LIPAc Machine Protection System

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

1. 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.
2. 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.
3. 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.

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