Accord. Template Summary

Transcription

1 Accord Template Summary AT_Fermenters_C1_Summary_R01 Document: System: Function: Accord Template Summary. Fermenters: AT_Fermenters_C1 Small Brewery Revision: R01 27 th March 2017 AT_Fermenters_C1_Summary_R01 Page 1 of 25

2 Introduction Accord Template for Brewhouse with a series of Vessels and Lines. This document is to assist Engineering staff with installation and usage of Accord Template, it is assumed that the reader is familiar with PLC programming, Scada setup, and Accord Builder. This Accord Template is for a Small Brewery system with 4 Fermenters. The template maybe easily adapted for specific installations by renaming and modifying equipment and program items in Accord Builder and in HMI applications. AT_Fermenters_C1_Summary_R01 Page 2 of 25

3 Index 1 System Description Process Summary List of Programs Process Steps Installation Requirements Restoration in Builder Import to Server Setup HMI Communication Service in Server Setup Device Logging and Log Data Archiving Loading HMI Design project Connecting for HMI Runtime 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 S7 Hardware and Library...25 AT_Fermenters_C1_Summary_R01 Page 3 of 25

4 1 System Description The system will provide 1. Automatic and Manual Operation of all devices and instruments. 2. Automatic Control of Fermentation Programs, with selectable Steps, Step Setpoints and Temperature Gradient Setpoints. 3. Automatic Routing for Fill, Empty, and CIP Programs. There is full automatic operation, including the ability to change step on or steps at any time. The program will run according to selections, using the setpoints chosen, 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 Vessel, program or 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 Accord Builder Model AT_Fermenters_C1_M_R01.bak Builder Accord HMI project AT_ Fermenters _C1_HMI_R01 HMI Accord S7 Project AT_ Fermenters_C1_S7_R01 Simatic Manager The S7 Project contains the Accord PLC Library A S7398 Each part may be downloaded separately or as a combined file. AT_Fermenters_C1_Summary_R01 Page 4 of 25

5 2 Process Summary 2.1 List of Programs Fermentation: Fermenter Vessels FV01 to FV04 The Fermenatation starts automatically after Filling. Each vessle has a program with 10 Fermentation steps. These steps each have unique Target Step temperature and Temperature change Setpoints, for control of temperature by changing the Setpoint every 60 minutes. In this way, a Step which is to hold the temperature may have a Temperature Change Setpoint of 0. The fermentation programs are configured to Step On automatically when the Target Step temperature is reached for each Step. Each Fermenter will then go to a Storage state when the Fermentation is finished. CIP: CIP of Fermenter and CIP Filling and CIP Emptying Line These programs open routes and exchange signals with a CIP Centre. The signals are configured as Digital Inputs and Outputs. Signals are provided for CIP Active and Vessel Low Level. AT_Fermenters_C1_Summary_R01 Page 5 of 25

6 2.2 Process Steps Fermenters: The following are the states of each Fermenter Vessel. Step FV01 States Startup Step FV01 Filling FV01 Emptying FV01 CIP FV01 Clean FV01 Fermentation Stage 01 FV01 Fermentation Stage 02 FV01 Fermentation Stage 03 FV01 Fermentation Stage 04 FV01 Fermentation Stage 05 FV01 Fermentation Stage 06 FV01 Fermentation Stage 07 FV01 Fermentation Stage 08 FV01 Fermentation Stage 09 FV01 Fermentation Stage 10 FV01 Storage FV01 not Clean Fermenter Vessel Description Fill from Brewhouse Empty to BBT Area CIP from CIP Centre Fermenter is Clean after CIP Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Fermentation Step Vessel in Storage after Fermentation Vessel needs CIP after Emptying The Fermentation and Storage steps are carried out within the Fermenter Program, other steps are carried out with Fill, Empty and CIP Programs. AT_Fermenters_C1_Summary_R01 Page 6 of 25

7 Step CIP FV01 Startup Step CIP FV01 Initial Check CIP FV01 Wait for CIP System CIP FV01 CIP Supply Stage CIP FV01 CIP Return Stage CIP FV01 Program Finish CIP of Fermenter Description Check if CIP is allowed Wait for Signals CIP through Fermenter CIP return from Fermenter Finish Program Step Fill FV01 from Brewhouse Startup Fill FV01 Initial Check Fill FV01 Initial Line Flush Fill FV01 Push Water to Drain Fill FV01 Fill Fermenter Fill FV01 Push to Fermenter Fill of Fermenter Description Check if Filling is allowed Flush line from Brewhouse to Drain at Fermenters Push Flush water to drain with wort Beer Fill wort into Fermenter Push remaining beer to Fermenter with Water Step Empty FV01 - Startup Step Empty FV01 - Initial Check Empty FV01 - Initial Line Flush Empty FV01 - Push from Fermenter Empty FV01 - Empty Fermenter Empty FV01 - Push with Water to BBT Area Empty of Fermenter Description Check if Emptying is allowed Flush line from Fermenters to Drain at BBT Push Flush water to drain with Beer Empty Beer from Fermenter Push Beer in Empty Line to BBT with Water AT_Fermenters_C1_Summary_R01 Page 7 of 25

8 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) or other HMI application PLC Editor: (Simatic Manager or TIA or equivalent) OPC Server (Kepware or equivalent) Optional Software Accord Recipe Manager Accord Plan 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_Fermenters_C1_Summary_R01 Page 8 of 25

9

10

11 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_Fermenters_C1_Summary_R01 Page 11 of 25

12

13

14

15 3.4 Setup HMI Communication Service in Server In Server Settings tab select Communications, Advanced and select the Connection type and IP Address as required. Select Remote clients if the HMI Runtime is being run on another PC. AT_Fermenters_C1_Summary_R01 Page 15 of 25

16

17 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. 3.6 Loading HMI Design project Open Accord HMI Design and load project by accessing the file AT_Fermenters_C1_HMI_R01.lhp. AT_Fermenters_C1_Summary_R01 Page 17 of 25

18

19

20

21

22 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. 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 updated 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 Rename 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. AT_Fermenters_C1_Summary_R01 Page 22 of 25

23 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. 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. AT_Fermenters_C1_Summary_R01 Page 23 of 25

24 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. 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_Fermenters_C1_Summary_R01 Page 24 of 25

25 5. S7 Hardware and Library Graphic of S7 Hardware configuration for the installation. Compoenents may be modified as desired. The S7 Library required is contained in the S7 Project for the system.