Summary
GTD has been awarded the contract to upgrade the LIPAc Machine Protection System (MPS), delivering a turnkey solution based on NI cRIO technology that meets IEC 61508/61511 safety standards. This project enhances fast response times, robustness, and flexibility for Beam Inhibition interlocks, ensuring LIPAc’s operational safety and uptime.
Overview
- Scope: Design, procurement, installation, and commissioning of a modern MPS using COTS NI cRIO controllers.
- Architecture: Modular NI cRIO chassis with deterministic real-time performance, redundant power supplies, and safety-rated I/O modules deployed in industrial enclosures.
- Safety Compliance: All hardware and software components are selected and validated to achieve SIL targets in accordance with IEC 61508/61511, covering interlock functions related to Beam Inhibition.
- Integration: Custom rack-mount panels and cable harnesses interface with LIPAc’s existing beamline sensors, actuators, and control cabinets, ensuring seamless connectivity and maintainability.
GTD’s Role
- System Design & Procurement
- Developed detailed Safety Requirements Specifications (SRS) and defined SIL levels for all interlocks.
- Selected NI cRIO hardware—chassis, RIO modules, and safety I/O—to withstand LIPAc’s environmental conditions.
- Produced custom enclosures, rack panels, and cable harnesses to integrate seamlessly with existing control infrastructure.
- Software Development & Validation
- Implemented real-time interlock logic in LabVIEW Real-Time to continuously monitor beam current, vacuum levels, and magnet statuses, ensuring inhibition commands execute in under 10 ms.
- Developed automated test frameworks and a hardware-in-the-loop (HIL) test bench to simulate fault scenarios, validating that every safety function meets SIL requirements.
- Generated comprehensive documentation, including traceability matrices, source code repositories, and Safety Integrity Plans (SIPs), to support regulatory audits and future maintenance.
- Integration & Commissioning
- Installed NI cRIO racks on-site and connected all I/O channels to LIPAc’s sensors and actuators.
- Conducted Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) to verify sub-10 ms response times and correct interlock behavior under all prescribed conditions.
- Trained LIPAc operations staff on diagnostics, preventive maintenance, and emergency procedures, ensuring a smooth handover and minimal downtime.
By executing this comprehensive upgrade, GTD reaffirms its leadership in delivering SIL-compliant, mission-critical safety systems for high-performance accelerators. The new NI cRIO-based MPS will provide LIPAc with enhanced protection, faster fault response, and scalable expansion capabilities—further solidifying GTD’s reputation as a trusted partner in safety-critical control engineering.