Peru Detergent Plant Operation Manual

Intredevco Powder Detergent Plant Operation Manual

Hangzhou YuTong electric Co.,ltd Fax:+86 571 871 51457 No. 1 / 26

Manual

Intradevco detergent plant



Part: Slurry premaking section: 1、Start ：When Computer power on,the control system startup

automatic。

Notice:when control system is running,don’t run other

application。

2、Main control menu。

When system running,display main control menu as:

Each part of the main control system: Solid head tank:

1. V1111: Minor Raw

material silo;



2. V1112: Sodium Sulfate silo;

3. V1113:STPP silo;

4. V1114:Sodium Carbonate silo;

Each silo show: 1. HLevel:high level,in kg,if the weight great than HLevel,the

colour of the PV display will turn to Red colour;

2. LLevel:low level,in kg,if the weight Less than LLevel, the

colour of the PV display will turn to Red colour;

3. ActiveV:present weight of the raw material inside silos.

Liquid head tank:

1. V1101: process water

2. V1102A: silicate

3. V1102B: liquid Caustic

4. V1100:Sokalan

5. V1103:Sulfonic Acid



Control parameter:

1. HLevel: high level(meter),if the level greater than HLevel,PLC

will stop the transfer pump;

2. LLevel: low level(meter),if the level less than LLevel,PLC will

startup the transfer pump;

3. ActiveV:present high(meter)/temperature of the raw material

inside head tank;

4. SetP:setpoint of the liquid raw material,for example,if you set

60℃,then if the temperature less than 58℃(60-2),PLC will open

the heating Valve.If the temperature greater than 62℃

(60+2),PLC will close the heating Valve.

Liquid scale hopper: The section include the head

tanks,filling valves,and the

outlet valves.

Display Parameter:

1. SepP:setpoint of each

liquid raw material.

2. ActiveV:the weight of the raw material after the inlet valve be

closed.



Setup Parameter of the weighting Controller:

Tare:set the gross weight of the hopper.

Notices:you must set the function when the hopper is empty.

Demarcate(Calibration):set the scale of the hopper.when you put

100kg weight on the hopper,if system only show you 95kg,then

you must use the function.when you use the function,first you

must use the “Tare” function.then you can put more than 200kg

weight on the hopper.

Start/stop button:manual control the outlet screw.

SetValue:same as SetP.

Coarse&impulse:feeding control Parameter.because the feeding

screw has two speed(high speed and low speed),when begin

feeding,the feeding screw running at high speed,when the lose

weight greater than Coarse,the feeding screw will running at the

low speed,when the lose weight greater than

(setValue-impulse),it will stop.

Crutcher section:



Setup Parameter:

Current Temp.:the slurry current temperature.

Current Level:crutcher slurry current level(meter);

Empty level:mean when slurry level less than “Empty

level”,PLC will delay 30 seconds,then close the outlet valve.

Mix time after formula:the time when the lastest raw material

has been added,the mixer of crutcher running time,when the

time out,the slurry mixxing finish. Until the slurry is discharged.

Ageing tank:



Current Temp.:the slurry current temperature.

Current Level:crutcher slurry current level(meter);

High level(HH):the parameter is very important,it controls

the crutcher outlet valve which can be open.

Notices:so,the slurry discharged has two conditions:one is mixing

time,the other is temperature.



Formulation setup section: This section include two part:

1. The scale hopper Parameter setup.

2. The formulation Parameter setup.

The scale hopper Parameter setup:

Each scale hopper setup Parameter,same as the above menu.

(1). show the scale TAG, show the raw material

head silo/tank, mean the scale hopper has four raw material

head siloes/tanks;each hopper has eight formulaes(From 1#F to

8#F ),each formula be showed in the formula group.

(2).Formula startup:each formula can be stertup alone,for

example,you can startup 1#F,that you input the tag weight.when you

click , the formula correspond to this button will be startup.

(3).Cancel the formula:you can use the

button to cancel the formula that is



excuting.when you use the manul weighting mode,the weighting

process can be cancelled by the button be clicked.

(4).save the data:use the button to save the

formula data

(5).The scale hopper outlet valve/screw can be forced to open/startup

by the button



The formulation Parameter setup:

System

allow you setup 17 batches raw material for each crutcher.Each batch

data is showed in one group.For example:the No.1 batch is “V1104”

and “1#formula”,it mean when you begin a new formulation,system

will use scale hopper V1104 to dosing raw material,and the target

weight of the first batch if signed by V1104’s No.1 formula.

Notices:On the end of the automatic formulation,you MUST sign a

END.

Use crutcher A:mean you only use Crutcher A

for formula.



Use crutcher B:mean you only use Crutcher B for formula.

Use both Crutcher:mean you use Crutcher A&B for formula.

First use crutcher:if both crutchers are used,the you

can select which crutcher can be used

first.Otherwise,this selection cann’t be selected.

Circle:

Two selection is showed:once and Circle.If “once” is

selected,system only uses the formula for once. If

“Circle” is selected,system will circle uses the formula again and

again,until you cancel the automatic formula.

The button is used for transport formula data,that setup on

the top of the screen to the PLC. PLC will use the formula for

automatic formulation.

Notices: Scheduling data must include a “end” flag.

The button is used for startup the automatic

scheduling.

The button is used for Cancel the automatic

scheduling.



Spray section: The main menu is showed as follows:

High pressure pump:

High pressure pump PID control:pump outlet

pressure is detected by the pressure

sensor,and PLC control the pressure

automatic.

The control parameter of the high pressure pump:

(1).Automatic/Manual:The control mode of the pump.

Automatic mode:PLC control the Slurry Ring pressure



automatic. Slurry Ring pressure rest with the Setpoint. Manual

mode:the inverter output the fixed frequency, independent of Slurry

Ring pressure.

(2).Setpoint:the target pressure of the High pressure pump.It’s the

Slurry Ring pressure.

(3).Outout Freq:It’s the output frequency of the high pressure pump’s

inverter.It’s can be set only on the manual mode.

(4).PID setup:the parameter is very important for the control

quality.When the block is at the left,the control response is very

unresponsive,but the pressure is more steady.If the block is at the

right,the control response is very delicacy,but the pressure is not very

steady.

The control parameter of the screw pump:

Same as the high pressure pump.

:This check block is used for high pressure

pump,homogenize pump and screw pump interlock.When it be

selected,the high pressure pump shutdown,the homogenize pump and

the screw pump will stop automatic.When the homogenize pump



shutdown,the screw pump will stop automatic.

This check block is used for two high pressure

pumps.Some time,when the two high pressure

pump outlet is same,if the check block be selected,P1202B’s output

frequency will follow P1202A’s output frequency.

The burner system:

The section include burner and secondary fan.The burner is controlled

by the local. Only the secondary fan is controlled by the PLC.It’s

same as the high pressure pump..Center control room only display the

furnace’s chamber temperature and the tower top temperature.

The tower top control:

Tower top temperature:Indicate only,it’s

controlled by the local burner.

Tower top Negtive pressure PID



control:System detects the tower top pressure,then control the exhaust

fan rotate speed.

The exhaust system: The exhaust fan:two

control mode is provide:Automatic mode

and manual mode.When in automatic

mode,system depend on the tower top

temperature setpoint to control the fan rotate speed.

When it in manual mode,system depend on the manual setup

frequence control inverter output.

Notices:if at automatic mode,the parameter of GAIN must be adjusted

to be suit to the process.Range of the parameter is from 0~2(normal is

0.8).



Tower bottom temperature control:

tower

bottom temperature is control by secondly air fan.Control system

provides two control mode:Manual mode and automatic mode.

Manual mode:when you select this mode, will

be actived,you can input frequeue setpoint to control the secondly air

fan derectly.

Automatic mode:At the control mode,

is actived,you can set a setpoint (SV) to control the tower bottom

temperature.System control the the secondly air fan rotating speed

automatic.

Air lifter control system: Decanter negative pressure is

control by lifter fan.Control system provides

two control mode:Manual mode and

automatic mode.



Manual mode:when you select this mode, will be actived,you can

input frequeue setpoint to control the lifter fan derectly.

Automatic mode:At the control mode,

is actived,you can set a setpoint (SV) to control the Decanter

negative pressure.System control the the lifter fan rotating

speed automatic.

History and record of spray section

History window is shown as follow:



1. :you can change system sampling

period.

2.

This section show the history data which stored in the harddish.It can

be review anytime.

From the left to right:

Number:The record number.The first record number is “1”.

Date:the date of the data be recorded.

Time: the time of the data be recorded.

P_P1201A:the pressure of the homogenize pump(P1201A) outlet.

P_P1202A:the pressure of the high pressure pump(P1202A) outlet.

P_up_Ring:the pressure of the up-slurry Ring.

P_P1201B:the pressure of the homogenize pump(P1201B) outlet.

P_P1202B:the pressure of the high pressure pump(P1202B) outlet.

P_down_Ring:the pressure of the down-slurry Ring.

P_Tower top: the pressure of the tower top.

P_lifter: the pressure of the the air lifter.

T_up_Ring:the temperature of the up-slurry Ring.

T_down_Ring:the temperature of the down-slurry Ring.

T_Burner:the temperature of the hearth.



T_Tower_inlet:the temperature of tower inlet.

T_Tower_top:the temperature of tower top.

The trend line windows is separated into 5 sections.

1. the pressure of slurry A:

Axis x:shows the number of the record. Axis y:shows the pressure in Bar.

shows the line color mean.For example the red color line means Pressure P1201A.

2. the pressure of slurry B:same as trend A.

3. the pressure of tower top,and air lifter.

4. The temperature of tower top,up-slurry Ring and down-slurry

Ring.

5. The temperature of burner and tower inlet.

button use for view the previous page of the data record.



button use for view the next page of the data record.



Post blending section:

This section from Base Powder Silo to Post blending mixer.All the

controlled equipments is show on the main menu.

Base powder silo: Base powder silo attemper Post

blending system,make the system

runs continuity if you select track enable.

Track parameter setup: when you setup the parameters of Post blending section correct,and

anable the tracking function,then system can run continuity.



control window as left.

Control the base powder dosing belt as same as the other equipments

of Slurry premaking section and spray section.

Parameter setup:

1. Track enable: Enabel the track function of the

post blending section.It means base powder dosing belt setpoint

will depend on the powder level of the base powder silo.The

track’s principium will be described below.

2. Track base: ,is setpoint of track base(%),it means

persent of base powder in the base powder silo.If the silo is

empty,system shows 0%;if the silo is full,system show 100%.

If you set the value 50%,it means you want to adjust the base

powder silo’s level keeps at 50%,when the level greater than

50%,system increases the setpoint of the base powder dosing

belt; when the level less than 50%,system decreases the setpoint

of the base powder dosing belt;



3. Track error: this parameter set the doorsill of

tracking.If you set the track base data 50%,and track error

5%,and when the level of base powder between 45% and

55%,system should not changes the setpoint of the base powder

dosing belt.

4. Increasement Value: this parameter means the

increase value of the base powder dosing belt when base powder

silo powder level between each level range.For example:track

base=50%,track error=5%, Increasement Value=0.5t/h;dosing

belt current sp=7t/h;so:

For example:when level between 70% and 75%,dosing belt

sp=9.0t/h;



Auxiliary meterials system: Include Auxiliary meterials A/B/C.All 3 units is

same.

Normal parameter:

Track mode:

This select set each unit running mode,if you

select “Online”,this unit’s setpoint will follow the current of base

powder dosing belt.If you select “offline”,this unit will running alone.



Liquid dosing unit:Include the nonionic and

Perfume dosing pump.The dosing pump controls

very simple:frequeue/flux control.It means

system derectly output frequeue to control the

dosing pump flux.So,the maximum frequeue flux

must be calibrated.

Control mode selection:

each unit has two control mode:automatic and

manual.When you select automatic running

mode,PLC will controls the feeding screw/belt speed depend on the

flux setpoint.When you select the manual running mode,you can set a

frequeue data to control the motor directly.



History and record of Post blending section:

History window is shown as follow:

The left window shows the history record.It include the 4 dosing belt

flux,and 2 dosing pump output frequency.

The right 2 windows show the flux trend.Up window is basepowder

flux trend.down window show the other 3 dosing belt and dosing

pump output frequency.

Documents

Peru Detergent Plant Operation Manual