Fermilab Control System (“ACNET”) J. Patrick February 17, 2005.
The Fermilab Control System Jim Patrick - Fermilab CERN AB Seminar October 5, 2006.
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Transcript of The Fermilab Control System Jim Patrick - Fermilab CERN AB Seminar October 5, 2006.
The Fermilab Control System
Jim Patrick - FermilabCERN AB Seminar
October 5, 2006
October 5, 2006 Fermilab Control System - CERN AB Seminar 2
Outline
Accelerator Complex Overview Control System Overview Selected Control System Features Migration Efforts Summary
Fermilab Accelerator Complex
J. Patrick
September 19, 2006
NUMI
Recycler
miniBooNE
Tevatron
Main Injector
Linac
Booster
pbar
Fixed Target
e-cool
October 5, 2006 Fermilab Control System - CERN AB Seminar 4
Fermilab Accelerator Complex
400 MeV Linac (up to 15 Hz) 8 GeV Booster Synchrotron (up to 15 Hz) 120 GeV Main Injector Synchrotron (~0.5 Hz) 980 GeV Tevatron Superconducting Synchrotron/Storage
Ring 8 GeV Debuncher/Accumulator for antiproton production 8 GeV “Recycler” for antiproton accumulation (same
tunnel as MI) with electron cooling
October 5, 2006 Fermilab Control System - CERN AB Seminar 5
Operating Modes
1.96 TeV proton-antiproton collider (24-30 hour stores) 8 GeV fixed target from booster (miniBooNE) - ~5 Hz 120 GeV fixed target from Main Injector - ~1/minute 120 GeV fixed target for NUMI (~0.5 Hz) 120 GeV from MI for pbar production (0.25 – 0.5 Hz)
Cycles interleaved Main Injector load contains batches for both NUMI and
pbar
October 5, 2006 Fermilab Control System - CERN AB Seminar 6
The Run II Challenge
Operate the Tevatron collider at > 10 x the luminosity of the previous (1992-6) run (began Mar 2001) Collider stores + pbar production Incorporate Recycler ring (May 2004)
With Electron cooling (July 2005)
Operate miniBooNE - (Dec 2001) Operate 120 GeV fixed target (Feb 2003) Operate NUMI high intensity neutrino beam (Dec 2004) Get all this working, all at the same time Meanwhile modernize the control system without affecting
commissioning and operation of the above Simultaneous collider and fixed target operation new to
Fermilab
October 5, 2006 Fermilab Control System - CERN AB Seminar 7
Outline
Accelerator Complex Overview Control System Overview Selected Features Migration Efforts Summary
October 5, 2006 Fermilab Control System - CERN AB Seminar 8
Control System Overview
Known as “ACNET” Unified control system for the entire complex
All accelerators, all machine and technical equipment Common console manager can launch any application Common software frameworks Common timing system
Three-tier system Applications Services Front-ends
Distributed intelligence Enabled by front-ends, special hardware System is tolerant to high level software disruptions
October 5, 2006 Fermilab Control System - CERN AB Seminar 9
Control System Overview
ConsoleApplications
CentralServices
IRMFront-Ends
JavaApplications
WebApplications
MOOCFront-Ends
LabviewFront-Ends
Open AccessClients
Field Hardware
ethernet
Database
CAMAC, VME, PMC, IP, Multibus, CIA, GPIB, …
field bus: VME, SLD, Arcnet, ethernet, …
Servlets ConsolidatorsCentral
Front-End
>500
120
70+70+
Application
October 5, 2006 Fermilab Control System - CERN AB Seminar 10
ACNET History
Originally developed for Tevatron in early 80’s Substantial evolution over the years CAMAC field hardware -> very broad diversity
Major modernization in the 90’s
PDP-11/Mac-16 front-ends -> x86 Multibus -> PPC VME DEC PCL network-> IEEE 802.5 token ring -> ethernet VAX database -> Sybase PDP-11 applications -> VAXstations
VAX only through 2000 Java framework, port to Linux since then
October 5, 2006 Fermilab Control System - CERN AB Seminar 11
Device Model
Maximum 8 character device names e.g. T:BEAM for Tevatron beam intensity Informal conventions provide some rationality More verbose hierarchy layer created, but not utilized/maintained
Each device has one or more of a fixed set of properties: Reading, setting, analog & digital alarms, digital status & control
Device descriptions stored in central Sybase database Monotype data, arrays are transparently supported Mixed type structures done, but support not transparent
Application (library) layer must properly interpret the data from the front-end and perform required data translations
~200,000 devices/350,000 properties in the system
October 5, 2006 Fermilab Control System - CERN AB Seminar 12
ACNET Protocol
Custom protocol used for intra-node communication Layered, task directed protocol developed in early 80’s
Old, but ahead of its time Currently uses UDP over ethernet
Timeout/retry mitigates UDP unreliability Very little packet loss in our network
Get/Set devices Single or repetitive reply; immediate, periodic, or on clock event Multiple requests in single network packet
Fast Time Plot (FTP) Blocks of readings taken at up to 1440 Hz returned every 0.5 sec.
Snapshot Block of 2048 readings taken at an arbitrary rate
October 5, 2006 Fermilab Control System - CERN AB Seminar 13
ACNET Protocol
Has proven to be very reliable, robust, scalable and extensible protocol for many years For example, new GET/SET protocol adds precise time stamps,
collection on event+delay, states, larger device address space
Main weakness is lack of transparent mixed type support But this is often done manually
Difficult to program, but high level API hides details Difficult to port to new platforms but has been done
October 5, 2006 Fermilab Control System - CERN AB Seminar 14
Timing and Control Networks
TCLK (Clock Events) Trigger various actions in the complex Dedicated 10 MHz serial network 256 possible events defined for the complex Includes 1 Hz GPS time sync
MDAT (Machine Data) General mechanism for rapid data transfer 36 slots updated at 720 Hz
Beam Sync – revolution markers derived from RF States – discussed later Both TCLK and MDAT are multicast at 15 Hz for central
layer processes that don’t require hard real-time response
October 5, 2006 Fermilab Control System - CERN AB Seminar 15
Application Environment
Console environment VAX based; Now mostly ported to Linux Integrated application/graphics/data access architecture C language (+ legacy FORTRAN)
Java environment Platform independent; Windows/Sun/Linux/Mac all utilized Full access to entire control system
Both environments have a standard application framework that provides a common look and feel
All applications launched from “Index Pages” Separate for Console, Java environments Tightly managed code in both environments
Also some web browser applications of varying styles
October 5, 2006 Fermilab Control System - CERN AB Seminar 16
Index Page
October 5, 2006 Fermilab Control System - CERN AB Seminar 17
Parameter Page
October 5, 2006 Fermilab Control System - CERN AB Seminar 18
Device Database GUI
October 5, 2006 Fermilab Control System - CERN AB Seminar 19
Synoptic Display (Web)
Drag&Drop Builder
Uses AJAX technology
October 5, 2006 Fermilab Control System - CERN AB Seminar 20
Alarms
Front-ends post (push) alarmsto central server for distributionand display
October 5, 2006 Fermilab Control System - CERN AB Seminar 21
Central Layer
Database Open Access Clients (“virtual front-ends”) Java Servlets
Bridge device requests from outside firewall and for web apps
Request Consolidation Requests from different clients consolidated to a single request to
the front-end
Alarms server Front-end download
Load last settings on reboot
October 5, 2006 Fermilab Control System - CERN AB Seminar 22
Database
Central Sybase database Three parts:
All device and node descriptions Application information
Used by applications as they wish Save/Restore and Shot Data database
MySQL used for data loggers Data volume too high for Sybase Not for general application use
Many older programs still use central “file sharing” system
October 5, 2006 Fermilab Control System - CERN AB Seminar 23
Open Access Clients (OACs)
“Virtual” front-ends Obey same ACNET communication protocol as front-ends
Several classes: Utility – Data loggers, scheduled data acquisition, virtual devices Consolidate devices across front-ends into single array Calculations – Both database driven and custom Process control – Pulse to pulse feedback of fixed target lines Bridges – to ethernet connected scopes, instrumentation, etc.
Easy access to devices on multiple front-ends Friendlier programming environment than VxWorks front-ends
Framework transparently handles ACNET communication Access to database, other high level operating system features Do not provide hard real-time response; clock events by multicast > 100; Almost all run in Java framework
October 5, 2006 Fermilab Control System - CERN AB Seminar 24
Front-Ends
MOOC – Minimally Object-Oriented Communication Very wide diversity of functionality Processors all VME (VXI) based
Very wide diversity of field hardware supported - CAMAC, Multibus, VME, VXI, CIA, ethernet attached instruments, etc.
VxWorks Operating System ~325 in the system
IRM – Internet Rack Monitor Turnkey system with 64 channel ADC + DAC + Digital I/O PSOS operating system ~125 in the system
Labview – Used for one or few of a kind instrumentation A front-end to the control system; only experts use Labview GUI
October 5, 2006 Fermilab Control System - CERN AB Seminar 25
Outline
Accelerator Complex Overview Control System Overview Selected Features Migration Efforts Summary
October 5, 2006 Fermilab Control System - CERN AB Seminar 26
Sequencer Overview
The Sequencer is an accelerator application which automates the very complex sequence of operations required to operate the collider (and other things)
Operation divided into “Aggregates” for each major step “Inject Protons”, “Accelerate”, etc.
Aggregates are described in a simple command language Easily readable, not buried in large monolithic code Easily modified by machine experts No need to compile/build etc.
The sequencer program provides an editor to assist writing aggregates Pick from list of commands
Aggregate descriptions are stored in the database
October 5, 2006 Fermilab Control System - CERN AB Seminar 27
Tevatron Collider Operation
Proton Injection
porch
Proton Injectiontune up
Inject Protons
Eject Protons
Inject Pbars
PbarInjection
porch
BeforeRamp
Flattop
Acceleration
Squeeze InitiateCollisions
Remove Halo
HEP
Pause HEP
ProtonRemoval
Unsqueeze
Deceleration
Extractionporch
Extract Pbars
Cogging
Recovery
Ramping
Flattop2
Reset
October 5, 2006 Fermilab Control System - CERN AB Seminar 28
Sequencer Overview
Each Aggregate contains a number of commands Set, get, check devices Wait for conditions Execute more complex operations implemented as ACL scripts or
specially coded commands Start regular programs (for example TeV injection closure) Start plots Send data to shot log …
The Sequencer program steps through the commands Stops on error Allow operator to restart at failed command
Fermilab sequencer is not a formal finite state machine It is not just for collider operations
Configure other parts of complex, studies
October 5, 2006 Fermilab Control System - CERN AB Seminar 29
Sequencer GUI
Inject Protons
October 5, 2006 Fermilab Control System - CERN AB Seminar 30
Sequencer Overview
The Fermilab complex employs “distributed intelligence” Separate sequencer instances for TeV, MI, pbar, recycler Lower level programs control complex operations such as
collimator movement for scraping Sequencer just issues high level control commands
Waveforms preloaded to ramp cards, triggered by clock events
“States” concept used to provide synchronization
October 5, 2006 Fermilab Control System - CERN AB Seminar 31
States
ACNET devices owned by STATES OAC process When a state device is set, it is reflected to the rest of the
control system by the STATES process Multicast Registered listeners
Thus can be used to trigger actions, do synchronization Condition persists in time unlike clock events Examples
Collider State Inject Protons, Inject pbars, Accelerate, HEP, etc.
Collimators – Commands for collimator movement Go to Init; Remove Halo, Retract for Store
Wire scanner profile calculation complete
October 5, 2006 Fermilab Control System - CERN AB Seminar 32
Waveform Generators
Magnets need to do different things at different times in the machine cycle
Rather than redownload on each cycle, custom function generator cards that preload up to 32 waveforms are used Correct one for a part of the cycle triggered by clock event Waveforms are functions of time and MDAT frame values On board processor does smooth interpolation
Thus waveforms need not be downloaded at each phase of the machine cycle Enhances reliability Reduced dependence on high level software in stable operation
October 5, 2006 Fermilab Control System - CERN AB Seminar 33Clock events
Clock Events and Waveform Generators
Example of preloaded hardware triggered by clock events
October 5, 2006 Fermilab Control System - CERN AB Seminar 34
Clock events
Time table Energy table Squeeze table
All three tables play simultaneously
Details of a Waveform Generator
October 5, 2006 Fermilab Control System - CERN AB Seminar 35
Finite State Machine (Java)
Graphical Drag&Drop Builder State machine description
stored in database FSM OAC runs machines Viewer application for control
and monitoring Primary current usage is e-cool
Pelletron control Keeps track of HV sparks and
beam related trips Automates recovery sequence
More formal state machine than sequencer, perhaps less scalable
October 5, 2006 Fermilab Control System - CERN AB Seminar 36
SDA
Sequenced Data Acquisition – Shot Data Analysis Record data at each step in collider operation in dedicated
database Compute and track injection efficiencies, emittance
growth, luminosity, … Variety of tools to extract, analyze data
Web reports created in real time “Supertable” summary – web page + Excel spreadsheet Many predefined plots available on the web SDA Viewer – spreadsheet like Java application SDA Plotter – plot snapshots and fast time plots Java Analysis Studio input module Java API for custom programs
October 5, 2006 Fermilab Control System - CERN AB Seminar 37
SDA Reports
October 5, 2006 Fermilab Control System - CERN AB Seminar 38
Data Loggers – aka “Lumberjack”
70 instances running in parallel on individual central nodes Allocated to departments to use as they wish, no central
management. Continual demand for more ~48,000 distinct devices logged
Rate up to 15 Hz or on clock or state event (+ delay)
80 GB storage per node in MySQL database Stored in compressed binary time blocks in the database Keyed by device, block start time Circular buffer; wraparound time depends on device count/rates
Data at maximum 1 Hz rate extracted from each logger to “Backup” logger every 24 hours Currently 850 million points extracted per day Backup logger is available online => data accessible forever
October 5, 2006 Fermilab Control System - CERN AB Seminar 39
Data Loggers
Logger tasks are Open Access Clients Reads via logger task rather than direct database access
Variety of retrieval tools available Standard console applications, Console and Java environments Web applications Java Analysis Studio programmatic APIs
Retrieval rates typically ~10-30K points/second
October 5, 2006 Fermilab Control System - CERN AB Seminar 40
Data Logger Plots
October 5, 2006 Fermilab Control System - CERN AB Seminar 41
Security
Limit access to the control system Control system network inside a firewall with limited access in/out
Limit setting ability Privilege classes (roles) defined Roles assigned to users, services, nodes Devices tagged with map of which roles may set it Take logical and of user/service/node/device mask
Allows fine grained control, but in practice Device masks allow all roles to set; flat device hierarchy tedious… A limited number of roles are actually used
Applications outside MCR start with settings disabled Settings must be manually enabled. Times out after some period
Applications started outside MCR exit after some time limit
October 5, 2006 Fermilab Control System - CERN AB Seminar 42
Remote Access
Console environment via remote X display Settings generally not allowed
Java applet version of console Java apps can be launched from anywhere via Webstart
Access to inner parts of control system only via VPN Servlets provide read access for some applications “Secure Controls Framework” – Kerberos authentication for low
level communication – allows read access outside firewall
Access from outside standard application environments: xml-rpc protocol used; bindings to many languages Readings of any device; setting of select “virtual” devices No setting of hardware associated devices Used by all current experiments; both fetch and input data
October 5, 2006 Fermilab Control System - CERN AB Seminar 43
Accountability
Considerable usage information is logged Who/what/where/when Most reports web accessible
Settings Errors – reviewed each morning Database queries Device reads from Java clients Application usage Clock (TCLK) events State transitions
October 5, 2006 Fermilab Control System - CERN AB Seminar 44
Minimize Restarts
Minimize need to restart parts of the system: Changes to the device or node database are multicast to the
control system, they do not need to be restarted to pick these up For many front-ends devices can be added without a reboot
When something is restarted, minimize what else must be restarted Restarts set state transition Monitor (periodic) requests automatically reestablished Application automatically recovers middle layer restart
October 5, 2006 Fermilab Control System - CERN AB Seminar 45
Redirection
The console manager may cause I/O requests to be redirected from the normal hardware.Possibilities alternatives are:
An OAC process A default “MIRROR” process reflects settings into readings
A Save file An SDA file This allows testing basic functionality of some applications
without risk This provides a potentially good framework for integrating
accelerator models, but hasn’t been done…
October 5, 2006 Fermilab Control System - CERN AB Seminar 46
Some Issues…
Short device names, no hierarchy Structured device properties not transparent Old fashioned GUI in console environment Lack of standard machine configuration description Lack of integration with models Lack of integration with Matlab and related tools Weak inter-front end communication Specific to Fermilab environment, no attempt at portability
October 5, 2006 Fermilab Control System - CERN AB Seminar 47
Outline
Accelerator Complex Overview Control System Overview Some Selected Features Migration Efforts Summary
October 5, 2006 Fermilab Control System - CERN AB Seminar 48
Migration Strategy
By the late 90’s VAXes had been eliminated from Fermilab except in the accelerator control system
Some migration strategy was essential CDF/D0 run until ~2006-8; BTeV until ~2012+ (since cancelled)
Strategy would have to be incremental Not possible to replace the entire control system in one shutdown Should be possible to replace a single application at a time
New and old parts would have to interoperate Should require no or minimal changes to front-ends
Most of these had been migrated from Multibus/i386/RTOS to VME/PPC/VxWorks in the 90’s
Implied that ACNET protocol would remain primary communication mechanism
October 5, 2006 Fermilab Control System - CERN AB Seminar 49
Migration Plan
Architecture developed using the Java language Multi-tier
Applications Data Acquisition Engines (middle layer) Front-ends (unmodified)
Applications divided into thin GUI client with business logic in DAE. Predated J2EE and related ideas Communication via Java RMI Drifted back to heavy client, DAE only does device access
Open Access Clients running in DAE (same Java virtual machine)
Device request consolidation across all Java clients
October 5, 2006 Fermilab Control System - CERN AB Seminar 50
Java Migration Progress
Required infrastructure was created prior to 2001 run start ACNET protocol DAE framework OAC framework Device access library Database access library Application framework Etc.
SDA implemented; continually evolved to meet needs Data acquisition Analysis tools
Most VAX OACs converted to Java and new ones written Java versions of many utility applications written
October 5, 2006 Fermilab Control System - CERN AB Seminar 51
Java Migration
SDA has been very successful in tracking performance of the accelerators
Data loggers had greatly expanded capacity and rate capability, this has been valuable
Ease of creating new OACs has been valuable Much more information is now available over the web Some machine applications have been written, but
machine departments did not in general embrace the Java application framework Some key Tevatron applications done Extensive operational usage in electron cooling Pbar source department also has many expert Java applications
October 5, 2006 Fermilab Control System - CERN AB Seminar 52
Java Application Migration Issues
Accelerator performance a higher priority Number of active applications badly underestimated Authors of many applications long gone Long transition period in division management Development environment much more difficult than VAX
Two-tier framework; device access API, development environment These issues were mostly corrected but late
Separate console managers, not easy to merge Primitive graphics => fast; fast application startup “If the Java application works differently, I don’t want to
learn how to use it.” “If the Java application works the same, then why should I
use it?”
October 5, 2006 Fermilab Control System - CERN AB Seminar 53
Console Migration to Linux
In the fall of 2003, a division wide group was formed to assess the strategy for controls migration
The base of active applications was determined to be much larger then generally believed; more than 800
Porting all of these to Java with the resources available, while operating and upgrading the accelerator complex was deemed impractical
A port the VAX console infrastructure and all active VAX applications to Linux was initiated in ~March 2004
The Java framework continues to be supported and new applications written using it. Nothing backported!
October 5, 2006 Fermilab Control System - CERN AB Seminar 54
Linux Migration Phases
Phase I Console infrastructure ACNET communication protocol Core libraries Emulate VAX development environment (MECCA) ~1M lines of code Done entirely by controls department
Phase II Applications Done incrementally, not en masse In practice, most porting done by controls department personnel Some porting and extensive testing done by other departments
Phase III Remaining VAX services
October 5, 2006 Fermilab Control System - CERN AB Seminar 55
Linux Port
Much harder than anticipated Large volume of code - ~3.5M non-comment lines Extensive interdependencies – Primary/Secondary
application communication K&R C -> ANSI C++
C++ compiler required for variable argument capability Stricter compiler did catch some actual bugs Insisted all compiler warnings be addressed
Extensive use of VAX system services “BLOBs” in the database and in flat files and over network
Floating point issues Structure alignment issues
October 5, 2006 Fermilab Control System - CERN AB Seminar 56
Port Mechanics
Scripts developed to make many changes automatically Required manual changes flagged
Nightly builds with detailed web accessible reports Liason assigned from each department for Phase II Database developed with information on each application
Sensitivity to operations assigned to each application Status – imported, compiles, builds, all manual issues addressed,
initializes, tested, certified, default Linux
Testing of sensitive applications requires scheduling Certification of sensitive applications requires keeper +
department liason + operations sign-off Dual hosted console manager developed that runs
applications on correct platform (maintained in database)
October 5, 2006 Fermilab Control System - CERN AB Seminar 57
Application Tracking
October 5, 2006 Fermilab Control System - CERN AB Seminar 58
Status
Applications Certified
Phase I completed ~late 2005
Phase II expected to be complete by end of 2006
Linux usage in operations began at end of shutdown in June 2006
Very modest impact on operations. No lost collider stores!
Phase III expected to be complete by mid 2007 (next shutdown)
Begin Beam Operation
October 5, 2006 Fermilab Control System - CERN AB Seminar 59
Modernizing BPMs and BLMs
BPMs in Recycler, Tevatron, Main Injector, Transfer Lines Performance issues Obsolete hardware technology Need for more BPMs in transfer lines Replaced with a digital system using Echotek VME boards
Beam Loss Monitors in Tevatron and Main Injector Obsolete hardware technology Additional features needed with more beam in MI, Tevatron Replaced with new custom system (still in progress)
All were replaced in a staged manner without interruption to operations Library support routines provided common data structure for both
old and new systems during the transition period Enormous improvement in performance and reliability
October 5, 2006 Fermilab Control System - CERN AB Seminar 60
Outline
Accelerator Complex Overview Control System Overview Some Selected Features Migration Efforts Summary
October 5, 2006 Fermilab Control System - CERN AB Seminar 61
Collider Peak Luminosity
October 5, 2006 Fermilab Control System - CERN AB Seminar 62
Collider Integrated Luminosity
Recent observation of Bs mixing by CDF
October 5, 2006 Fermilab Control System - CERN AB Seminar 63
NUMI Performance
Total NuMI Protons Starting 3 Dec 2004
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date
pro
ton
s (
xE
17
)
Best current measurement of neutrino oscillationdespite problems with target, horn, etc.
October 5, 2006 Fermilab Control System - CERN AB Seminar 64
MiniBooNE Performance
October 5, 2006 Fermilab Control System - CERN AB Seminar 65
Accelerator Future
Tevatron collider is scheduled to run for ~3 more years Emphasis for complex will then be neutrino program
Recycler + pbar accumulator get converted to proton stackers for NUMI – up to ~1 MW average beam power
NOA experiment approved – 2nd far detector in Minnesota
ILC accelerator test facilities under construction These will not use ACNET but instead probably some combination
of EPICS and the DESY DOOCS system used at TTF Strategy not yet determined – broad collaborative facility Some interoperation efforts with EPICS; bridge in middle layer
Evaluating EPICS 4 “Data Access Layer” (DAL)
October 5, 2006 Fermilab Control System - CERN AB Seminar 66
Java Parameter Page/EPICS Devices
October 5, 2006 Fermilab Control System - CERN AB Seminar 67
Summary
The control system has met the Run II Challenge Accelerator complex has gone well beyond previous runs in
performance and diversity of operational modes Unified control system with solid frameworks and distributed
intelligence was instrumental in this success
During accelerator operation the control system has been substantially modernized Incremental strategy essential It is difficult to upgrade a large system while operating! It is difficult to get people to upgrade a system that works! The control system will finally be VAX-free at the next major
shutdown currently scheduled for June, 2007 Control system will be viable for the projected life of the complex