Difference between revisions of "Solenoid Controls Redesign"

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'''To-do for solenoid controls redesign'''
 
'''To-do for solenoid controls redesign'''
 +
 +
 +
'''Obsolete...replaced by Fastrack schedule'''
  
  
 
* Recommendations from Director's Review (Electrical System and Quench Protection) and Lehman Review
 
* Recommendations from Director's Review (Electrical System and Quench Protection) and Lehman Review
−
** determine if cold diodes can increase quench detection - '''NO, Nov-2011'''
+
** determine if cold diodes can increase quench detection - '''No, Nov-2011'''
 
** add fast DAQ system prior to testing first coil - '''Done'''
 
** add fast DAQ system prior to testing first coil - '''Done'''
 
** add tests for internal shorts, shorts to ground and ground faults in coil and power supply to start-up sequence
 
** add tests for internal shorts, shorts to ground and ground faults in coil and power supply to start-up sequence
−
** add second dump circuit breaker
+
** add second dump circuit breaker - '''Not needed, Mar-2012'''
−
** add additional quench circuit diodes
+
** add additional quench circuit diodes - '''Not needed, Mar-2012'''
−
** add second quench detector (connected to second dump breaker)
+
** add second quench detector - '''PLC adequate as redundant QD - Mar 2012'''
 
** add center tap to dump resistor and monitor ground current in the PLC
 
** add center tap to dump resistor and monitor ground current in the PLC
 
** add UPS on dump breakers to avoid fast discharges
 
** add UPS on dump breakers to avoid fast discharges
Line 16: Line 19:
  
 
* Logbook research
 
* Logbook research
−
** check elog for all problems
+
** check elog for all problems - '''Done Mar-2012'''
  
  
  
 
* Infrastructure
 
* Infrastructure
−
** get fourth rack, install temporary wheels, bolt to other three racks
+
** get fourth rack - '''Done Nov 2011'''
−
** install computer and other equipment
+
** connect fourth rack to other three racks
 +
** procure and install computer in racks
  
  
Line 28: Line 32:
 
* Cryo system
 
* Cryo system
 
** need specs, new channels, new functionality, etc. from Jonathan - '''Done Dec 2011'''
 
** need specs, new channels, new functionality, etc. from Jonathan - '''Done Dec 2011'''
 +
** complete P&I diagram
 
** update mechanical/electrical interface drawing
 
** update mechanical/electrical interface drawing
 +
 +
 +
 +
* Vacuum system
 +
** design and create drawings
 +
** purchase and implement vacuum control system
  
  
  
 
* Wiring
 
* Wiring
−
** add new equipment
+
** add new equipment, modify for PXI system
 
** document trip chains
 
** document trip chains
 
** label circuit breakers
 
** label circuit breakers
−
** implement Sequence-Of-Events (SOE) module, need additional wiring and relays
+
** design and implement SOE circuits, need additional wiring and relays
 
*** prototype use of SOE module and relays in controls test stand - '''Done Dec-2011'''
 
*** prototype use of SOE module and relays in controls test stand - '''Done Dec-2011'''
−
** improve voltage range and eliminate cross-talk on voltage tap channels
+
** identify and connect to internal power supply trip chains where feasible
−
*** change connection scheme?
+
** improve voltage range and eliminate cross-talk on voltage tap channels '''Done Mar-2012 use PXI system'''
−
*** change current limiting scheme?
+
 
−
*** requirements:  fast vs slow, high vs low voltage, high vs low precision
+
−
*** 17+ voltage taps, at least two connections/tap, sometimes three
+
  
  
 
* Danfysik power supply
 
* Danfysik power supply
−
** use 435NBX to talk to power supply
 
 
** implement dump resistor center-tap ground fault detector
 
** implement dump resistor center-tap ground fault detector
 
** lockbox for door key  
 
** lockbox for door key  
 
** lock/tag/try procedures for dump resistor
 
** lock/tag/try procedures for dump resistor
 
** procedures to check for dump resistor integrity and diode polarity prior to startup
 
** procedures to check for dump resistor integrity and diode polarity prior to startup
−
 
+
** bring Danfysik techs out to upgrade/refurbish all old Danfysik supplies
 +
** do we have enough redundancy on overcurrent protection?
 +
*** Do we need shunt?  can we use zfct for redundancy?  use flux sensor?
  
  
Line 57: Line 67:
 
** need sub-coil inductances from Floyd/George - '''Done Dec-2011'''
 
** need sub-coil inductances from Floyd/George - '''Done Dec-2011'''
 
** modify QD for final configuration
 
** modify QD for final configuration
−
*** test imbalance range adjustment in lab
+
*** test imbalance range adjustment in lab '''Done Nov-2012'''
−
** do we need a second QD?  second technology?  do we need to design our own?  use PLC?
+
  
  
  
 
* Instrumentation
 
* Instrumentation
−
** implement system to isolate fault detectors and determine time sequence of trips
 
−
*** internal power supply faults
 
 
** implement RS232 connections to all devices (e.g. vacuum gauges)
 
** implement RS232 connections to all devices (e.g. vacuum gauges)
−
** Use RTI 435NBX instead of Point I/O serial modules
+
*** list from Mark - '''Done Dec-2011'''
−
** Replace shunt with flux-monitoring sensor
+
*** Use RTI 435NBX instead of Point I/O serial modules
 +
**** Check out RS485 instead of RS232
 +
*** Use RTI 490NBX for Ethernet/IP readout
 +
** replace shunt with flux-monitoring sensor '''Done Feb-2012 use CEBAF board readout of ZFCT'''
 +
** design and build breakout box
  
  
  
−
* NI fast DAQ
+
* NI PXI fast DAQ
−
** test new module
+
** test PXI system - '''Done Feb-2012'''
−
** purchase three more modules
+
** program and connect to PLC, EPICS
−
** connect to PLC, EPICS
+
  
  
  
 
* A-B PLC programming
 
* A-B PLC programming
−
** consider existing program a prototype, rework for 15-20 year lifetime
+
** consider existing program a prototype, rework for 15-20 year lifetime - '''Agreed Nov-2012'''
−
** send Josh to A-B training - '''Jan-2012'''
+
** send Josh to A-B training - '''Done Jan-2012'''
 
** use custom ("add-on") instructions to simplify everything
 
** use custom ("add-on") instructions to simplify everything
 
** use function block, structured text and ladder logic as appropriate
 
** use function block, structured text and ladder logic as appropriate
 
** add new channels, modify old ones according to latest channel assignments
 
** add new channels, modify old ones according to latest channel assignments
 +
*** connect to Cryo PLC via ControlNet
 +
*** SOE module
  
  
  
 
* A-B HMI improvements
 
* A-B HMI improvements
−
** fault sequence screens
+
** SOE fault sequence screens
 +
** other error screens
 
** Viewpoint
 
** Viewpoint
 
*** get screens on the web
 
*** get screens on the web
 
*** security?
 
*** security?
 +
 +
 +
 +
* Archiver
 +
** determine which channels need archiving
 +
** determine role of A-B vs EPICS archiver
  
  
Line 103: Line 122:
 
* EPICS
 
* EPICS
 
** new channels
 
** new channels
 +
*** generate channel lists, identify those that should be exposed as EPICS PV's, create EPICS database
  
  
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* UPS power
 
* UPS power
 
** solenoid controls racks
 
** solenoid controls racks
−
** Danfysik control circuits and contactor?
+
** Danfysik control circuits and contactor
−
** target? other cryo and vacuum systems?
+
** target
−
** cooling systems (dewpoint)?
+
** other cryo and vacuum systems?
 +
** FDC cooling systems (dewpoint)?
 +
** BCAL readout cooling system (dewpoint)?
 +
** CDC/FDC gas system?
 +
** network switches
 
** downtime due to power loss is deciding factor
 
** downtime due to power loss is deciding factor
  

Latest revision as of 11:11, 15 August 2012

To-do for solenoid controls redesign


Obsolete...replaced by Fastrack schedule


  • Recommendations from Director's Review (Electrical System and Quench Protection) and Lehman Review
    • determine if cold diodes can increase quench detection - No, Nov-2011
    • add fast DAQ system prior to testing first coil - Done
    • add tests for internal shorts, shorts to ground and ground faults in coil and power supply to start-up sequence
    • add second dump circuit breaker - Not needed, Mar-2012
    • add additional quench circuit diodes - Not needed, Mar-2012
    • add second quench detector - PLC adequate as redundant QD - Mar 2012
    • add center tap to dump resistor and monitor ground current in the PLC
    • add UPS on dump breakers to avoid fast discharges
    • perform Failure Modes and Effects Analysis (FMEA)


  • Logbook research
    • check elog for all problems - Done Mar-2012


  • Infrastructure
    • get fourth rack - Done Nov 2011
    • connect fourth rack to other three racks
    • procure and install computer in racks


  • Cryo system
    • need specs, new channels, new functionality, etc. from Jonathan - Done Dec 2011
    • complete P&I diagram
    • update mechanical/electrical interface drawing


  • Vacuum system
    • design and create drawings
    • purchase and implement vacuum control system


  • Wiring
    • add new equipment, modify for PXI system
    • document trip chains
    • label circuit breakers
    • design and implement SOE circuits, need additional wiring and relays
      • prototype use of SOE module and relays in controls test stand - Done Dec-2011
    • identify and connect to internal power supply trip chains where feasible
    • improve voltage range and eliminate cross-talk on voltage tap channels Done Mar-2012 use PXI system


  • Danfysik power supply
    • implement dump resistor center-tap ground fault detector
    • lockbox for door key
    • lock/tag/try procedures for dump resistor
    • procedures to check for dump resistor integrity and diode polarity prior to startup
    • bring Danfysik techs out to upgrade/refurbish all old Danfysik supplies
    • do we have enough redundancy on overcurrent protection?
      • Do we need shunt? can we use zfct for redundancy? use flux sensor?


  • Quench detector
    • need sub-coil inductances from Floyd/George - Done Dec-2011
    • modify QD for final configuration
      • test imbalance range adjustment in lab Done Nov-2012


  • Instrumentation
    • implement RS232 connections to all devices (e.g. vacuum gauges)
      • list from Mark - Done Dec-2011
      • Use RTI 435NBX instead of Point I/O serial modules
        • Check out RS485 instead of RS232
      • Use RTI 490NBX for Ethernet/IP readout
    • replace shunt with flux-monitoring sensor Done Feb-2012 use CEBAF board readout of ZFCT
    • design and build breakout box


  • NI PXI fast DAQ
    • test PXI system - Done Feb-2012
    • program and connect to PLC, EPICS


  • A-B PLC programming
    • consider existing program a prototype, rework for 15-20 year lifetime - Agreed Nov-2012
    • send Josh to A-B training - Done Jan-2012
    • use custom ("add-on") instructions to simplify everything
    • use function block, structured text and ladder logic as appropriate
    • add new channels, modify old ones according to latest channel assignments
      • connect to Cryo PLC via ControlNet
      • SOE module


  • A-B HMI improvements
    • SOE fault sequence screens
    • other error screens
    • Viewpoint
      • get screens on the web
      • security?


  • Archiver
    • determine which channels need archiving
    • determine role of A-B vs EPICS archiver


  • EWEB
    • create tag lists
    • security?


  • EPICS
    • new channels
      • generate channel lists, identify those that should be exposed as EPICS PV's, create EPICS database


  • UPS power
    • solenoid controls racks
    • Danfysik control circuits and contactor
    • target
    • other cryo and vacuum systems?
    • FDC cooling systems (dewpoint)?
    • BCAL readout cooling system (dewpoint)?
    • CDC/FDC gas system?
    • network switches
    • downtime due to power loss is deciding factor



Notes

  • max ramp rate in the hall is approximately 10V / 20H = 0.5 A/sec


Possible future improvements

  • monitor selected circuit breakers so operators can quickly find them when they trip
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