Intredevco Powder Detergent Plant Operation Manual

Manual Intradevco detergent plant

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Intredevco Powder Detergent Plant Operation Manual

Part: Slurry premaking section:

1Start When Computer power on,the control system startup automatic Notice:when control system is running,dont run other application 2Main control menu When system running,display main control menu as:

Each part of the main control system:

Solid head tank: 1. V1111: Minor material silo;
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Raw

Intredevco Powder Detergent Plant Operation Manual

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

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Intredevco Powder Detergent Plant Operation Manual

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.
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Intredevco Powder Detergent Plant Operation Manual

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:
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Intredevco Powder Detergent Plant Operation Manual

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:

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Intredevco Powder Detergent Plant Operation Manual

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.

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Intredevco Powder Detergent Plant Operation Manual

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

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Intredevco Powder Detergent Plant Operation Manual

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

by the button

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Intredevco Powder Detergent Plant Operation Manual

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 V1104s 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.
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Intredevco Powder Detergent Plant Operation Manual

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 cannt 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.
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Intredevco Powder Detergent Plant Operation Manual

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
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Intredevco Powder Detergent Plant Operation Manual

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.Its the Slurry Ring pressure. (3).Outout Freq:Its the output frequency of the high pressure pumps inverter.Its 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
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Intredevco Powder Detergent Plant Operation Manual

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,P1202Bs output frequency will follow P1202As 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.Its same as the high pressure pump..Center control room only display the furnaces chamber temperature and the tower top temperature.

The tower top control:

Tower top temperature:Indicate only,its controlled by the local burner. Tower top Negtive pressure PID
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Intredevco Powder Detergent Plant Operation Manual

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).

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Intredevco Powder Detergent Plant Operation Manual

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.
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Intredevco Powder Detergent Plant Operation Manual

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:

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Intredevco Powder Detergent Plant Operation Manual

1. period. 2.

:you can change system sampling

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.
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Intredevco Powder Detergent Plant Operation Manual

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.

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Intredevco Powder Detergent Plant Operation Manual

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

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Intredevco Powder Detergent Plant Operation Manual

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.

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Intredevco Powder Detergent Plant Operation Manual

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 tracks 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 silos 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;

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Intredevco Powder Detergent Plant Operation Manual

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;

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Intredevco Powder Detergent Plant Operation Manual

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 units setpoint will follow the current of base powder dosing belt.If you select offline,this unit will running alone.

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Intredevco Powder Detergent Plant Operation Manual

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.

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Intredevco Powder Detergent Plant Operation Manual

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.

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