ToddProtection PDF

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Machlne roLecuon and lnLerlocks
CL8n AcceleraLor School - May 2014
Machlne
1v1 ben[amln.Lodd[cern.ch
CERN
ben[amln.Lodd[cern.ch
1o 1ake Away 1oday
* rlsk analysls ls a core parL of every englneer's Loolbox
- zero rlsk does noL exlsL
* speclcauon of proLecuon and lnLerlocks ls a compromlse
- Lhey don'L add Lo Lhe funcuon, buL are an lnsurance for when Lhlngs go wrong.
- Lhey do add Lo complexlLy, so wlll make Lhe sysLem less rellable.
* Lhe proLecuon conLexL ls vlLal
-need Lo conslder sysLem, machlne and organlsauonal level lmpacL
CERN
ConLenLs
1. 1he ConLexL - AcceleraLor Challenges
SLored 8eam Lnergy
SLored Magneuc Lnergy
2. 8lsk Analysls
SafeLy - roLecuon - lanL
owerlng roLecuon
lnLerlock lmplemenLauon
3. An Lxample 8eallsauon
8eam lnLerlock SysLem
lallure Modes LecLs and CrlucallLy Analysls
4. Murphy's Law - Lessons Learned 11 #2 3 4,5) /6) ")7 11
SepLember 2008
!anuary 2013
CERN
CL8n
CL8n AcceleraLor Complex
CMS
ALlCL
A1LAS
LPC-b
CERN
ben[amln.Lodd[cern.ch 6 of 43
LPC Magneuc Cycle
12 baLches from SS
(each 218 or 288 bunches)
=3 M! per baLch
energy ramp
23 M! Lo 360 M!
ln[ecuon phase
3 M! Lo 23 M!
CERN
SLored energy ln Lhe magneL clrculLs ls 9 C!
1echnologlcal Challenges
7
.1o see Lhe raresL evenLs.
LPC needs hlgh lumlnoslLy of 10
34
[cm
-2
s
-1
]
3 x 10
14
p per beam

. Lo geL 7 1ev operauon.
LPC needs 8.3 1esla dlpole elds wlLh clrcumference of 27 kms (16.3 mlles)

. Lo geL 8.3 1esla .
LPC needs super-conducung magneLs <2k (-271C)
wlLh an operauonal currenL of =13kA
cooled ln super uld hellum
malnLalned ln a vacuum

1 ppm
Lwo orders of magnlLude
hlgher Lhan oLhers
A magneL wlll CuLnCP
wlLh mllll!oule
deposlLed energy
SLored energy per beam ls 360 M!
parucle uence near machlne
= radlauon-LoleranL elecLronlcs
CERN
8
[11]
klneuc Lnergy of 200m 1raln aL 133 km/h = 360 M!
[2]
CERN
9
[11]
klneuc Lnergy of 200m 1raln aL 133 km/h = 360 M!
klneuc Lnergy of Alrcra Carrler aL 30 km/h = 9 C!
[3]
CERN
roLecuon luncuons
10
10-20x energy per magneL of 1LvA18Cn
magneL quenched = hours downume
many magneLs quenched = days downume
100x energy of 1LvA18Cn
Lmergency ulscharge MagneL Lnergy owerlng roLecuon:
8eam uump 8eam Lnergy 8eam roLecuon:
magneL damaged = $1 mllllon, monLhs downume
many magneLs damaged = many mllllons, many monLhs downume
0.000003 of beam losL lnLo a magneL = quench
0.003 beam losL lnLo magneL = damage
lallure ln proLecuon - compleLe loss of LPC ls posslble
CERN
roLecuon luncuons
11
8m long absorber CraphlLe =
800C
ConcreLe
Shleldlng
8eam ls 'palnLed'
dlameLer 33cm
[4]
CERN
roLecuon luncuons
12
1o proLecL agalnsL fasLesL fallure modes = 400 s over 27km
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CERN
Comparlson of LPC wlLh oLhers
powerlng ls spllL lnLo sub-secLors:
energy ln each clrculL manageable, allows for a sLaged commlsslonlng

[13]
[3]
CERN
SS LxperlmenL aL 430 Cev
ConLrolled SS experlmenL Lo quallfy slmulauons
AL 430Cev . 8x10
12
proLons causes damage
beam slze o
x/y
= 1.1mm/0.6mm
laLe 2mm Lhlck
6 cm
8x10
12
6x10
12
4x10
12
2x10
12
0.1 LPC lull 8eam Lnergy! 8eam ln LPC ls 10x smaller!!
[14]
[6]
CERN
8",9'-: 8.(')$/(9 ,9* ;,2)'0
CERN
16
[11]
vacuum
ressure
vacuum ump
Speed ConLrol
!"#$%&$ '()#*
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lulll operauonal requlremenLs
lanL SysLems:
vacuum Lxample:
malnLaln correcL pressure
CERN
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.,*/)*%&$
17
[11]
vacuum
ressure
vacuum ump
Speed ConLrol
vacuum
ressure
vacuum valve
AcLuaLor
Lnsure planL sLays wlLhln llmlLs
lanL roLecuon:
lanL SysLems:
vacuum Lxample:
malnLaln correcL pressure
bad pressure = close valves
CERN
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18
[11]
vacuum ump
Speed ConLrol
vacuum
ressure
vacuum valve
AcLuaLor
Sensors, AcLuaLors and rocess may be comblned
no rules regardlng comblnauon
MusL meeL funcuonal requlremenL
Lnsure planL sLays wlLhln llmlLs
lanL SysLems:
CERN
19
[11]
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Access
doors
8eam
absorbers
personnel safe
buL machlne aL rlsk
eople ln perlmeLer - sLop machlne
ersonnel SafeLy SysLem:
cannoL be merged wlLh planLs
MusL meeL legal requlremenL
CERN
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[11]
revenL damage Lo machlne
revenL undue sLress Lo componenLs
Machlne roLecuon SysLem:
no rules regardlng lmplemenLauon
CERN
21
[11]
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powerlng proLecuon closely
coupled Lo powerlng planL
revenL damage Lo machlne
revenL undue sLress Lo componenLs
no rules regardlng lmplemenLauon
CERN
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22
[11]
ersonnel SafeLy SysLem:
lanL SysLems:
danger wlll exlsL - prevenL - exLracL energy
danger exlsLs - proLecL - exLracL energy
CERN
So.
Lach of Lhese sysLems has a [ob Lo do.
LveryLhlng LhaL can malfuncuon, wlll evenLually malfuncuon.
repare for and accepL malfuncuon as normal".
lf Lhey malfuncuon, we are ln a Lough slLuauon
8ulld Lhe sysLems uslng a rlsk-based approach
e.g. SafeLy SysLems - lLC 61308 lnsplred
CERN
Cood undersLandlng of Machlne,
LqulpmenL and CperaLlons
Pazard Chaln ldenLlflcaLlon and Analysls
8lsk ClasslflcaLlon
8lsk 8educLlon ueLermlnaLlon
roLecLlon luncLlon SpeclflcaLlon
roLecLlon (Sub-)SysLem SpeclflcaLlon
lan:
hu 1hesls
lndlvldual SysLem 1esLs & Commlsslonlng
Machlne CheckouL & 8eam Commlsslonlng
CperaLlon
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lndlvldual SysLem
1esLs &
Commlsslonlng
Machlne CheckouL
& 8eam
Commlsslonlng
CperaLlon
roLecuon SysLem Llfecycle
[7]
CERN
Assess Lxlsung
ueslgn SysLem
sysLems lnvolved ln proLecuon are unlque
cerLaln Lechnologles used have never been Lrled on Lhls scale before
hlgh cosL of fallure

developmenL and analysls of machlne proLecuon as lf lL were a safeLy sysLem
worked example
ulpole MagneL roLecuon - <=>
[7]
CERN
Cood undersLandlng of Machlne,
LqulpmenL and CperaLlons
Pazard Chaln ldenLlflcaLlon and Analysls
8lsk ClasslflcaLlon
8lsk 8educLlon ueLermlnaLlon
roLecLlon luncLlon SpeclflcaLlon
roLecLlon (Sub-)SysLem SpeclflcaLlon
lan:
hu 1hesls
lndlvldual SysLem 1esLs & Commlsslonlng
Machlne CheckouL & 8eam Commlsslonlng
CperaLlon
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lndlvldual SysLem
1esLs &
Commlsslonlng
Machlne CheckouL
& 8eam
Commlsslonlng
CperaLlon
[7]
CERN
CERN
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MagneL
Cryogenlcs
ower ConverLer
LqulpmenL under ConLrol
[9]
CERN
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ower ConverLer
[9]
CERN
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134 ln serles
MagneL
Cryogenlcs
ower ConverLer
[9]
CERN
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- 8eslsuve zone appears ln a magneL
- l
2
8 losses begln
- Zone heaLs up
(heaL propagaLes Lo nelghbourlng magneLs)
- uamage Lo magneLs
Pazard Chaln: from Cuench Lo uamage.
?@A ln serles
[9]
CERN
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0"(1("2-(34
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- 8eslsuve zone appears ln a magneL
- l
2
8 losses begln
- Zone heaLs up
(heaL propagaLes Lo nelghbourlng magneLs)
- uamage Lo magneLs
Pazard Chaln: from Cuench Lo uamage.
WhaL roLecuon luncuons and roLecuon SysLems are ln place?
?@A ln serles
[9]
CERN
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when quench occurs. 1urn o ower ConverLer B CD.C") = E
ropagaLe Cuench = orange = 2
LxLracL Lnergy = purple = 3
Llnk 8elaLed ClrculLs = green = 1
[9]
CERN
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ower AborL
when quench occurs. 1urn o ower ConverLer = CD.C") = E
ropagaLe Cuench = (.,9F) = G
LxLracL Lnergy = purple = 3
[9]
CERN
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LxLracL Lnergy = CD.C") = E
[9]
CERN
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Lnergy LxLracuon
Loop
[9]
CERN
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when quench occurs. 1urn o ower ConverLer B CD.C") = E
ropagaLe Cuench B (.,9F) = G
LxLracL Lnergy B CD.C") = E
Llnk 8elaLed ClrculLs B F.))9 = ?
[9]
CERN
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CERN
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[9]
CERN
classlfy probablllLy and consequence uslng rlsk maLrlx
rlsk, lf funcuon dldn'L exlsL, accordlng Lo sysLem experLs.
!
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[9]
CERN
classlfy probablllLy and consequence uslng rlsk maLrlx
rlsk, lf funcuon dldn'L exlsL, accordlng Lo sysLem experLs.
!
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[9]
CERN
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CERN
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[9]
CERN
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requlremenLs
[9]
CERN
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requlremenLs
[9]
CERN
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CERN
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CERN
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CERN
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Pow do we quallfy a sysLem meeLs a level? Pow abouL programmable loglc?
[1]
CERN
So.
Lach of Lhese sysLems has a [ob Lo do.
LveryLhlng LhaL can malfuncuon, wlll evenLually malfuncuon.
repare for and accepL malfuncuon as normal".
lf Lhey malfuncuon, we are ln a Lough slLuauon = rlsky"?
8eallse funcuons uslng a hlgh-rellablllLy approach, deLermlne fallure raLes and modes
CERN
H9 IJ,6C") ;0-')6:
K#-% K)*D$/(9 L)5)" E
CERN
1he LPC 8eam lnLerlock SysLem
[8]
CERN
1he LPC 8eam lnLerlock SysLem
Plgh uependablllLy
Plgh SafeLy
Plgh 8ellablllLy
Plgh AvallablllLy
MalnLalnable
.[8lS] musL reacL Lo a slngle change ln uSL8 L8Ml1 by correcLly acuonlng Lhe relevanL
8LAM L8Ml1 wlLh a safeLy beer Lhan or equal Lo 8lsk 8educuon Level 3. Less Lhan 1 of
mlsslons musL be aborLed due Lo fallures ln Lhe 8eam lnLerlock SysLem..."
8lS has a dependablllLy speclcauon
[8]
CERN
88L3 or beer?? = lMLCA
lallure Modes, LecLs and CrlucallLy Analysls
ln whaL way can someLhlng go wrong?.
.when lL does go wrong, whaL happens Lo Lhe sysLem?.
.and [usL how much of a problem does Lhls cause?
[8]
CERN
lMLCA
lMLCA sLarLs aL Lhe ComponenL Level of a sysLem
geL subsysLem schemaucs, componenL llsL, and undersLand whaL lL does
8reak a large sysLem lnLo blocks, denlng smaller, manageable sub-sysLems
geL M18l of each componenL on Lhe llsL, derlve
lAlL
(mlsslon)
derlve fallure modes and fallure mode rauos for each componenL
explaln Lhe eecL of each fallure mode on boLh Lhe subsysLem and sysLem
deLermlne Lhe probablllLy of each fallure mode happenlng. uraw concluslons!
lMu-97
MlL-Pu8k-338
MlL-Pu8k-338
MlL-Pu8k-217
[8]
CERN
lMLCA
MlL-Pu8k-217l
or manufacLurer
lMu-97
MlL-Pu8k-338
8lll of MaLerlals
[8]
CERN
CERN, the LHC and Machine
Protection
36 of 29
lMLCA
ueslgner
knowledge
MlL-Pu8k-338
Schemauc
muluply Lhrough
[8]
CERN
uependablllLy vs. Congurauon
[8]
CERN
So.
lL's clear LhaL Lhls ls a huge amounL of work
Mlmlnlse Lhe number of sysLems whlch need Lhe hlghesL levels
Mlnlmlse Lhe parLs of Lhe sysLems whlch need any level aL all
SeparaLe crlucal funcuon from non-crlucal funcuon
CERN
+D.C40M- L,N O 8.,$/$," IJ,6C")
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CERN
!"
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Pazard Chaln had been ldenued ln lnlual sLages.

robablllLy classled as negllglble
8lsk 8educuon Level was Lherefore mlnlmum

lnsLallauon dld noL conform Lo slmulauons.
noL all clrculLs had been commlssloned Lo 3 1ev - llnal Maln ulpole ClrculL Commlsslonlng

LlecLrlcal laulL aL 3.2 1ev ln dlpole bus bar, beLween quadrupole and dlpole
osL-Analysls: 8 = 220 n, nomlnal = 0.33n
LlecLrlcal Arc developed and puncLured hellum enclosure
osL-Analysls: 400 M! dlsslpaLed ln cold-mass and arclng
Pellum 8elease lnLo Lhe lnsulaung vacuum
osL-Analysls: ressure wave caused mosL damage
CERN
Case 1: SepLember 2008
61
ulpole clrculL = maln bendlng magneLs
ulpole MagneL 133 ln serles
13kA (3ppm)
190v
ower ConverLer
CERN
62
Pellum 8aLh
1.9k = -273C = -436l
ulpole MagneL 133 ln serles
13kA (3ppm)
190v
ower ConverLer
ulpole clrculL = maln bendlng magneLs
CERN
63
Lscape ulode
lf magneL quenches = paLh for currenL MagneL roLecuon luncuon
CERN
64
!
Lscape ulode
Cuench ueLecLor
deLecLs magneL quench
CERN
63
!
Lscape ulode
Cuench ueLecLor
Lrlggers
Cuench PeaLer
spreads energy along magneL
CERN
66
!
Lscape ulode
Cuench ueLecLor
Lrlggers
Cuench PeaLer
spreads energy along magneL
Lnergy LxLracuon ClrculL
AcceleraLes sLored clrculL energy dlsslpauon
CERN
67
!
normal sequence..
CERN
68
!
CERN
69
!
13 kA forward currenL
100mP dlpole lnducLance

Slngle magneL energy = 8.3 Mega!oules
ClrculL magneL energy = 1.3 Clga!oules
7 1ev operauon:
mllll!oules = Cuench
CERN
70
!
Cuench! (L
0
)
CERN
71
!
Cuench! (L
0
)
Cuench ueLecLed (L
1
)
CERN
72
!
Cuench! (L
0
)
Cuench ueLecLed (L
1
)
Cuench PeaLer AcuvaLed (L
2
)
CERN
73
!
Cuench! (L
0
)
Cuench ueLecLed (L
1
)
2
)
CERN
74
Cuench ueLecLed (L
1
)
Cuench! (L
0
)
2
)
ower ConverLer SwlLched C (L
3
)
!
CERN
73
Cuench ueLecLed (L
1
)
Cuench! (L
0
)
2
)
3
) 8eam aborL (L
3
)
!
CERN
76
Cuench! (L
0
)
!
Cuench ueLecLed (L
1
)
2
)
3
) 8eam aborL (L
3
)
Lnergy LxLracuon SwlLches Cpened (L
3
)
CERN
77
!
Cuench! (L
0
)
Cuench ueLecLed (L
1
)
2
)
3
) 8eam aborL (L
3
)
3
)
ulode SLarLs Lo ConducL (L
4
)
CERN
78
Cuench! (L
0
)
Cuench ueLecLed (L
1
)
2
)
3
) 8eam aborL (L
3
)
3
)
ulode SLarLs Lo ConducL (L
4
)
ClrculL Lnergy ls ulsslpaLed (L
3
)
!
CERN
79
19
Lh
SepLember - commlsslonlng lasL clrculL Lo 3 1ev = 9kA forward currenL
!
CERN
80
19
Lh
! ! ! !
CERN
81
19
Lh
! !
CERN
82
19
Lh
! !
MagneL lnLerconnecL
CERN
MagneL roLecuon
83
MagneL lnLerconnecL
CERN
ldeal 13 kA Connecuon Scheme
Superconducung Cable
1ln - Sllver lolls
LongdlLudlnal vlew - lled wlLh Solder
Cross Secuon vlew
Superconducung
Cable
Copper
SLablllser
CERN
Cbserved lnLerconnecuons
CERN
MagneL roLecuon
86
CERN
lncldenL and ressure Wave
PT
QV QV QV QV QV SV SV
Cold-mass
Vacuum vessel
Line E
Cold support post
Warm Jack
Compensator/Bellows
Vacuum barrier
Q D D Q D D D Q D D D Q D D D Q D
1. ressure Wave propagaLes lnslde lnsulauon vacuum enclosure
2. 8apld ressure 8lse
Self acLuaung rellef valves could noL handle pressure
ueslgn: 2kg Pe/s lncldenL: 20 kg Pe/s
3. lorces on Lhe vacuum barrlers (every second cell)
ueslgn: 1.3 bar lncldenL: 8 bar
Several Cuadrupoles ulsplaced by 30 cm
Cryogenlc llne connecuons damaged
vacuum Lo aLmospherlc pressure
CERN
lncldenL locauon
ulpole 8us bar
CERN
CollaLeral uamage
Cuadrupole-dlpole lnLerconnecuon
Cuadrupole supporL
Maln uamage Area: 700m

39 dlpoles and 14 quadrupoles eecLed
moved Lo surface:
37 replaced and 16 repalred

CERN
MagneL roLecuon
90
! !
CERN
MagneL roLecuon
91
! ! !
lnLerconnecL lmpedance ls measured
Lnergy LxLracLed lf lmpedance unaccepLable
CERN
2009: LPC repalr and consolldauon
14 quadrupole magneLs
replaced
204 lnLerconnecuons
repalred
4km beam-Lube
cleaned
longlLudlnal resLralnlng
sysLem quadrupoles

900 porLs for hellum
pressure release
6300 new deLecLors and
230km cables for
new lnLerconnecL roLecuon SysLem
CollaLeral damage mlugauon
39 dlpole magneLs
replaced
CERN
H"6(-' H9('4).
+D.C40S- L,N #9 8.,$/$)
>,9D,.0 GQ?E
CERN
!"#$%
'"()$%*$%
+,$(-.
!%"*$-*/"(
!"#$%/(0
1(*$%2"-34
'%5"0$(/-4
6
7
8
9
quench LesLs forced a quadrupole magneL quench, all four proLecuon funcuons falled Lo acuvaLe
Slx monLhs earller a LhundersLorm Lrlpped several CS deLecLors
lqueL Leam needed Lo manually lnLervene Lo rearm
osL-Analysls: mlugauon of Lhls need by new rmware, plqueL dld noL lnLervene
llrmware updaLe was noL applled Lo Lhls parucular clrculL
osL-Analysls: ume and revalldauon pressure
Mlsslng rearm does noL prevenL Lhe clrculL from belng powered
ClrculL powered and unproLecLed for slx monLhs
LvenL was repeaLed as fallure of proLecuon funcuons was noL ldenued lmmedlaLely
lallure of Lhls naLure on dlpole clrculL represenLs mosL crlucal rlsk level for CL8n.

CERN
!"#$%
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CS proLecuon funcuons have Loo hlgh a 8lsk 8educuon Level

1. Cuallcauon of CS luncuons
2. Addluon of lndependenL Lnergy LxLracuon Loop SLudy
CERN
39 !(9$"D-#(9T
CERN
Comlng Soon.
2010 3.3 4 x 10
13
2.0 x 10
32
2011 3.3 2.0 x 10
14
3.6 x 10
33
2012 4 2.2 x 10
14
7.7 x 10
33
LS
1-2
=6.3 =3 x 10
14
=1 x 10
34
ear
eak Lnergy
[1ev]
eak lnLenslLy
[p]
eak LumlnoslLy
[cm
-2
s
-1
]
97
CERN
1o 1ake Away 1oday
* rlsk analysls ls a core parL of every englneer's Loolbox
- zero rlsk does noL exlsL
* speclcauon of proLecuon and lnLerlocks ls a compromlse
- Lhey don'L add Lo Lhe funcuon, buL are an lnsurance for when Lhlngs go wrong.
- Lhey do add Lo complexlLy, so wlll make Lhe sysLem less rellable.
* Lhe proLecuon conLexL ls vlLal
-need Lo conslder sysLem, machlne and organlsauonal level lmpacL
As englneers bulldlng power sysLems, you need Lo undersLand how Lhey wlll be used
CuallLauvely and quanuLauvely deLermlne how and how llkely Lhlngs are Lo go wrong
ln Lhe academlc - lndusLrlal world of PL, you cannoL LrusL only lL worked ln Lhe pasL"
Speclcally lf you ask how rellable ls Lhls" and Lhe reply ls greaL, lL never broke down yeL".
1ake a closer look.
CERN
U#9V
W4,9% X(DV
CERN
8eferences and lurLher 8eadlng
ConcepL developed ln collaborauon wlLh by M. ZerlauLh eL al. (CL8n) [1]
lcLure source: http://en.wikipedia.org/wiki/File:Alstom_AGV_Cerhenice_img_0365.jpg
Shared as: http://creativecommons.org/licenses/by-sa/3.0/deed.en
[2]
lcLure source: http://militarytimes.com/blogs/scoopdeck/2010/07/07/the-airstrike-that-never-happened/
Shared as: public domain
[3]
ulagram courLesy 8. Coddard, !. uyhoven eL al. (CL8n) [4]
LlvlngsLon ploL - courLesy 8. Assmann (ex CL8n), adapLed from:
hp://lndlco.cern.ch/evenL/113634/sesslon/7/conLrlbuuon/7/maLerlal/slldes/1.pdf
[3]
8ased on work from v. kaln eL al
hp://cds.cern.ch/record/838162/les/lhc-pro[ecL-reporL-822.pdf

[6]
h. u Lhesls - M. kwlaLkowskl CL8n
hp://cds.cern.ch/record/1632194/les/CL8n-1PLSlS-2013-216.pdf
[7]
h. u Lhesls - 8. 1odd CL8n
hp://cds.cern.ch/record/1019493?
[8]
Machlne roLecuon of 1he Large Padron Colllder aL CL8n
hps://leeexplore.leee.org/sLamp/sLamp.[sp?Lp=arnumber=6136929
[9]

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