1. CONSOLIDATION OF THE CONTROL SYSTEM OF THE SUBU CHEMICAL POLISHING MACHINE TE-VSC-ICM Automation Forum João Rodrigo Alvelos Ferreira 20th November 2014 TE-VSC-ICM

2. 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

3. SUBU | Control System Consolidation REVERSE ENGINEERING HARDWARE SPECIFICATION PROCESS SPECIFICATION SOFTWARE IMPLEMENTATION HARDWARE DESIGN ASSEMBLY AND COMMISSIONING

4. 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. sadf

5. 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.

6. 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.

7. SUBU | SOFTWARE IMPLEMENTATION The new control software was implemented in UNICOS-CPC, CERN’s in-house framework for Continuous Process Control.

8. SUBU | SOFTWARE IMPLEMENTATION UNICOS ARCHITECTURE INPUT/OUTPUT OBJECTS FIELD OBJECTS CONTROL OBJECTS Digital I/Os, Analog I/Os OnOff (valves, pumps, compressors), Analog, AnaDO,... Process Control Objects, PID, Alarms

9. SUBU | SOFTWARE IMPLEMENTATION PROCESS CONTROL OBJECTS SOAPWATERSULFSUBU FLOW_CONTROL MAIN

10. SUBU | SOFTWARE IMPLEMENTATION PCO HIERARCHY SOAPWATERSULFSUBUFLOW_CONTROL MAIN V5V12 V4V11V3V10V9V2 V1VP VSV7 V6 P1P2F1 F2

11. SUBU | SOFTWARE IMPLEMENTATION PCO MODES SOAPSULF FLOW_CONTROL MAIN Mode 1 - Polishing Mode 2 - Leaching WATERSUBU On Off Circulation (SUBU) Mode 1 - Dump Mode 2 - Shower Mode 3 - Loop Normal Mode 4 - Loop SUBU Mode 5 - Water Fill

12. SUBU | SOFTWARE IMPLEMENTATION STATE MACHINES (GRAPH 7) State Machine for the Leaching Process (partial) State Machine for the Polishing Process (partial)

13. SUBU | SOFTWARE IMPLEMENTATION UNICOS SCADA

14. SUBU | HARDWARE DESIGN SUBU Machine Wall Cabinet Relays Solenoids PSU Compressed Air Commands Feedback PATCH PANEL SUBU CONTROL CRATE

15. SUBU | HARDWARE DESIGN

16. SUBU | ASSEMBLY AND COMMISSIONING SUBU CONTROL CRATE PATCH PANEL

17. João Rodrigo Ferreira rodrigo.ferreira@cern.ch +41 764 871 719