SCADA, Recipe and Report Operation Manual for · PDF fileSCADA & RRS Operator Manual - Page 10 of 28 ... When all materials are discharged into mixer and mixer temperature reaches

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SCADA & RRS Operator Manual - Page 1 of 28 - Precision Control Pte Ltd

SCADA, Recipe and Report Operation Manual for

Compounding Machine

Project by: Precision Control Pte Ltd Project Completion Date: 10th Sept 2008

Manual Written by: Ma Wei Zhong

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Table of Contents

1. STARTUP SCADA SYSTEM

2. OPERATE RECIPE

3. COMMON PARAMETER

4. HOW TO RUN RECIPE IN AUTO MODE

5. HOW TO OPERATE IN MANUAL MODE

6. AUTO SEQUENCE DESCRIPTION

7. REPORTS

8. TRENDS AND ALARMS

9. GRAPHIC PAGES

10. PROCESS CONTROL AND INTERLOCK

11. MAJOR ALARMS

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1. Startup SCADA SYSTEM When restart the computer, the plant monitoring and control system will automatically startup by itself. After the system start up, one monitor will display page “Main Menu” and the other will display page “Overview” later (2-5 seconds delay). Operator should key in the user name and password at the login form. Click the button “LOGIN” to open the log form. If the system not automatically startup because of some errors, please click the icon named “runtime” on windows desktop to start the HMI system. (Normally, it will not happen.) Picture1: Main Menu

Notice: Don’t click button “TAGDUBUG” and “TEST1”. They are only used for the engineer.

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2. Operate Recipe Picture3 is an example for a recipe. 1) Enter recipe page a.) Click on the button “RECIPE & REPORT” on “MAIN MENU” graphic, enter the recipe start page. b.) Key in user and password, enter recipe operation page. 2) Setting: a.) Press “add” and enter the Product name, Product code in the window of “add product information”. b.) Select the process and sub-process in sequence of discharging to mixer and blender in the form of hot mixer recipe and key in the values of every sub-process: set value, set error, item no., material code and delay time. Item no. and material name need to be configured in the form of material configuration in advance. c.) Select “end” as the last process (Mixer and Blender are all necessary). d.) Press “generate” button to generate hot mixer step and cooling blender step automatically. And key in temperature set values in these two forms, the other set values are calculated automatically and do not need key in manually. Notice: You can not select the same sub-process in one recipe. You must put the same name of process together and can not insert other process into it. Available Process and sub-process selection for MIXER WT-101 HP-M01, HP-M03 WT-102 HP-M04 WT-103 HP-M02 WT-403 CV401, CV402, CV403, CV404, CV405, CV406, CV407, CV408 BF404 BAG WT-406 HP-406 END Any fields not in use in the recipe will be kept blank. Available Process and sub-process selection for BLENDER WT-302 HP-105 END Any fields not in use in the recipe will be kept blank. 3) After you select process and set values necessary, click the button “save” to add this recipe to database. 4) You can select a recipe from the name list and click button “Detail” to select a recipe from database. Then you can delete it or replace it after some modification. 5) After all, select the recipe you require and click button “download”. Then the data will be sent to PLC.

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Picture2: Overview

Picture3: Recipe operation

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3. Common Parameters There are many parameters can be set on HMI. Most of these parameters do not need to be modified after you set them once. The manual will especially direct the parameters that should be often set. 1) Charging setting: On some sub graphics, you can find some frames or pop-up windows like these

two. There are some parameters you can set.

WT SP: WT101 charging weight value. It will be set automatically when you download the recipe (Auto Batch) or key in value for manual charging. WT SP ERR: WT101 charging weight value acceptable % error. It will be set automatically when you download the recipe or key in value for manual charging. INFLIGHT SP: Preset value of charging weight. For Example: If you set “WT SP” 100 and “INFLIGHT SP” 10, the charging sequence will stop automatically when the increased weight equals to 90. LOW SPEED WT: At the start of charging sequence, feeder begins to run at high speed and run at low speed when the remainder weight reaches low speed set weight. HIGH SPEED SP & LOW SPEED SP: the feeder speed setting.

Notice: not all charging setting frame are identical. WT403 do not need to set the feeder speed and BF404 just only need to set the number of bags you required.

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Picture4: Mixer & Blender

2) Recipe Delay Time: “Next batch start Mixer” delay timer: When DCV301opens and then closes, the timer will start to count. Mixer will not run and jump to step1 until the timer is over. The operator can key in set value of this timer (seconds). “Blender starts to discharge” delay timer: When blender temperature reaches cooling temperature set value, there will be a delay to stop the blender and open the discharge valve DCV201. The operator can key in set value of this timer (seconds). “Mixer running watch dog” delay timer: When DCV301opens and then closes, the timer will start to

count. And it will be reset and start to count again once any one of material charging to mixer. When the timer is over and the buffer hopper above extruder is level high at the same time, mixer will stop at once.

Press START after HOLD batch

resume and MIXER panel switch

to AUTO mode low speed.

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3) Exhaust fan stop delay timer and vacuum high alarm delay timer

Click the exhaust fan 401 and 402 on WT101&102 &103 sub graphics, the operator can set two timers. a.) Exhaust fan stop delay timer: When WT101 or WT102 or WT103 transfer sequence finished, the

rotary valve will stop first, and the exhaust fan will not stop until the timer count is over. b.) Vacuum high alarm delay timer: When vacuum high sensor is activated, pressure release valve

will not open until the timer count is over. 4) Batch Number Picture5: Running Batch

Green Highlight for current step.

AUTO or MAN Mode. Select AUTO Mode for Auto Batch.

Actual batch no.

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Batch number set: How many batches the recipe will run, the operator can key in the number of total batches here.

Actual batch number: Display which batch is running now. The operator also can key in the number when the recipe is not started.

Notice: Don’t forget to check the batch number settings before start the recipe

Mo Number for each downloaded recipe, please key in the correct number before starting product, otherwise recipe can not start to run.

The quantity of each recipe, be similar to Mo Number, please key in the correct value. Notice: Please ask your supervisor if you can’t make sure the correct number above. 4. How To Run Recipe In Auto Mode 1) Make sure that all valves, motors, feeders and materials are ready and the panel selectors switch to

AUTO mode. 2) Select the require recipe which was preset in the database. Download the recipe.

Enter the total number of batches and the beginning batch number for each recipe. 3) Check all parameters described above. 4) Click the button “Auto Batch” on the “Running Batch” graphic to select the system to run in auto

mode. 5) Click “Auto” button on the “Mixer & Blender” graphic to make the mixer run in auto mode. 6) Click the button “Start Product” on the “Running Batch” graphic and the recipe will start. Mixer will run in high speed after step1 discharge completed. (At least 10 seconds) Operator doesn’t need to operate mixer and blender after starting recipe in auto mode. 7) Click the button “Stop Product” on the “Running Batch” graphic to stop all the sequence running

now. It will take some time to delay the exhaust fan stop. 5. How To Operate In Manual Mode 1) Make sure that all valves, motors, feeders and materials are ready. 2) Check all parameters described above. 3) Make sure the Manual Switch on panel is “AUTO” 4) Click the button “Manual Batch” on the “Running Batch” graphic to select the system to run in

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manual mode. 5) Click the button “Manual” on “Mixer & Blender” graphic to make the mixer run in manual mode. 6) Key in “WT SP” “WT SP ERR” on charging setting frame. 7) Click the button “Start” on charge frame to start charging. The charging sequence will automatically

stop when the increased weight reaches the SP.

8) Only for WT101, WT102, and WT103: When charging completes, operator can start the transfer

sequence. Click the button “Start” on transfer frame to start transfer. It will be also completed automatically.

Notice: Make sure you click the correct “Start” button. Don’t make mistake.

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9) When all materials are ready by manual operation, start mixer on “Mixer & Blender” graphic and open discharge valves.

10) Open discharge valves: Click the discharging valves, there will be a valve operation window appears.

Click button “Open” to open valve to discharge the material to Mixer. The manual sequence will automatically stop and close the valve when receiving hopper is empty. So though you can click the button “Close” to close valve manually, operator doesn’t need to click the button to close the valve in normal operation. Notice: operator cannot operate the valve while system runs in auto mode normally, however if “Hold Next Batch” button is clicked and mixer is in manual mode, operator can operate the valve to discharge material manually even though it is in auto batch mode now.

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11) Discharge the material one by one. Operator should monitor the temperature and start to discharge material into Mixer in time.

12) When all materials are discharged into mixer and mixer temperature reaches the SP, open DCV301 on Mixer & Blender graphic to discharge production into blender.

13) Open DCV201 on Mixer & Blender graphic to discharge production to extruder when the cooling temperature reaches the SP.

6. Auto Sequence Description WT101 charging sequence: Weight and acceptable +/- % error of HP-M01and HP-M03 SP is written by recipe database. (Download recipe) The One not required will be set to zero. When starting the charging sequence, feeder will begin to run at high speed and run at low speed once the remainder weight reaches the fine dosing set weight. FD_M01 will run and BFV_M01 opens. Materials from HP-M01 will be conveyed into WT101. The increasing net weight of WT101 will be compared with the set weight of HP_M01. Once the net weight reaches the set weight, the charging sequence will stop. FD_M01 will stop and BFV_M01 closes. The % error will be calculated and show on the graphic. Then M03 is the same as above. Sequence will be stopped/on hold and alarm activated if the following events occur. a) % error more or less than acceptable tolerance. b) During charging if net weight does not increase after 60 seconds. c) Process control instruments failure. For example: Valve or motor Feedback alarm.

When the above alarms occurred, the sequence will be stopped and alarm activated. Operator will have to check what cause the problems and take the corrective action. After taken the corrective action, operator will need to reset the alarm and selecting the followings: a) Continue To continue the charging process from the last status where the charging process stops b) Skip Skip the interrupted charging process and advance to next process or end the charging immediately if

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it is in last process. (For example: Skip M01 and start to run M03 charging sequence.) c) Abort (Only be used in manual mode) Stop the charging process sequence. WT102, WT103, WT403 andWT406 charging sequences are similar with WT101 charging sequence. WT302 charging sequence Weight and acceptable +/- % error of WT302 SP is written by recipe database. (Download recipe) WT302 must have the required material store before starting the sequence. The WT302 (LC_302) process weight will be captured and stored in a buffer register when the sequence starts. FD-302 will run, BFV302 and BFV202 open. Materials from WT302 will be conveyed into blender. The decreasing weight of WT302 (LC_302) will be used to subtract from the initial WT302 captured weight when sequence starts. The result of this subtraction is compared with the set weight. Once the set weight reaches or operator stop or sequence alarm, the charging sequence will stop. FD302 will stop; BFV302 and BFV202 close. The % error will be calculated and show on the graphic. Sequence will be stopped/on hold and alarm activated if the following events occur. a) % error more or less than acceptable tolerance. b) During charging if net weight does not increase after 60 seconds. c) Process control instruments failure. For example: Valve or motor Feedback alarms. When the above 3 alarms occur, the sequence will be on hold and alarm activated. Operator will have to check what cause the problems and take the corrective action. After taken the corrective action, operator will need to reset the alarm and selecting the followings: a) Continue To continue the charging process from the last status where the charging process stop b) Skip Skip the interrupted charging process and end the charging immediately. c) Abort (Only be used in manual mode) Stop the charging process sequence. Enable or Disable WT302 Charging. During auto batch running, charging of WT302 to blender can be enabled or disabled by clicking “Enable/Disable” button on the WT302 sub-graphic. Bag charging sequence: Belt Feeder BF404 There are 2 proximity sensors installed beside the belt feeder. One is to detect the present of bags on the belt feeder and the other one is to count the number of bags dropped into the mixer. The number of bags required is written by recipe database. (Download recipe) The bag charging sequence will not run if the proximity sensors cannot detect any bag on the belt.

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Once Bag charging sequence start, the belt feeder (BF404) will run and BFV304 opens. The number of bags dropped into the mixer will be detected by the proximity sensor. Once the number of bags required reaches, the sequence will stop. But the valve BFV304 will close twice after a timer delay (Close and then open, close again after that). Sequence will be stopped/on hold and alarm activated if the following events occur. a) Watch dog timer reaches the set value. b) Belt feeder motor trip or BFV304 feeder back alarm. When the above alarms occurred, the sequence will be stopped and alarm activated. Operator will have to check what cause the problems and take the corrective action.

After taken the corrective action, operator will need to reset the alarm and selecting the followings: a) Continue To continue the charging process from the last status where the charging process stop b) Skip Skip the interrupted charging process and end the charging immediately. c) Abort (Only be used in manual mode) Stop the charging process sequence. Material transfer sequence for WT101 to RHP_401: After all the require materials weight from HP_M01and HP_M03 have been charged into WT101 and the sequence completes, transferring of the WT101 materials to RHP_401 can be ready to start. The exhaust fan EH401 will run first for some seconds before the rotary valve RV-101 start to run. The time can be set on graphic. The above process will continue until the WT101 gross weight is less than zero set point (kg) and then rotary valve stops. After “Exhaust fan stop delay timer” count is over, the exhaust fan stops. (How to set “Exhaust fan stop delay timer” please refer to common parameter.) The above transfer sequence will be interlock/stopped by the following alarms: a) Vacuum Switch VAH-401 activated and the vacuum delay timer expired. b) RV-101 or EH-401 motor trip/run feedback alarm. c) BFV-411, BFV-411A/B feedback alarm.

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Material Transfer Sequence for WT102 to RHP402 or WT103 to RHP403 is similar with the one of WT101 to RHP_401

When the above alarms occurred, the sequence will be stopped and alarm activated. Operator will have to check what cause the problems and take the corrective action. After taken the corrective action, operator will need to reset the alarm and the transfer sequence will start immediately by click “Start” button on graphic. Notice: Charging and transfer sequence will not run if the destination silo is not empty or the total required batches reach the set quantity. When all materials are ready, the mixer sequence will start and jump to step1. Batch hold: (operate on “Running Batch” display page)

Operator can hold the sequence, click the button “HOLD” before step1,

then the sequence will hold on step0 (not jump to step1 though all conditions are ready).

Click the “CONTINUE” button or itself to reset the hold.

Then the mixer sequence will follow the recipe to run step by step: discharging, discharging ok, monitor temperature, temperature ok, discharging next, discharging ok, monitor temperature… Step hold: (operate on “Running Batch” display page)

Operator can hold the sequence on next discharging step, click the button “HOLD STEP”, then the next discharging will not run.

Click the “CONTINUE” button to reset the hold step.

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When recipe have been completed, (reach the total number of batch) there will generate a total report automatically. 7. Reports

How to open the report: 1) Click the button “recipe & report” on graphic “Main Menu” or the button “recipe” on graphic

“Running Batch” , you will see the graphic “Reports login”

2) You can select batch report, total report or month report from the top menu “Report”.

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3) If you choose batch report, then you should select Mo No. and Batch No.

.

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4) If you choose batch total report, then you should select Mo No.

5) If you choose batch total report, then you should select start time and end time.

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8. Trends & Alarms Trending is a visual representation of past and current activity that can be used to provide a better understanding of the performance of your plant. In this system, trends are used to trail analog variable tags historical values such as temperature or weight etc. The trend system can provide a better understanding of the performance of your plant and equipment. It can be used for dynamic visual analysis (trend and SPC graphs), production records, or for regularly recording the status of equipment for efficiency and preventive maintenance. Citect can collect and store any amount of data. The only restriction on the amount of data that you can store lies on the size of the hard disk on your computer. (Citect uses an efficient data storage method – ensuring that space on your computer’s hard disk is maximized). For long-term storage, you can archive the data to disk or tape (without disrupting your runtime system). For efficient storage, you should store trend files on a compressed volume. The trend system is based on real time samples. The trend system expects a return of one data point each time it samples the data. Although gaps in the data can be filled, you should ensure that your field device can return data values at the rate you specify (especially if you are using sample periods of less than 100 ms). Click button “TREND” on “Main Menu” graphics to enter trend graphics.

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Mainly setting:

Pen selections correspond to the color.

Span time

Set trend scale

Click this button to back to the last page

Notice: Hold the cursor on the icon, and then it will display the description about this icon, like this example. So the operator can easily operate Trend display.

Click button “ALARM” on “Main Menu” graphics to enter alarm graphics.

Display the alarm information; click the alarm to acknowledge it.

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Operator also can hold the cursor on icon to display the description of this icon.

Click this button to back to the last page

Operator also can click the icon on top right corner on every page to enter the alarm page. Alarm icon 9. GRAPHIC PAGES. 9.1 WT-101 Charging & WT-101 Transfer graphic page

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9.2 WT-102 Charging & WT-102 Transfer graphic page

9.3 WT-103 Charging & WT-103 Transfer graphic page

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9.4 WT-302 and BF-404 Charging graphic page

9.5 WT-302 and BF-404 Charging graphic page

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9.6 WT-403 Charging graphic page

9.7 Running Batch graphic page

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9.8 Mixer & Blender graphic page

10. Process Control and Interlock

a) HL-201 Activated: Mixer auto batch step 1 will not start until alarm recovered. b) Before operator clicks the auto batch start button, he needs to click the auto batch mode button

and auto mixer mode button in advance. c) After selecting the required recipe and downloading it to PLC, operator should confirm the

correct recipe is downloaded and then clicks the auto batch start button.

d) If HL-201 is not activated, mixer will then run at low speed.

e) PLC will start preparing materials for mixing according to the selected recipe.

f) After the main materials required for the batch are ready, Step 1 will turn on (Green) and the first material required will be charged into the Mixer. Once the first charging completed, mixer turns to run at high speed.

g) Interlock for Materials Preparation and Transfer Process.

Transfer process cannot start if the Material is still in the weighing process.

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Weighing process cannot start if the transfer process is running.

h) When mixer auto batch reaches its last step, PLC will activate the discharge valve open to let material in mixer dump into blender.

i) After the delay timer is up, mixer discharge valve closes. Blender step 1 will start when the

discharge valve is closed and HL-201 not activated.

j) In the last step of blender, if cooling temperature reaches the SP and blender delay timer is up, blender discharge valve will open. After 2 minutes delay, blender discharge valve closes and blender completes its first batch. 2nd of mixer batch will start to run on the mixer after the mixer Delay timer is up.

11. MAJOR ALARMS.

When the alarms below are activated, the panel alarm light will be on and buzzer sounds. To reset the alarm sound, press the ESC key on the keyboard. The buzzer will go off but the alarm light will remain to be on until the alarms are all recovered.

Citect will display the alarm status and description in the alarm page No. Descriptions Alarms 1 BF-404 Trip 2 EH-401 Trip 3 EH-402 Trip 4 FD-302 Trip 5 FD-M01 Trip 6 FD-M02 Trip 7 FD-M03 Trip 8 FD-M04 Trip 9 PPM-413 Trip

10 PPM-413A Trip 11 RV-101 Trip 12 RV-102 Trip 13 RV-103 Trip 14 HL-201 High Level 15 HL-103 High Level 16 Panel Emergency Stop Button Activated 17 Power Supply Failure Activated 18 WT-101 Charging Sequence a) % error for HP-M01 /HP-M03 Alarm b) Charging weight not increasing. Alarm c) LL-M01, LL-M03 during charging. Alarm d) Process control instruments failure. Alarm

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19 WT-103 Charging Sequence a) % error for HP-M02 Alarm b) Charging weight not increasing. Alarm c) LL-M02 during charging. Alarm d) Process control instruments failure. Alarm 20 WT-102 Charging Sequence a) % error for HP-M04. Alarm b) Charging weight not increasing. Alarm c) LL-M04 during charging. Alarm d) Process control instruments failure. Alarm 21 WT-302 Charging Sequence a) % error. Alarm b) Charging weight not increasing. Alarm c) Process control instruments failure. Alarm 22 WT-403 Charging Sequence a) % error. Alarm b) Charging weight not increasing. Alarm c) Process control instruments failure. Alarm 23 Bags Charging Sequence a) Bags not present on belt before charging Alarm b) Charged bag less than require. Alarm c) Process control instruments failure. Alarm 24 Transfer Sequence WT-101 to RHP-401 a) Vacuum Switch VAH-401 Alarm b) Process control instruments failure. Alarm 25 Transfer Sequence WT-103 to RHP-4031 a) Vacuum Switch VAH-403 alarm b) Process control instruments failure. alarm 26 Transfer Sequence WT-102 to RHP-402 or RHP-301 a) Vacuum Switch VAH-402 alarm b) Process control instruments failure. alarm

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SCADA, Recipe and Report Operation Manual for · PDF fileSCADA & RRS Operator Manual - Page 10 of 28 ... When all materials are discharged into mixer and mixer temperature reaches