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TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 1 CERN Portuguese Teachers Programme, 4 Sep 2009 Dr. Paulo Gomes on behalf of the team CERN TE CRG with the precious contributions of the colleagues: Project Associates (NTU-Athens, AGH-Krakow) Industrial Support Cryogenic Operation AB CO Slide 2 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 2 CERN Portuguese Teachers Programme, 4 Sep 2009 2 460 m 170 m 270 m Sector = 3.3 km Slide 3 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 3 CERN Portuguese Teachers Programme, 4 Sep 2009 energy per beam: 7 TeV luminosity: 10 34 cm -2 s -1 main dipoles field: 8 T current: 12 kA main magnets superconducting: 1200 D + 400 Q Slide 4 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 4 CERN Portuguese Teachers Programme, 4 Sep 2009 in all magnets +QRL: 10 000 cryogenic sensors & actuators super-fluid liquid He bath temperature: 1.9 K cryo distribution line feeding magnets every: 107 m Slide 5 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 5 CERN Portuguese Teachers Programme, 4 Sep 2009 support and cool Current Leads that power the magnets 5 000 instruments Slide 6 16 cavities grouped on 4 modules, on IP4 200 cryo instruments Slide 7 tunnel - radiation sector = 3.3 km alcoves - radiation free CERN Control Centre surface - local control room Ethernet Technical Network point-to-point cables 180 cryogenic CV without electronics 100 m CIET PVSS data server CRYO-SCADA PVSS data server 4x Profibus 1.5 Mbit/s 4x WorldFIP 1 Mbit/s 8 FEC WorldFIP Ethernet Gateway 500 ms cycle FieldBuses large distances industrial electronics protected areas CVs electronics moved into protected areas front-end electronics radTol custom made intelligent CV positioners with electronics 100 FIP crates custom rad-tol electronics 2 PLC Siemens S7-400 500 ms cycle 100 m Slide 8 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 8 CERN Portuguese Teachers Programme, 4 Sep 2009 2 000 sensors and actuators 100 FIP crates 2 Siemens S7-400 PLCs 500 Closed Control Loops 1 100 alarms & interlocks PLC cycle 500 ms 5 600 objects of 16 types 250 000 lines of SCL source code >3 Mbytes of machine code AND... the last 5 sectors were to be deployed at a rate of 1 new sector every 2 weeks Slide 9 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 9 CERN Portuguese Teachers Programme, 4 Sep 2009 17 055 instrumentation channels 1 738 Profibus components 798 FIP crates 855 cards 5 000 cable numbers specification files for manufacturing FIP Crates specifications for control software PLC, FEC, SCADA LHC Layout Database XML files for Mobile Test Bench cabling files for connecting & inspecting cables Slide 10 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 10 CERN Portuguese Teachers Programme, 4 Sep 2009 2d 1d 1h 0.5d Specs *.xls Specs *.xls Specs xls Proces Logic *.xls Proces Logic *.xls Process Logic Layout DBs Deployment Compilation Test Template Templates Code generationChecker Templates Code generation Slide 11 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 11 CERN Portuguese Teachers Programme, 4 Sep 2009 CIET for Instrumentation Experts CRYO-SCADA for operation 200 panels / sector 40 synoptics, 35 bar-graphs, 60 alarms & interlocks Repetitive panels use parameterized templates Parameters generator, directly from DB Slide 12 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 12 CERN Portuguese Teachers Programme, 4 Sep 2009 The control software production relies strongly on databases a set of databases and on automatic generation tools a package of automatic generation tools, which have been developed to create code in several steps, according to a well established methodology UNICOStoolsessential The UNICOS automated generation & checking tools proved to be essential for flexible and robust PLC code generation automatic code generation Thanks to extensive automatic code generation, we achieved reduced software-production time and effort increased code reliability minimised risk of human mistakes simplified long term maintenance 1 new sector every 2 weeks We managed to reach a deployment rate of 1 new sector every 2 weeks, while in parallel giving support and modifications on other operating sectors And Slide 13 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 13 CERN Portuguese Teachers Programme, 4 Sep 2009 At 10:28, one beam of protons was steered around the machine for the 1 st time Around 15:00 the other beam circulated in the second ring (anticlockwise) (http://cdsweb.cern.ch/journal/article?issue=39/2008&name=CERNBulletin&category=News%20Articles&number=1&ln=en) Slide 14 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 14 CERN Portuguese Teachers Programme, 4 Sep 2009 In Sector 3-4, during powering tests (without beam) at high current (9 KA) for 5 TeV a fault occurred in one electrical connection between magnets, resulting in mechanical damage and release of helium from the magnets into the tunnel. During the ramping-up of current, a resistive zone developed in the faulty connection An electrical arc punctured the L He enclosure, leading to a release/expansion of He into the insulation vacuum of the cryostats; the pressure-relief system was not able to contain the rise of the He pressure; large pressure forces displaced some magnets; several magnets were contaminated with dust; and had their multilayer insulation blankets damaged; (http://press.web.cern.ch/press/PressReleases/Releases2008/PR14.08E.html) Slide 15 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 15 CERN Portuguese Teachers Programme, 4 Sep 2009 http://cdsweb.cern.ch/record/1176912.flv Slide 16 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 16 CERN Portuguese Teachers Programme, 4 Sep 2009 Sector 3-4 was warmed and 53 magnets were taken to the surface for repair or cleaning New systems were installed, to ensure that similar incidents will not happen again: enhanced protection system, with more sensitive measurement of resistance (early detection of high-resistance, and quench, of electrical connections) new pressure relief system, with installation of extra relief valves (avoid high pressure to build inside the magnets) the anchoring of the LHC magnets to the floor was strengthened In all LHC sectors, 10 000 high-current superconducting electrical connections were tested: the ones with critically high resistance were repaired the remaining ones do not pose problem for safely running below 5 TeV (http://press.web.cern.ch/press/PressReleases/Releases2009/PR02.09E.html, PR06.09E.html, PR13.09E.html) Slide 17 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 17 CERN Portuguese Teachers Programme, 4 Sep 2009 After finishing cooling and electrical-tests on all sectors, the LHC beams will restart in Nov09; During a few weeks: Inject and capture proton beams in each direction, for a few days, take data for collisions at the injection energy (0.5 TeV), gradually increase energy up to 3.5 TeV per beam (= 1/2 nominal E); Run at 3.5 TeV to collect data and gain experience then, increase energy towards 5 TeV per beam; At the end of 2010: run with lead ions After that: shut down and do the necessary to have 7 TeV per beam in 2011 ( http://press.web.cern.ch/press/PressReleases/Releases2009/PR13.09E.html) Slide 18 Slide 19 Slide 20 TE / CRG / Paulo Gomes The Control System for the LHC tunnel cryogenics, p. 20 CERN Portuguese Teachers Programme, 4 Sep 2009 http://www.youtube.com/watch?v=fxJqVsQ6yjc.flv Slide 21