Template Summary. AT_Reactor_C2_Summary_R01. Accord Template Summary. Reactor 1 Configuration 2 : AT_Reactor_C2. Revision: R01 20 th Feb 2017

Transcription

1 Accord Template Summary AT_Reactor_C2_Summary_R01 Document: System: Function: Accord Template Summary. Reactor 1 Configuration 2 : AT_Reactor_C2 8 Stage Reactor Revision: R01 20 th Feb 2017 AT_Reactor_C2_Summary_R01 Page 1 of 21

2 Introduction Accord Template for Small Reactor This document is to assist with installation and usage of this Template for Accord, it is assumed that the reader is familiar with process engineering and Accord Builder. This Accord Template for a small Reactor, to provide combination reaction of two ingredients, for Pharmaceutical type process plants. The template maybe easily adapted for specific installations by renaming and modifying equipment and program items in Accord Builder and in Accord HMI. This Reactor implementation is in S88 Style, with separate Equipment Modules for each Section and overall Procedures for managing programs using the Equipment Modules. AT_Reactor_C2_Summary_R01 Page 2 of 21

3 Index 1. System Description Process Summary P&ID Process Steps Installation Requirements Installation Restoration in Builder Import to Server Setup HMI Communication Service in Server Setup Device Logging and Log Data Archiving Loading HMI Design project Customisation Changing the Model Name Importing Modified Project Changing the Model reference in HMI To add an Equipment Item To add a Program Item To rename an Item To modify an Item...21 AT_Reactor_C2_Summary_R01 Page 3 of 21

4 1. System Description The system will provide 1. Automatic and Manual Operation of all devices and instruments. 2. Automatic Control of CIP Program, with selectable Steps, Decisions and Setpoints The system provides Reaction for two ingredients using Mixing, Temperature and Pressure. The program will run according to selections and using the setpoints chosen and will There is full automatic operation, including the ability to change to any step in the Program at any time. automatically stop on critical alarms and resume on Alarms reset and resume commands.. The system may be easily customised; It is easy to add or delete a tank, phase, step and also to change any Step Time or Temperature Setpoint for any step in the system. Step Order may be changed in Builder or Recipe Manager Setpoint Values may also be changed in Builder or HMI or Recipe Manager. Decision States may also be changed in Builder or HMI or Recipe Manager. Template Contents The Template includes the following Item Name Editor Process Drawing AT_Reactor_2_C1_DWG_R01.png -- Accord Builder Model AT_Reactor_2_C1_M_R01.bak Builder Accord HMI project AT_Reactor_2_C1_HMI_R01 HMI Accord S7 Library AT_Reactor_2_C1_S7_R01 Simatic Manager Accord TIA Library AT_Reactor_2_C1_TIA_R01 Siemens TIA Process Description Reactor C2 Process Description R01 MS Word Each part may be downloaded separately or as a combined file. AT_Reactor_C2_Summary_R01 Page 4 of 21

5 2. Process Summary 2.1 P&ID Source The required Batch Amounts are entered and the required destination Tank is Selected. The available destination Tanks are Tank A Tank B Tank C These, as well as any other items in the model, may be easily renamed in Model and HMI. AT_Reactor_C2_Summary_R01 Page 5 of 21

6 2.2 Process Steps There are 25 Steps configured in the Program and Steps are run according to Decisions. 1 Production Procedure Startup Step 2 Initial Pressure and Temperature 3 Derive Material A and B required amounts 4 Reset Charging Flowmeter 5 Pause before Charge with Material A 6 Charge with Material A 7 Reset Charging Flowmeter 8 Pause before Charge with Material B 9 Charge with Material B 10 Reaction Step 1 11 Reaction Step 2 12 Reaction Step 3 13 Reaction Step 4 14 Reaction Step 5 15 Reaction Step 6 16 Reaction Step 7 17 Reaction Step 8 18 Holding before Transfer to Tank 19 Check Availability for Transfer 20 Empty Reactor to Tank A 21 Empty Reactor to Tank B 22 Empty Reactor to Tank C 23 Empty Reactor to Drain 24 Temperature and Pressure to Safe Values 25 Ending Step AT_Reactor_C2_Summary_R01 Page 6 of 21

7 3. Installation This Template acts as a working system and a good template for similar systems. Systems may differ in many ways; Item naming, Nr of items, Nr of Tanks, Nr of crystallisation stages, etc. The following are brief guides to help customisation. Please remember that changes made to the Model in Accord Builder will be also in Builder documents and in PLC or Emulator after import and download. Changes will also be automatically available in Accord Recipe, Plan and Reports. 3.1 Requirements The use of the Template to deliver a working system requires Installation of Software and PLC Hardware, PC Hardware. Software Accord Builder Accord Server Accord HMI or InTouch (64 tag licence) PLC Editor: (Simatic Manager or TIA or equivalent) OPC Server (Kepware or equivalent) Optional Software Accord Recipe Manager Accord Batch Accord Reports MS Word, Excel MS Visio to change drawing InTouch Version 10.1 Hardware Siemens PLC or compatible equipment, VIPA, Helmholtz.. Desktop or Panel PC with Windows 7 or later Networking of PC and PLC via Ethernet AT_Reactor_C2_Summary_R01 Page 7 of 21

8 3.2 Installation The following assumes that required editors and PLC hardware are installed and set-up Restoration in Builder The Model.bak is loaded to Accord Builder. In Builder File menu select Restore and browse for the.bak file AT_Reactor_1_C2_M R01.bak. Open this and the Model will be loaded in Builder. The Model is loaded and may be modified. Run the Consistency Check when ready to import to Server. AT_Reactor_C2_Summary_R01 Page 8 of 21

9 3.2.2 Import to Server Following customisation the Model may be imported to Accord Server. An OPC profile must be setup in Server before import. If the project is being downloaded to a PLC then the PLC must be connected to the PC and the Accord PLC Library must be installed in the PLC. Setup of an OPC Profile for Emulator For more information on this please refer to Accord Server Manual. For this document the Accord Emulator is used. After testing Emulation the Project may be downloaded to PLC at any time. AT_Reactor_C2_Summary_R01 Page 9 of 21

10 To Import the Module from Builder, use Import Project button in Server Project Manager Tab. Import Project Screen Use the Refresh button in bottom Right Hand corner to refresh project list if necessary. AT_Reactor_C2_Summary_R01 Page 10 of 21

11 Space may be reserved in Server for spare items to be added using Partial Downloads. The import is then completed by pressing Download. AT_Reactor_C2_Summary_R01 Page 11 of 21

12 The Project should appear in the Server Project Manager tab field as above. The project is now ready for Emulator. If downloaded to a PLC then it is ready for Operation. AT_Reactor_C2_Summary_R01 Page 12 of 21

13 3.2.3 Setup HMI Communication Service in Server In Server Settings tab select Communications, Advanced and select the Connection type and IP Address as required. AT_Reactor_C2_Summary_R01 Page 13 of 21

14 3.2.4 Setup Device Logging and Log Data Archiving Device Logging All Devices may be logged. Logging is set up in the Settings Tab. Select Historian and then select Devices to be logged and in the case of Values select the log deadband, which is the change required to generate a new entry. Deadband values should be large enough to not cause excessive logging to PC hard-drive. Types of devices for logging are in the Groups drop down list and all the devices of a type will be presented when the Group is selected. AT_Reactor_C2_Summary_R01 Page 14 of 21

15 Log Database Archiving Archiving is the storage of logged data to an archive database. These archives may be copied from the PC using SQL copying. Archiving is a background function, it does not require any events or interaction. The Archive will occur when the log database is of the filesize specified in Max Size or after the number of days specified and it may also be specified to only occur at an off-peal time. Archiving uses PC resources and is usually set up for a time when background functions can be implemented without causing any delay on other functionality. AT_Reactor_C2_Summary_R01 Page 15 of 21

16 3.2.5 Loading HMI Design project Open Accord HMI Design and load project by accessing the file AT_Reactor_1_C2.lhp. All items will reference the Accord Model Project Name CIP Set 1 Tank. Screens and Objects may be accessed by usual manner. Connecting for Configuration A connection to Accord Server is necessary for both modifications in HMI Design and for running the HMI application in Runtime. The following Mimic Screen should be present when in Runtime In HMI Design - the Status in the bottom Left hand Corner should be Connected before modifications or deploying to Runtime. Ensure Server is started before refreshing. If Status shows Disconnected then click on Disconnected and a popup for Configuration appears. Use the Refresh button in the bottom Right Hand Corner and HMI Design will find the available Accord Servers and the required one may be selected. AT_Reactor_C2_Summary_R01 Page 16 of 21

17 Use the Refresh button in the bottom Right Hand Corner and HMI Design will find the available Accord Servers and the required one may be selected. Then press Save to finish the connection. Connecting for HMI Runtime In Tools select Service Manager and use the Refresh Button to find the IP Address of the Accord Server being used for the installation. Use the Refresh button in the bottom Right Hand Corner and HMI Design will find the available Accord Servers and the required one may be selected. Again Save when required is selected. AT_Reactor_C2_Summary_R01 Page 17 of 21

18 4 Customisation Data should be uploaded from PLC to Builder Model before any modifications. Use the Sync function in Server Tools for this. Items in the Model may be changed and the Cross Reference and Consistency Checks will allow secure modifications. Accord is an integrated environment so all changes to Model are available in HMI, Recipe, Reports, as appropriate. Depending on the change, an item may need to be re-assigned using Project Explorer in Accord HMI. 4.1 Changing the Model Name. 1. In Accord Builder This is carried out initially in Builder. The Project Model Summary contains the Model Name and this may be changed to a new name. If required the Model may be saved as a new Model using Save As. This will provide a new Model when importing. 4.2 Importing Modified Project If the Model Name, or any item for control purposes is changed, then the modified Model must be re-imported to Server. For a new Model name a Full Download is required, otherwise for modifications a Partial Download will be sufficient. Remember to assign reserve space for items for modifications when doing a Full Download. For items modifications, -Partial Download- The Model is imported as before and Partial Download is selected. Server will examine the existing configuration and compare to the new configuration and make all required adjustments into the Server database and PLC data configurations. During Partial Downloads items that have been deleted from the Model are deleted also from the PLC, and are deactivated before deletion. In this case the deletion means the configuration data is not used or referenced anymore, and this configuration area will be used for any new items that are downloaded. AT_Reactor_C2_Summary_R01 Page 18 of 21

19 4.3 Changing the Model reference in HMI If the Model name is changed in Builder then the Devices in HMI will need to be update also; Then when the modified Model is imported to Server, the items/devices must be updated in the HMI Project. To do this click on the Rename Project Bindings on the top right of the HMI Design screen, above Properties. A Remane Project panel allows input of the existing project name and the new project name Enter the required names and click Save; the HMI will be updated with replacement Project Name for devices. 4.4 To add an Equipment Item Equipment Items are: Valve, Motor, Digital In, Digital Out Signal, Instrument or Drive 1. In Accord Builder Drag in the appropriate icon into the unit Or Copy an existing item, using right-click copy and paste Or Right-click on the Unit and use Add Valve, etc Configure the item and give the new item an appropriate I/O address. Use the Edit I/O Table from the top menu to see all the existing I/O and to modify for the new item if required. Remember that this table can be copied to excel, modified by auto-fill and copied back, if required. When an Analog Output; a Drive or Control Valve, that has a PID Loop controller, is copied then PID Loop Controller is also copied automatically. The Process Variable for the PID Loop will have to be changed or confirmed. AT_Reactor_C2_Summary_R01 Page 19 of 21

20 2. In Server and Accord HMI or other module The new device will be available for placing on screen as required. The quickest way is to copy an existing device and select the new device name using the built-in HMI Explorer. 4.5 To add a Program Item Program Items are: Program, Step, Operation, Alarm, Condition, Decision, Setpoint, 1. In Accord Builder Drag in the appropriate icon into the unit Or Copy an existing item, using right-click copy and paste Or Right-click on the container and use Add Operation, etc Configure the item and add to Steps etc as required. 2. In Server and Accord HMI or other module The new item will be available for placing on screen as required. The quickest way is to copy an existing device and select the new device name using the built-in HMI Explorer. 4.6 To rename an Item 1. In Accord Builder Simply right click on the item and use Rename function. The new name will be populated through all the places it is used in the Model. 2. In Server and Accord HMI or other module Server treats a renamed item as a new item. On import and Partial Download the original Equipment Item will be deleted in PLC and Server, and the item must be reassigned in HMI. This is done by clicking on the item and selecting configure change and using the Project Explorer or Lists to find the new renamed item. All settings for the item will be imported also. The renamed item will be available in other modules (Reports, Plan ), and must be inserted into any configurations. The original named item will not be available any more. AT_Reactor_C2_Summary_R01 Page 20 of 21

21 4.7 To modify an Item 1. In Accord Builder Open the item Properties by right-clicking on the item. The texts, times and setpoints associated with the item can be changed easily. Interlocks and activations can also be seen and changed here if required. 2. In Server and Accord HMI or other module The modified model is imported to Server and properties changes will be assigned to items in HMI automatically. AT_Reactor_C2_Summary_R01 Page 21 of 21