consolidation of the control system of the subu chemical polishing machine te-vsc-icm automation...
TRANSCRIPT
CONSOLIDATION OF THE CONTROL SYSTEM OF THE SUBU CHEMICAL
POLISHING MACHINETE-VSC-ICM Automation Forum
João Rodrigo Alvelos Ferreira
20th November 2014TE-VSC-ICM
SUBU | Control System Consolidation
The SUBU Chemical Polishing machine performs the chemical polishing of copper RF cavities for several particle accelerators using a mix of chemicals known as SUBU. The machine was designed and built in the early nineties.
• Current control system is based on the Siemens S5 series of PLCs and a customized touch panel solution.
• S5 has been discontinued: Siemens does not provide support anymore and spares will become increasingly hard to find.
• To guarantee that the machine can be kept in operation the control system must be upgraded
SUBU | Control System Consolidation
REVERSE ENGINEERING
HARDWARE SPECIFICATION
PROCESS SPECIFICATION
SOFTWARE IMPLEMENTATION
HARDWARE DESIGN
ASSEMBLY AND COMMISSIONING
SUBU | REVERSE ENGINEERING
Fully reverse-engineer (wiring, PLC connections, existing equipment, control strategies) from on site analysis and testing , feedback from the operator, and existing documentation.
SUBU | HARDWARE SPECIFICATION
Understand current hardware installation. Produce a new, up to date, hardware specification that allows for proper choosing of new control hardware. Select and buy the required parts.
SUBU | PROCESS SPECIFICATION
From test runs of the current system, analysis of the existing but limited documentation, and feedback from the machine operator, define and document the different steps involved in the polishing process. These must be re-implemented in the new system.
SUBU | SOFTWARE IMPLEMENTATION
The new control software was implemented in UNICOS-CPC, CERN’s in-house framework for Continuous Process Control.
SUBU | SOFTWARE IMPLEMENTATION
UNICOS ARCHITECTURE
INPUT/OUTPUT OBJECTS
FIELD OBJECTS
CONTROLOBJECTS
Digital I/Os, Analog I/Os
OnOff (valves, pumps, compressors), Analog, AnaDO, ...
Process Control Objects, PID, Alarms
SUBU | SOFTWARE IMPLEMENTATION
PROCESS CONTROL OBJECTS
SOAP WATER SULF SUBU
FLOW_CONTROL
MAIN
SUBU | SOFTWARE IMPLEMENTATION
PCO HIERARCHY
SOAP WATER SULF SUBU FLOW_CONTROL
MAIN
V5 V12 V4 V11 V3 V10 V9 V2 V1 VP VS V7 V6
P1 P2 F1 F2
SUBU | SOFTWARE IMPLEMENTATION
PCO MODES
SOAP SULF
FLOW_CONTROL
MAIN• Mode 1 - Polishing• Mode 2 - Leaching
WATER SUBU
• On• Off• Circulation (SUBU)
• Mode 1 - Dump• Mode 2 - Shower• Mode 3 - Loop Normal• Mode 4 - Loop SUBU• Mode 5 - Water Fill
SUBU | SOFTWARE IMPLEMENTATION
STATE MACHINES (GRAPH 7)
State Machine for the Leaching Process (partial) State Machine for the Polishing Process (partial)
SUBU | SOFTWARE IMPLEMENTATION
UNICOS SCADA
SUBU | HARDWARE DESIGN
SUBU Machine
Wall Cabinet
Relays
Solenoids
PSU
Compressed Air
Commands
Feedback
PATCH PANEL
SUBU CONTROL CRATE
SUBU | HARDWARE DESIGN
SUBU | ASSEMBLY AND COMMISSIONING
SUBU CONTROL CRATE
PATCH PANEL
