Global Horz. & Vert.Correctors -A

90 24 V 1.25 A 2 Channel Bipolar Linear Analog Curr. Regulator - 4 Shunts

10015 (3.8)

2000 Hz4 Quadrant

Insertion Horz. Correctors -B

12 30 V 30 A Unipolar Switch-ModeAnalog Curr. Regulator – 2 DCCTs

503.8

DC1 Quadrant

Skew Quad Corrector-C

30 20 A 20 A Bipolar LinearAnalog Curr. Regulator – 2 DCCTs

10015 (3.8)

DC4 Quadrant

Alignment Horz. & Vert. Correctors -D

180 25 V 22A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator - 4 DCCTs

253.8

3 Hz2 Quadrant

Dipole Trim –Corrector -E

27 15V 4 A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator – 4 DCCTs

10015 (3.8)

DC4 Quadrant

Dipole Trim –Corrector -F

3 20 V 10 A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator – 4 DCCTs

10015 (3.8)

DC4 Quadrant

There is a total of 997 power supply channels used for the storage ring


Power Supply Configuration

This configuration is used for Quadrupole magnet circuits.

Two DCCTs are used, one for feedback and the other for redundant monitoring.

Power Supply Controller – Performs all high level functions for the power supply – setpoint / ramp generation and diagnostic monitoring

There are no local controls for the power supplies. Every thing has to go through the control system.

All the power supplies components have been tested separately and final testing is when they are assemble in the equipment racks.

The design incorporates a large amount of monitoring instrumentation that will be need for testing.

There are 9 fast and 3 slow analog signal, ~ 8 temperature sensors, 8 digital Inputs for each power supply ( ~ 27,916 signal for the storage ring)

Power Supply is made up of standard building blocks


PS Control System Interface For One Storage Ring Cell

Controls Group Responsibility

PS Group Responsibility

There will be a large effort in testing communications between IOC, Cell controller and PSC cards

There are DVM/Scanner & 1-wire interface units in each of the 3 PS Rack Groups A,B, & C


Block Diagram for Slow and Fast Orbit Correction PS Operation

We will have application software to confirm the 10 kHz update rate of power supply setpoint and readbacks.

Cabling used in the are mostly very short is already assembled & tested


Block Diagram for Booster Mode Operation

PSI # 1Dual Channel

PSI # 2Single Channel

PSI # K

PSCPower Supply Controller # 1

PSC Master- - - - - - - - - -

SDI

PSCPower Supply Controller # 2

PSCPower Supply Controller # M

Booster PS # 1

Booster PS # X

Booster PS # 2

Booster PS # 3

Fiber Optic Link 50Mbit/s

SDI protocol100Mbit

Booster Power Supply Control

SDI - LOOP

IOCVME Chassis

WithTiming Event

Reciever

Standard Ethernet

BoosterPower Supply

TimingSignals

Power Supply Timing Interface

NSLS II is supplying the power supply controls hardware for the booster.

There will be ~ 60 channels of ps control.

Testing will be responsibility of the booster vendor. (But since we will have a considerable set of software tools already developed we be helping with the testing.)


Power Supply Rack Configurations

Within the each of the 30 cells of the storage ring there are 3 power supply rack groups. A,B&C (~90 rack groups total)

Controls network switches and PS IOC shares one rack bay in rack group B.

There 1 set of network switches and 1 PS IOC for each cell.

The controls network will be installed and made functional very early in the installation phase.

There is only a small amount of cables that leave a PS rack group – network, limited timing, PS output, Thermal Switch, & 1-wire. .This configuration is for Rack Group B


Mezzanine - Equipment Area – 1 Cell out of 30

3-D View of Equipment Enclosures & Cable Tray

Power Supply RG C

Power Supply RG B

Beam Instru.RG D

Vacuum & EPSRG E

Insertion DeviceRG F

PPSCabinet

Power Supply RG A

There will be a large number of instruments , components, & cables that will have to be installed and tested.


Series Magnet Circuits Thermal Interlock System

Ethernet SCADA/Control

Network

Power To Magnet

Input From Thermal Switches

Interlock Relay To Power Supply Controller

INPUT MODULE

OUTPUT MODULEPower Supply

Regulator/Controller

POWER SUPPLY

MAGNETThermal Switches

Single PLC located in computer room

This system is used when multiple magnets are powered in series. ( Dipole & sextupole)

One interlock interface is located in each cell.


Power Supply Integrated Testing Software

• Test applications are being developed for control, monitoring, long term logging, and alarming for power supplies on the storage ring mezzanine and injector service bldg.

• PS Controls/Interlocks - on/off and current setpoints & fault tests and status readbacks. • Real time monitoring on analog and digital signal. • Logging of power supply operating data over extended periods of time.• Low & high current stability tests with temperature sensor data for power supplies, rack environment, and

magnet. Test of current regulator and monitoring instrumentation.• Semi-automated tests to confirm polarity of magnet field of the dipole, quad, sext, and correctors. Hall

probe fixture to be interfaced into controls system and manually moved into place for each magnet. • Semi-automated tests to confirm the locations and operation of temperature sensors. Either a heat

source will be applied to each sensor or turning off devices to see temperature change.• Manual test of thermal switches location , confirm the right switch interlocks the correct power supply.• Test reports generated by controls applications as prove the tests were preformed and the data is

correct. (No paper data sheets – all data stored electronically) • Booster power supply applications- Ramp downloads, read-backs data plotting, and setup of

timing and ramp triggers.• Software tools for diagnoses of power supply faults. Applications to setup the trigger conditions for

circular buffers in the PSC and read and display data from them.• This testing will take a considerable amount of time, that is why we will start immediately as the

equipment is installed. We have scheduled ~ 10 days of testing per cell.


Electrical Utilities

Front of enclosures

Front of enclosures

This is one of 30 Cells

Conduits to Tunnel

AC Power Distribution 30 KVA UPS &

UPS Power Distribution

• Temperature controlled equipment racks,• Normal power & UPS power distribution to racks and various pieces of standalone equipment.• “1-wire” temperature & power monitoring will be incorporated in to the distribution equipment.• The UPSs are all connected to the network and will have monitoring software.• Not shown are Power Line Transient Recorders located at each sub-station – All network connected.


Electrical Utilities

Almost all equipment racks are temperature controlled (~ 580 )

Equipment inlet air temp. is held constant at 24 °C.

System is design to remove ~ 5 kW of heat from each heat exchanger using 13 °C chilled water.

All the PID controllers are connected to the control system. ( ~ 700 units)

There will be a number of “1-wire” temperature sensors that will be installed to monitor the operation of the cooling system ~ ( 4000 sensors)

The “1-wire” system uses the same hardware interface with the power supply systems.

Application software is in development for monitoring and logging data.


Mechanical Utilities – Water Systems

Testing will be done for all secondary DI and AL systems

NSLS II is supplying control programming for these water systems.

This Configuration is used in all of the 5 service building – Secondary DI & Aluminum


Electrical & Mechanical Utilities Testing Software

• Same type of applications that are used for power supply testing are needed for both electrical and mechanical utilities.

• The utilities must be completely operational before full current power supply testing or vacuum bake-outs can be done.

• Applications that record that electrical utilities devices are in the correct physical location for temperature sensors , humidity sensors, rack temperature controls, water leak detection systems, current & voltage monitors, UPSs, and Power Analyzers.

• Applications that will confirm the operation of the water systems through the control system.• The Controls system also has an interface to the conventional facilities building systems –

Primary DI, Process chilled water, & HVAC.• Stability runs - operation of all electrical & mechanical utilities equipment for extended times. Data

will be logged for baseline data.• Monitors and logger will be arranged in small groups to allow for easy testing. By cells or service

bldg.• Alarming function will also be tested.• Test reports generated by controls applications as prove the test were preformed and the data is

correct. (No paper data sheets – all data stored electronically)


Fast Orbit Feedback System

BPM system has a pilot tone calibration feature. This signal is injected right at the girder in the tunnel.

Application software will be developed that will modulate this pilot tone to simulate a beam moving.

The software will then record the response of the power supplies to confirm the overall system response.

There are 240 BPM, 30 cell controllers, 90 fast dual plane corrector PSCs , & 180 slow dual plane corrector PSCs.

Diagram supplied by Yuke Tian


Other Systems

• There are a number of other systems that will have to be tested through the control system. • These system will used the same set of tools for control, monitoring, long term logging, and

alarming. • Same type of applications that are used for power supplies will be used for verification of

operations and locations of devices that these other systems will use.• Vacuum systems – large number of gages, pumps, and valves will have to be tested. Controls

have to be operational before bake-out can start. Interlock function into the EPS system also needs to be tested. Testing will be done on a cell by cell basis.

• Beam Instrumentation – Beside the BPMs there are a number of other system that will need testing, Cameras, Flags, tune measurements, etc.

• RF System – Low level RF, High Power RF, and cryogenic systems. There are only a few systems, but a lot of specialized testing that will take considerable effort.

• PPS - Personal Protection Systems – Testing of read-only function for all areas.• EPS – Equipment Protection Systems – Mostly involves the control and interlocks for the front

ends. • Top-Off Safety – This is being defined at this time.• Insertion Devices – Testing will be developed for confirming the operation of the device’s

mechanical and electrical systems.


Conclusions

• Very large number (tens of thousands) of signals will have to be verified that they are working and located in the correct location.

• Automation of this testing is required to meet schedules.• The hardware designs for most systems have been done to allow this automation to

occur.• The various ASD groups are working with the controls group in developing the

application programs needed for this testing. • Low level software drivers for hardware have been progressing very well. Next step is

the final version of mid-level applications. The controls group has been working on a universal set of applications that will be tailored to each groups requirements.

• We plan to have mockup of a power supply rack group ready by the beginning of the year. This will have production hardware. Here we will test out the software and testing procedures for power supplies.

• The first storage ring cell will be ready for integrated testing in the spring of 2011.

1 BROOKHAVEN SCIENCE ASSOCIATES Integrated Testing George Ganetis Integrated Testing ASAC Review...

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