A Masi, LHC Collimators Low Level Control Commissioning Status

LHC Collimators Low Level Control Commissioning status

A. Masi

1. Control system hardware upgrades2. Control system software changes3. Commissioning status

Contents

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

Old controls rack configuration New controls rack

Control cables protection system

New PXI high availability

chassis

Added KVM for PXI remote

management

Not touched !!!!

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

High Availability PXI chassis designed and manufactured for the

LHC collimators project

Redundant hot swappable power supply

Health Monitoring

card

Redundant easy replaceable fans

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

New electrical distribution chassis

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

TDI improvements

• connection to the BETS

• Installation of the interferometric gap measurement system

Optical connectors

NI RDIO

HSSL Interface

Europa Crate

Redundant power-supply

Optical link cards to the BETS ready to be produced

• An additional FESA class will be added to publish and manage the interferometric gap measurement

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

LVDT Position drift due to external field

The I2PS is not

affected

- Optimized dimensions and winding parameters

- Test Installation during 2012 Christmas Break

- Ratiometric reading

- 1 micrometer uncertainty with lower supply currents

- Temperature compensation

- No effect on the measured position of an external magnetic field

10 LVDT affected by magnetic interference problem replaced with a new designed Ironless Inductive Position Sensor (I2PS)

See CWG talk by A. Danisi on Sep 2013

A Masi, LHC Collimators Low Level Control Commissioning Status

1–Control system hardware upgrades

New temperatures sensors integration

• 140 new temperature sensors integrated in the existing PLC monitoring system

• Hardware commissioning successfully performed

• New configurations files generated for the UNICOS framework

• Monitoring software commissioning with EN-ICE automatic scripts in progress

A Masi, LHC Collimators Low Level Control Commissioning Status

2–Control system software changes

Main software changes:

• MDC (Motor Drive Control) : upgraded to LabView 2011, software architecture improved and optimized

• PRS (Position Readout & Survey) : upgraded to LabView 2011, software architecture improved and optimized, integrated reading of I2PS

• DIM library : updated and added a more efficient acknowledgement mechanism

• FESA class : completely re-written in FESA 3.0

A Masi, LHC Collimators Low Level Control Commissioning Status

2–Control system software changes

Impact for operation:

• Added separation limits :• PRS errors : Two new bits will be added for separation : B17 : POSITION_OUT_OF_SEPARATION

B18: SEPARATION_TIMEOUT

• PRS warnings : A new bit will be added for separation : B5 : POSITION_OUT_OF_SEPARATION_WARNING

• A new allarm

• Two new properties to define the Active IP:        

- SeparationActiveIP :   like betastar, used to select the separation value to be used- SeparationThreshold : like betastar, 4 2D arrays defining limits to be interpolated (Inner/Outer for gap upstream and downstream)

• Waiting for new telegram definition

• Some old alarms can be removed or simplified

• Additional information have been added to the postmortem buffer: - pmGapUpSeparationInnerLimit                        - pmGapUpSeparationOuterLimit                        - pmGapDownSeparationInnerLimit                        - pmGapDownSeparationOutererLimit                        - pmSeparationValue

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning plan

Commissioning guidelines:

• As for 2008 the following steps will be followed before making the full system fully operational:• Hardware commissioning EN-STI

• Position sensors calibration EN-STI + support of the collimation team for the new collimators

• Functional tests on the entire system or system subsets EN-STI + Collimation Team

• Machine Interlocks test Collimation Team

• Dry-run BE-OP

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning status

 

Number of systems

Network Installation

230V power supply

R2E cablingControl System

Installation

Systems ready for commissioning

US15 4 OK OK OK OK OK

UA23 6 + TDI OK OK - OK OK

UA27 2 OK OK - OK OK

UJ33 7 - OK - Ok YES

USC55 4 OK OK OK OK OK

US65 1 - OK - OK OK

TZ76 21 OK OK OK OK OK

UA83 2 OK OK - OK OK

UA87 5 + TDI OK OK - OK OK

BA7 1 OK OK - OK YES

The commissioning plan is being defined according to the installation status and the dates of the cool down

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning status

EN-STI Hardware commissioning status

Task Status Comments

Collimators + control system functional HW commissioning

Completed

Position sensors calibration and validation Completed Including the new I2PS sensors

Interlocks chain HW tests Completed

Remote Reset tests Completed

Remote Torque measurements Completed

New temperature sensors integration in UNICOS

Completed

Temperatures hardware commissioning In progress Expected to finish by the end of the week (2/03/2015)

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning status

• Task: Software (i.e. all the chain FESA + DIM + PRS/MDC) functional test

• Status: Completed

• Action: STI

• Test plan coverage percentage: 80 %

• Tool used: Test bench in 272 + Our own custom sequencer

• Comments: the test plan is not able to cover:

• Beta star and energy limits dynamic test

• Timing payloads

• Stress conditions related to the operation of several collimators on the same gateway

• What have been missing in our tests plan

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning status

• Task: Stress tests on the low level software

• Status: In progress

• Action: STI/Collimation team

• Test plan coverage percentage: try to cover at least the 1st year operation cases

• Tool used: All the LHC collimators + most demanding operational sequences

• Comments: The idea is to stress the system as much as possible and to cover the rare operational scenarios. For instance:

• The longest profiles possible

• Exceptions test (i.e. bad profiles, bad limits, commands to be rejected in the current state)

• Stop/Resume profiles

• Unusual tilt conditions

A Masi, LHC Collimators Low Level Control Commissioning Status

3. Commissioning plan

• Task: Operation commissioning

• Status: In progress

• Action: Collimation team

• Test plan coverage percentage: try to cover at least the 1st year operation cases

• Tool used: All the LHC collimators + common operational sequences

• Comments: The goals are:

• Discover functional bugs escaped to our functional verification

• Analyze system health data during the system normal operation

• Discover as much as possible problems on the new hardware

A Masi, LHC Collimators Low Level Control Commissioning Status

4. Conclusions

• All the LHC collimators are operational and are in commissioning phase

• The last months operation of the entire system has been precious to detect hardware problems, verify the behavior of the low level with several collimators in parallel, discover bugs escaped to our validation procedure

• A special thank to the collimation team for their efforts and the strong interaction with the experts

• In the coming 3 weeks the effort should focus on the extension of the operation test plan coverage to take into account at least the 1st year of operation

• The key of success is testing, testing and again testing ….