1. Performance of RHIC Vacuum Instrumentation and Control
H.C. Hseuh and L.A. Smart
Collider-Accelerator Department
Brookhaven National Laboratory
April 11, 2005
Outline:
Description of RHIC Vacuum I & C
Performance and Reliability
Summary
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

2. RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

3. BNL Collider-Accelerator Vacuum Systems
3.8 km x 2, <10-10 Torr
150m, 10-8 Torr
~500m, 10-9 Torr
800m, ~1x10-8 Torr
200m, ~2x10-11 Torr
~900m, ~10-10 Torr
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

4. RHIC Vacuum Instrumentation
(Excludes ~ 800 vacuum devices for the injector chains)
~ 1600 Vacuum Devices w/ remote control and monitoring
Beam Vacuum Systems (Warm + Cold)
420 CCGs, 150 TCGs, 15 RGAs w/ E-M
170 SIPs, 320 TSPs
133 Sector Gate Valves
Insulating Vacuum Systems
130 CCGs, 230 TCGs, 76 RGAs w/ FC
~ 42 TMPs (with isolation valves, TCG, CCG, …)
Control and Monitoring
8 PLCs  4 FEC (VME Power PC)  CLC (Control Level Consoles)
~140 CCG Analog Signals to MADC (for fast logging)
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

5. Control Architecture Based on Programmable Logic Controller (PLC)
8 Allen-Bradley PLC 5-40E or 5-20E processors
2 Co-processor + expander sets in each PLC
OS-9 real-time operating system
RS-485 multi-drop serial interface ports for GC, IPC, RGA, TMP
< 5-second update time with ≤ 32 devices at each port
Inputs from GC and IPC set points
Outputs for valve interlock (thru 2 out of 3 set point voting scheme), Beam Permit Link (any valve closed), RF & Kicker interlocks
PC GUI at two locations w/ Data Highway links to all PLCs for diagnostics and downloading programs (independent of CLC)
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

6. Control Architecture –cont’d
Distributed PLC Control
Relieves CLC of low-level tasks - simpler software & hardware
Front-end computer (FEC)
4 VME based Power PC processors
100 Mb/s Ethernet links to CLC and PLC co-processors
Console Level Consoles (CLC)
Control & monitoring via spreadsheets, graphics, alarms
Data Logging and LogView
Elog for machine operations
Elog (e.g. Vacuum Elog) with each subsystem
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

7. RHIC Vacuum I&C System with RS-485 Networks
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

8. PLC, Co-Processors, I/O Modules
GC, IPC, TSP, PLC, PC/GUI, …
At service buildings
PLC, Co-Processors, I/O Modules
TMP w/ GC, SLC w/ RS485 serial link
TMP, CCG, TCG & Valves on Cryostats
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

9. LogView for diagnostics…
e.g. ∆P vs. I & bunch length
Most useful applications for Vacuum
Spreadsheets Live monitoring and control, open architecture, no password
Logging & View from minutes to 720 Hz with synchronized time stamps; compare ∆P with other machine variables with ~msec resolution
Vacuum ELog Vacuum maintenance and operation details entered by technicians and staff for diagnostics and archives
Graphic Display 2-D, 3-D, waterfall…
Bunch Length
IR10 Pressure rise
IR2 Pressure rise
Fill 5160
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

10. Spreadsheet for Turbopump Operation
Spreadsheet for RGA Operation
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

11. Performance and Reliability of Vacuum PLC and Controls Interfaces
8 PLC, Processors & BPL – very reliable for machine operation, device I/L…
PLC and GC are backed by UPS, IPC backed by Generators
14 Co-processors - hung several times a week, but does not affect beam
Communication errors? Resulted in no logged data,
Remote soft reset (close/open ports)
Some required local manual reset
Must be checked daily
Common software for all subsystems at control console
Spreadsheet, Graphic Display, Alarm…
LogView allows comparison with other machine parameters
Machine ELog and Vacuum ELog – detailed archives for diagnostics
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

12. Performance and Reliability of Vacuum Devices
GC, CCG - < 3% failure per yr
HV cards (thermistors ➱ abnormal readings)
CC gauges (neon bulbs, ➱ no ion current)
IPC - ~ 5% failed in 2003, less in 2004
HV cards, chassis
TMP - In-house designed Station Logic Controller
Possible radiation–induced errors ~ once a week (FIV, PIV closed)
Some need ring access for reset
RGA - Single filament, custom software, 6 masses only
~ 5% filament failure per yr
Hardware and software are no longer supported by vendor
TSP - In-house design to accommodate long cable run
With local step-up (I) transformer, manual operation
Remote capable, but not implemented
SGV - ~ 5% faulted (momentarily) in 2004, resulted in BPL faults
Stuck open due to corrosion in solenoid
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

13. Summary
Reliability of RHIC Vacuum Instrumentation are much better than other sub-systems over the last five years
PLC based control has worked reliably for vacuum and machine protection
Coprocessor RS485 interface is susceptible to communication errors
Results in lost data
Update time of > seconds per port
Augmented with analog signals to MADC for fast (msec) logging
Identical GC, CCG and TCG for beam and insulating vacuums
CCG neon bulb disconnected during bakeout
Conversion kit is available but expensive
IPC works relatively well
Repair delays due to custom products
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland

14. Considerations for the Future
CCG - Buy gauges designed for operation at bakeout temperatures
IPC, GC - Buy off-the-shelf controllers to avoid repair delays for custom units
PLC - Include analog inputs for fast gauge monitoring
TMP – Any commercial turn-key stations with integrated valves and gauges?
RGA – Dual filaments
Avoid custom software and interfaces
TSP - Any commercial units for long cable run (with local transformer?)
With remote control?
SGV – Corrosion resistant solenoids?
RHIC Vacuum I&C
Hseuh & Smart
April 11-12, 2005
OLAV I, Geneva, Switzerland