Solenoid Controls Redesign

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To-do for solenoid controls redesign


  • 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 - NO, Mar-2012
    • add additional quench circuit diodes - NO, Mar-2012
    • add second quench detector (connected to second dump breaker) - 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, install temporary wheels, bolt to other three racks - Done Nov 2011
    • install computer and other equipment


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


  • Wiring
    • add new equipment
    • document trip chains
    • label circuit breakers
    • implement Sequence-Of-Events (SOE) module, need additional wiring and relays
      • prototype use of SOE module and relays in controls test stand - Done Dec-2011
      • connect to internal power supply trip chains when 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


  • 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
      • 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
    • connect to PLC, EPICS


  • A-B PLC programming
    • consider existing program a prototype, rework for 15-20 year lifetime
    • 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
      • new cryo channels
      • 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?


  • EWEB
    • create tag lists
    • security?


  • EPICS
    • new channels


  • UPS power
    • solenoid controls racks
    • Danfysik control circuits and contactor
    • target? other cryo and vacuum systems?
    • cooling systems (dewpoint)?
    • 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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