Autoclave #3 manual

Autoclave #3 operations and maintenance manual

table of contents

.Begin Table C.

1.0 Introduction 1

1.1 HP-TDC-PLC operation 1

1.2 Functional Description Format 1

1.3 Reference Designations 1

1.4 TDC and PLC Tags 1

1.5 PID Loop Tags 2

1.6 Control Point Tables Format 2

1.7 PID Control Addressing 2

1.7.1 PID Loop Tags vs. Loop number 2

1.7.2 TDC Interface Tables 2

1.7.3 PLC PID Parameter Tables 3

1.8 PLC & TDC Data Tables 3

1.9 Contacts 4

2.0 Functional Descriptions 6

2.1 Pressurization System 6

2.1.1 Pressure Control Points 6

2.1.2 Pressure System Overview 6

2.1.2 Pressure System Operation 6

2.1.3 Pressure Startup 6

2.1.4 Pressure Holds and Restarts 7

2.1.5 Auto Switch to Air 7

2.1.6 Blowdown and Blocking Valves 7

2.1.7 Pressure Gauges 7

2.1.8 Nitrogen Blocking Valve 8

2.1.9 Pressure Valves Adjustment 8

2.1.10 Pressure Trouble 8

2.2 Purge Autoclave Atmosphere 9

2.2.1 Purge Control Points 9

2.2.2 Purge Operation 9

2.2.3 Purge, Add Air 9

2.2.5 Purge Caution 10

2.3 Man in Autoclave 10

2.3.1 Man In Autoclave Emergency Switch 10

2.3.2 MAN IN AUTOCLAVE ALARM WILL DO THIS 10

2.3.3 Hyperbaric Unit 10

2.4 EMERGENCY STOP PUSHBUTTON 10

2.4.1 ESTOP WILL DO 10

2.4.2 ESTOP Differences 11

2.4.3 ESTOP Details 11

2.4.4 PLC NESTOP 11

2.4.5 ESTOP Thermoflux 11

2.5 Temperature Control 11

2.5.2 Block diagram 12

2.5.3 Part and Air Temperature Control Loops 12

2.5.4 Outputs to heating and cooling 12

2.5.6 Temperature feedback, HP and/or PLC 12

2.5.7 Parts and thermocouples 13

2.5.8 Setpoint Bias and Feedback control 13

2.5.9 Modes of Operation 13

2.5.10 Computer Shed 14

2.5.11 Trouble 14

2.5.12 Heating System by Thermoflux 15

2.5.13 Thermoflux Documents 15

2.5.14 Thermoflux SLC Program 15

2.5.15 Thermoflux Start Up 15

2.5.16 Heating System Alarms 16

2.5.17 Thermoflux Published Limits 16

2.5.18 Specific Heating Problems 16

2.6 Liquid Nitrogen Cooling 17

2.6.1 Cooling Exhaust Recirculation 17

2.6.2 LN2 Flow 18

2.6.3 LN2 Adaptive Gain 18

2.6.4 LN2 adaptive gain calculations 18

2.6.5 Configured LN2 Points 19

2.7 MOTOR OPERATED VALVES 19

2.7.1 Motor Operated Valve Operation 19

2.7.2 MOV Timers and Failures 19

2.7.3 Pressure System MOVs 20

2.7.4 Blocking Valve Vent MOV 20

2.7.5 Liquid Nitrogen Source Select MOVs 20

2.7.6 Vacuum System MOVs 20

2.7.7 Leak Test, Line Test and Calibrate MOVs 20

2.7.8 PLC Program Vacuum MOVs 20

2.7.9 Calibrate to Air, or AWACS Back Pressure 21

2.8 Solvent Extraction System 21

2.9 Oxygen Analyzer 22

2.9.1 Oxygen Analyzer Maintenance and Calibration 22

2.9.2 Oxygen Analyzer Operation 23

2.10 Set Point Limiting for Air Temperature 23

2.10.1 Setpoint Limiting Rational 23

2.10.2 Setpoint Limiting operation 23

2.11 RTU FUNCTIONS 23

2.11.1 Resetting the RTU System 23

2.11.2 RTU System Description 25

2.11.3 RTU Reference Manuals 25

2.11.4 ST3000 Smart Transmitters 25

2.11.5 RTU System Details 26

2.11.6 MiniCOP 26

2.11.7 Subroutine 102 26

2.11.8 Read MiniCOP to PLC 26

2.11.9 MiniCOP Software Test 27

2.11.10 Stand alone Minicop Program Test 28

2.11.11 Cold Boot MiniCOP 28

2.11.12 DATACONTROL Command Setup 28

2.11.13 GOTCHA 29

2.11.14 RTU Error Detection 29

2.12 Blowers 30

2.13 Door Stuff 31

2.14 AWACS 32

2.14.1 Configured points 32

2.15 STOP BEFORE PRECURE 33

2.16 Initialize Run 33

2.17 Startup 34

2.17.1 Deviation alarm limits 34

2.17.2 3QI126, OPERATOR CONTROLD NOT BACKUP (1137) 34

2.17.3 3QI124, OPERATOR CONTROLS READY (1150) 34

2.17.4 3QIRDY, EQUIPMENT READY TO RUN (1125) 34

2.17.5 3QI155B, CYCLE RUNNING 34

2.17.6 3QI152 CURE IS INITIALIZED 35

2.17.7 3QA110, ALARM LIGHT 35

2.18 Fischer Valve manuals 36

3.0 PLC Program 37

3.1 Honeywell PLC 37

3.2 Referenced documents 37

3.3 Using the PLC Loader software 38

3.4 PLC Program outline 40

4.0 TECHNICIAN NOTES 52

4.1 mX + b Equation 52

4.1.1 Conversion 52

4.1.2 Thermocouple scaling example 52

4.1.3 Pressurization split range 53

4.2 Generic Control Loop 53

4.3 PLC Programming Notes 54

4.4 What would you like here? 56

APPENDIX 56

.End Table C.

1.0 Introduction

This document describes the functions and operation of the autoclave hardware and Programmable logic controller (PLC) functions. The purpose and emphasis of this manual is provide the level of detail necessary to operate and maintain the autoclave control system. The level of discussion presupposes that the reader is familiar with the purpose and normal operation of the autoclave, that he/she is familiar with the Process and Control diagrams, and has access to the vender manuals and design documents.

This manual describes the functions of the system from the electro-mechanical process control devices, instrumentation, and operation. The other two major components, commonly known as the "Computer", are the TDC 3000 terminals and communications network, and the HP data collection computer. The TDC provides the operator interface,

custom graphics and the trending and reports that are available from the operator's consoles. The HP computer provides the process recipes, supervisory functions, and calculated part temperature. These functions also include the cure definition, initialization, and the run data report generation for QC.

1.1 HP-TDC-PLC operation

Several functions require all three of the major physical components. An example of the three components working together is the vacuum leak test. It is usually started during initialization by the HP computer, which then transmits the request across the TDC communications network to the PLC, which then performs the valve changes for the test. The PLC reads the vacuum transmitters and provides the data which can be read by either the TDC or the HP Computer. The HP then decides whether the test has passed or failed. This document concentrates on the functions provided by the PLC.

1.2 Functional Description Format

The functional descriptions include a description of the high level function, operator controls and operation, and down to the details of the actual valve and instrument operations (where it is necessary). There is a certain amount of overlap between this section and the chapter with detailed program descriptions. Section ??.?, PLC Program, is used as an adjunct to the documentation capabilities of the Honeywell Ms-Dos Loader package. The line comments in the program will often refer to the section in this document where additional information can be found.

1.3 Reference Designations

References to the physical components, such as valves and gauges, are made with the standardized reference designations that are detailed on page 1 of the Process and Control (P&Cs) diagrams. The three digit tag number is consistent through the documentation package. This number may be followed through the wiring diagrams to the PLC modules. One part of the wire number is the field device and the other part is the terminal strip or module that it connects to. The thermocouples and analog outputs (from the PLC's viewpoint) connect directly to the modules. All other field devices connect to the back panel terminal strips.

1.4 TDC and PLC Tags

The hardware tag numbers are carried through the PLC to the TDC with minor modifications. The hardware pressure transmitters are "PT"s, while the TDC calls them "PI"s. Thermocouples are temperature elements in hardware and "TI"s on the consoles. The leading number on the TDC Tag is not shown on the P&Cs since these drawings are specific to the Autoclave.

The switches in the TDC are called "Hand Indicating Switch". The Tag name is built from the prefatory autoclave number, "HIS", and the most relevant item tag number. For example, the Blowdown Switch, which locks the 4 inch vent valve open, is named "3HIS302". The switches on the TDC may be mapped to one or two points in the PLC. The TDC designation, "OP%" is the output from the TDC to the PLC. In the case of a switch it is a contact in the PLC program. The TDC designation "PV" is the input to the TDC from the PLC. The PLC program will set the on/off state of this element with a coil. In the case where the PV and OP% have the same PLC address, it is generally only a PLC contact. (Note that this differs from the operator interface switches in the #6 Modicon. Refer to the PLC Programming notes in the appendix for more details.)Tags, PLC vs. TDC

1.5 PID Loop Tags

An array of ten addresses per PID loop have been allocated for interface to the TDC. Six of the ten are configured as points on the highway. The PV (PICxxx), OP (aka Process Demand), and SP are analog inputs. These are read only points that yield a scaled indication on the TDC. The three tuning constants are counters, which simply pass the non negative, 16 bit, integer number. Since counters can not pass a decimal point, the tuning constants values are entered times one hundred, IE. a gain of 1 is entered as 100. The PID loops are written by Bill Ware of Honeywell in ladder logic. They have additional tables of variables used in the calculations. The most significant items are the SP (written to) and the PV, which are in engineering units times 10, such as PSI, Degrees F. and In Hg.

1.6 Control Point Tables Format

The start of each functional description includes a list of the major control points that are related to the operation of the function, and are configured on the highway. Each point includes the TDC Tag name, which may be one or two PLC tags, the PLC address, and a description of the function. The list may have points in common with other functions. A detailed description of the points as they relate to the function or internal programming is given in the text.

1.7 PID Control Addressing

1.7.1 PID Loop Tags vs. Loop number

The PID routine is written in ladder logic. It uses several tables of values that are accessed by indirect address operations. The actual datum address is determined by the beginning address of the particular table plus the loop number. The correlation is:

LOOP #      LOOP TAG    FUNCTION
1     3PIC300     Autoclave Pressure
2     3TIC500     Part temperature
3     3TIC540     Air temperature
4     3FIC600     Circulation Blower Horsepower
            control
5     3PIC450     Header 1 (West) vacuum
6     3PIC460     Header 2 (East) vacuum
7     3PIC440     (AWACS) Back pressure

1.7.2 TDC Interface Tables

The formatted data items on the TDC screens are usually done with the point type Analog Input, (AI). This allows the display to have a decimal point and/or a negative sign. Since the PLC uses integer arithmetic (without a decimal point) and the TDC Highway can not pass a negative number, this point type allows the transfer of real numbers. This point type expects the register value to be in the range of 0 to 4095 counts. The configured TDC low and high end engineering units are obtained from the point detail display, second page. The TDC configured parameters for each loop are in a group of 10 successive registers. The effective address is calculated as 10 times the loop number plus the starting address. The table below gives this correllation. The Point Type "XX" means that this point is not configured on the Highway.

HIGHWAY INTERFACE TAGS
Parameter Point Type Start Addr.

PV in Engn. Units (read only)       XX    6141
Process demand (Output)       AO    6142
SP in Engn. Units (PLC writes)            XX    6143
K Proportional gain .01 - 99.9            C     6144
T1 Integral gain Min/Repeat         C     6145
T2 Deriv. gain (rate) Minutes       C     6146
Low end PLC engn units        XX    6147
High end PLC engn units       XX    6148
A/D input bias (4 mA offset)        XX    6149
SP in 0-4K counts read only         AI    6150
T3 Tuning, rate decay time          C     6620

The low and high end Engineering Units values in this table is used only within the PLC. The TDC and the HP maintain their own copies of these values. Also, the smart transmitters are generally set up with these same scaling values.

1.7.3 PLC PID Parameter Tables

The TDC interface tables are written to and from another set of tables. These are not configured on the TDC Highway. They are accessed with indirect address registers. The effective address is calculated as Loop Number plus Starting Table Address. These items and two coils are given below.

PID TABLES
Parameter Starting Address

Output (Process Demand)       5970
A/D raw analog input          5520
PV in engn units (X 10)       6020
MCC Manual Control Command (PD in Man.)   5190
Scan flag         1900
Auto (On) / Manual Mode flag        1650
Proportional term (K X error)       5920
Integral term           5720
Derivitive term (Rate action)       5570

The last three values are useful for watching the effects of the tuning constants. Refer to volume 1 of the Honeywell 626-1202 Manual for an explanation of how all of this works.

1.8 PLC & TDC Data Tables

The three methods of getting analog information into the PLC (and to HP and TDC) from real I/O are Thermocouple Modules, Analog Input Modules, and the Novatech RTU. The highway can not access any of these devices directly, so the PLC "Pulls" the data, massages the values, and puts them into tables. The starting address of these tables are given as a guide to where they are located in the tag listings. These addresses can be "Searched" for in the PLC program to find rungs that show the table.

Start of Operator switches and indicators       1000
Open current loop status                  1101
PID Deviation alarms                1200
Vacuum valves, source select              1401
Solvent extraction valves select                1451
Deviation alarms limits (Engn. X 10)            4111
Cure specification (downloaded)                 4201
Cure specs, same table, used by PLC in run            4701
Analog Inputs, (rescaled 0 to 4095)       4330
RTU data table (0 to 4095)                4350
Thermocouple inputs                 4400
Thermoucouple channel open status         4501
RTU channel status (register values)            7950
RTU channel status (coils)                1550
Search for 1566 and 1582
RTU channel ignore bad channel registes         5101

1.9 Contacts

These venders and representatives have been involved in the Autoclave Modernization Project. They can provide technical and/or repair information.

Honeywell:

Mike Keser, PLC expert, sales representative, and a helpful soul.
He does not handle this area any more, but can frequently answer technical questions off the top of his head. (503) 526-5113.

Repairs of PLC hardware, L.A. (800) 423-3704 Give them a P.O. number for repairs and priority orders for replacement.

Repairs and parts for Smart Transmitters and other Honeywell products: (800) 223-8947.

Mark Michaels, TDC equipment sales representative and service. Bellevue: 453-7559. His voice message box is 559. (He has the telephone number for Service Dispatch) Steve Buck is the TDC Technical service representative for this area.

Honeywell ICD, PLC headquarters in York Pa. (717) 848-1151 The next four people can be reached with this number. The accuracy of the information from some of the people at this office leaves room for improvement.

Bill Ware, PID routines author and most knowledgeable person in the PLC (IPC) division at York, Penn.

Scott Young, MiniCop Basic Program author and general PLC information. Contact at York, Penn. Ask for Marketing.

Tom Deller, Technical Services, York, Penn. PLC classes and documentation.

Les Furguson, Mgr. of MS-DOS Loader/Terminal software. Feel free to call him at any hour of the day or night if you encounter problems with the Loader software.

TDC Technical Support, Consultation fees paid through July 1989. Daytime, Az. hours. (800) TAC-PMSD Tell them the System Number is "HWJ".

Bud Gaynot (215)641-3402, Dick Lucas (X3405) Engineers for smart transmitters at Ft. Worth, Penn. They are very interested the quality of the smart transmitters. They will want a Detailed description of problems and/or failures of any Smart Transmitters.

Worcester "Wooster" and SVF Motor Operated Valves:
Industrial Valve and Fitting Co. 922-3175

AUSCO Valves:
Automatic Switch Co, Bellevue 454-6167
Larry Blane, George Ross, Jack Mosteller

Fischer Valves and Flow Sensors:
PCE Pacific Co. of Bellevue, 823-2112
Tom Fritsler is very knowledgeable about all of the green valves. Get the Serial Number off of the valve, along with the other ratings on the plate before calling him. (They keep records of all valves by serial number.)

ISI, Woodinville, HP software:
481-6325 Contacts: Ken Roberts, Michael Robbins. Normally coordinate these calls through Rob Stitt in Facilities Engineering, X1-3427

Novatech, RTU manufacturer. Information contact: Arlen Nipper , Bob Sardou (913) 491-3248 Office hours in Kansas City, 8 am. to 5 pm.
Honeywell sold their equipment as an "Off the Shelf" item, but has not done very well with support and/or information. Novatech is a small company which will be much more helpfull than York, Pa.

Thermoflux, heating system manufacturer on AC #3 and AC #5. Bob Moon,(918) 747-9394

2.0 Functional Descriptions;

.2.1 Pressurization System

2.1.1 Pressure Control PointsPressure Control Points

3HIS300     Backup pressure control
3PC300S     Setpoint for backup pressure
3HIS302     Open and lock blowdown valve
3HIS320     Close and lock N2 gas blocking valve
3HIS310     Air/Gas select
3PIC300     Pressure PV in use by PID controller
3PC300SP    Read only Set Point
3PC300OP    Read only Process demand
3PI301      Pressure gauge #1
3PI302      Pressure gauge #2
3HIS301     Select pressure gauge #2
3QAD301     Pressure gauges differ by > 2%

2.1.2 Pressure System Overview

The autoclave may be pressurized with either plant air or with nitrogen. The plant air pressure is regulated down to about 100 to 110 PSI. The nitrogen source is directly off the accumulators, so that this pressure can vary from a low of 160 PSI to a high of 365 PSI. The control valves for filling the autoclave are located at the south east corner of the chamber. The 1 inch and the 4 inch vent control valves are located on top. The autoclave has two safety relief valves that will open at about 225, depending on temperature, and a rupture disk that is currently 225 PSI at 350 degrees. A high pressure limit switch is located by the door controls. It will shut down the fill valves and open the vents until the pressure returns below the limit, which is a drop of about 25 PSI. Under fault conditions of a stuck open fill valve, it will cycle on and off; this will be a noticeably dramatic event.

2.1.2 Pressure System Operation

The pressure system is automatically controlled during a normal run by the cure specifications. Operator intervention is only necessary to handle exceptional circumstances, but even Backup will not allow pressure in the autoclave if the equipment and controls are not ready. Equipment Ready and Operator Controls Ready are necessary to start a run.

means that the door is closed and locked, there is no Man-In-Autoclave alarm, nor is the Emergency Stop button pushed in. The Ping Pong Valve closed status is part of the Operator Controls Ready indicator. The manual section entitled "Startup" lists the complete definition of these indicators.

Initialization on the HP Computer will set the autoclave to use nitrogen. Closing the door will turn on the automatic purge switch. The start-up screen also contains the Auto Switch To Air on Cooldown switch. It should be left on. Ocassionally, these controls will end up set incorrectly. The Equipment Status screen will tell you what is preventing startup.

2.1.3 Pressure Startup

The normal cycle starts with pressurization to the Vent Bags Pressure. The pressure ramp is put on hold until the bags are actually vented. If the bags do not vent for some reason, then pressure will not continue. This hold can not be turned off by the operator. The Post Pressurization Leak Test, abbreviated PPLT, is ocassionally used after pressure is applied, but before the bags vent. The system turns on Operator Hold when this specified pressure (setpoint) is reached. The operator is expected to initiate the test and to turn off the hold after it is complete.

2.1.4 Pressure Holds and Restarts

The hold on the temperature system is generally released when the pressure is at the first (and usually only) soak pressure. If the pressure does not come up to this setpoint, then the temperature hold may not be released. The temperature hold release may be specified in the cure to release at a number of minutes into any pressure segment. If the temperature hold does not release as expected, check the cure specification pages. Pressure may be held by temperature and released when either the Part Temperature reaches the specification, or at a number of minutes into a temperature segment. Since pressure can hold and release temperature, and temperature can hold and release pressure, it is possible to devise a cure specification that will lock up. No parts use this lockup cure at present, but the option exists if it becomes necessary.

Most cures call for continuous pressure over the entire cycle, but more than one pressure ramp and soak level may be specified. The run moniter shows the presure segment number and the soak time remaining. These segments and times are what is specified on the Cure screens. Odd segments are ramps and Even segments are soaks.

2.1.5 Auto Switch to Air

The Auto Switch To Air on Cooldown function uses the cure specification to select Air during the last cooldown ramp. The pressure in the autoclave must be below 100 PSI, and the Part Temperature must be below 280 degrees. The switch to air is accompanied by the sound of the nitrogen blocking valve closing. This event also initiates the Purge function. Refer to the Purge discussion below.

2.1.6 Blowdown and Blocking Valves

The Blowdown can occur for several reasons. The normal blowdown occurs when the last temperature soak at room temperature is completed. The pressure soak timer may also time out, although this is rarely used. The Emergency Stop Button will blowdown, but Man-In-Autoclave will not. Unintentional intervention may also cause blowdown and/or termination of the cure cycle. That is the right autoclave that you have up on the screen, isn't it? Turning off the power to the PLC will cause termination of the run, as will putting it into Program Mode.

The Blowdown Switch and the Nitrogen Blocking Valve Switch on the Startup Screen are there for emergency use. Normally, they need not be touched. The Blowdown switch will over ride the automatic functions and open the vents and close the fill valves. The Nitrogen Blocking valve will close this valve and keep it closed. Before starting a run, the Blowdown Switch indicater will say "BLOW", and the output will say "CLOSE". The indicator will change to "CLOSE" once the run is started. The blocking valve output will indicate "OPEN" and the indicator will say "CLOSED" before the run. At the start of the run, the indicator will change to "OPEN" if nitrogen has been selected. Stated simply, you can force the blowdown valve open but you can not force it closed. You can force the Nitrogen Blocking Valve closed, but you can not force it open.

Pressure Backup will not allow pressure if the equipment and controls are not correct. It is used primarily for testing, but it is necessary to put pressure and temperature into backup if the run gets trashed by a power bump, ESTOP, or other operational anomolies.

2.1.7 Pressure Gauges

Two Pressure gauges are provided for controlling autoclave pressure. The alarm 3QAD301 indicates that these two transmitters read differently by more than 2%. If you get this alarm, look at the two readings on the Bypass screen. A failure of the gauge being used to control pressure will cause one of two events: either full pressurization or complete venting. The switch that selects which gauge to use is also on this screen, it is 3HIS301. These gauges are operated in analog mode and do not go through the RTU. This means that the readings will go seriously amuck if someone connects the Smart Field Communicator, (SFC) to the gauge. If this occurs during a run, switch to the other gauge and go discuss family lineage with them.

2.1.8 Nitrogen Blocking Valve