A P P L I C A T I O N. Nutricia Polska. Control system for jar-packed baby-foods manufacturing department

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1 A P P L I C A T I O N N O T E FOOD PRZEMYSŁ INDUSTRY SPOŻYWCZY Nutricia Polska Control system for jar-packed baby-foods manufacturing department R E L I A B L E S O L U T I O N O F A U T O M A T I O N S Y S T E M S

2 Doc. No. ENPN003 Version: ASKOM and asix are registered trademarks of ASKOM Spółka z o.o., Gliwice. Other brand names, trademarks, and registered trademarks are the property of their respective holders. All rights reserved including the right of reproduction in whole or in part in any form. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior written permission from the ASKOM. ASKOM sp. z o. o. shall not be liable for any damages arising out of the use of information included in the publication content. Copyright 2006, ASKOM Sp. z o. o., Gliwice ASKOM Sp. z o. o., ul. Józefa Sowińskiego 13, Gliwice, tel. +48 (0) , fax +48 (0) , office@askom.com.pl

3 APPLICATION NOTE NUTRICIA Process Control System Configuration Nutricia, one of the leading manufacturers of baby-foods, started to upgrade their Opole plant in The aim of the operation has been to increase the plant's production capabilities. ASKOM was granted a contract to supply a new process control system. The comprehensive contract included the following tasks: designing electrical and instrumentation parts of the system; specifying the required hardware deliveries; working out control system software; assembling the object; deploying the software; and putting the entire system into operation. Construction has been split into three basic phases. Approximately 65% of the entire scope was completed within Phase 1, finished in September Current work on Phase 2 is accompanied by deployment of the batch process control system software. The process of manufacturing jar-packed baby-foods is a typical example of batch processes some well defined portions of various products are prepared according to some recipes. Since the range of manufactured products is very broad, it is particularly desirable that the selected control system was able to easily define new recipes and to modify the existing ones. Compatibility with the S88 (ANSI/ISA ) standard was another requirement. All the above requirements are well met by the PCS7 system version 6.0 with the Simatic BATCH package, manufactured by Siemens. This system has been selected for the project. Process Control System Configuration. MARCH 2005 page 1

4 NUTRICIA APPLICATION NOTE The Operator Layer One of the basic requirements that heavily influenced the selected PCS7 system configuration was that the system must be highly reliable and available. To that end a configuration with a redundant OS server, a pair of client workstations and an independent Simatic BATCH server (to be made redundant by linking with an analogous server deployed at another manufacturing department to be upgraded in the near future) has been used. One of the operator workstations is equipped with the Batch Control Centre software package for controlling batch production processes. Another independent workstation is used to enter new/edit existing recipes. Operator Workstation No. 2, equipped with the WebNavigator software, additionally plays the role of a WWW server that serves process information to any standard Web browser working in the company intranet. Control Stations and I/O Circuitry The process is controlled by two AS stations. The I/O circuitry standard has been selected in regard to the following three basic factors: its elements must be simple to assemble on the plant, the configuration must be flexibly modifiable and the modules must be hot-swapped. Both control stations presently accommodate jointly 10 ET200S nodes with over 500 I/O modules. A capability to replace a network interface with a programmable module is an additional advantage of the ET200S standard. This feature turned out to be an important one when it came to control processes, which time requirements couldn t be met by classical configuration (distributed I/O elements). The manufacturing process run at the baby-food department needs to be locally controlled at 11 production nodes. Two types of touch screen panels have been used to accomplish that control: MP270 panels equipped with 10" diameter colour screens have been located at nodes covering some more complex technology fragments, and TP170B panels equipped with 5.7 diameter colour screens elsewhere. The speed of approximately one hundred drives used within the process (i.e. almost a half of all drives) must be regulated. Various engine power levels are involved, from 0.37 kw up to 40 kw. A natural solution was to use some frequency converters equipped with the PROFIBUS-DP interface, enabling them to be linked to the control stations. Micromaster converters from the 420 and 440 families manufactured by Siemens have been selected. They provide not only a high level of performance, but also can be seamlessly integrated with the PCS7 system. Weighing equipment was another one to be selected. Presently 7 batching scales have been deployed within the system, and the projected total is 10. Weighing functions have been accomplished with the help of the SIWAREX U weighing processors. The latter can be seamlessly integrated with the PCS7 system since a respective software library is available. Safety of the Installation The entire process has been divided into 25 emergency stop groups defined according to the following principles: all elements of a group must be localized within the same room; each group covers a logically distinguishable technology fragment; for each group at least one emergency stop (safety) push-button is installed. Pushing a safety button in a group immediately and unconditionally stops all electrical devices belonging to that group. The devices are stopped by shutting down their power supplies. The designed solution is compatible with the EN standard; it meets all the requirements of the Safety Category 1 and Stop Category 0. Safety Category may be easily increased to 2 by installing some safety relays. page 2 MARCH 2005

5 APPLICATION NOTE NUTRICIA Software System software has been mostly written in the CFC graphical language. Sequential control functions have been programmed with the help of the SFC package, whereas most of the more complex functions have been programmed with the help of the SCL language. Every process device may be manually controlled both from operator panel and from each workstation. Analogously both interfaces may be used to change the operational mode and to configure process parameters. A special maintenance mode may be activated only by a suitably authorized user. In that mode the drives may be steered outside their normal operating range (interlocks are disabled), but the control may be performed exclusively from the nearest operator panel. In order to help the operator to run the process, the standards used to visualize the process on the operator panels are (as far as the panel technical capabilities allow) identical to those used to visualize the process on the workstation screens. In particular, the same shapes and colours have been used to depict icons representing drives, control stations and installation layouts. Experience collected so-far confirms that the adopted automation solution has been well-chosen. The manufacturing technology was constantly being modified, practically all the time from the moment the system was put into operation, and automation followed up. New devices are successively deployed, assembled and put into operation, while the existing machinery and control algorithms are modified or upgraded. All modernization works are being performed without interrupting plant production. MARCH 2005 page 3

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