03-03-14 Functionality BRAUMAT Classic

SIEMENS

BRAUMAT Classic

Short Description

Functionality

Author: Siemens AG, A&D CC F&B, Erlangen, Germany

Siemens AG, A&D AS PA PM, Karlsruhe, Germany

Datum: 14.03.03

Author: Name Department City Phone Email Guenther Fischer A&D CC F&B Erlangen +49(9131) 98-1548 [email protected] Karlheinz Nötscher A&D AS PA PM Karlsruhe +49(9131) 98-1608 [email protected]

BRAUMAT Classic 1 / 52 Automation and Drives Control System Siemens A&D CC F&B / Germany 03-03-14_Functionality_BRAUMAT_Classic.doc 14/03/03

mailto:[email protected]

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Table of Contents

1 INTRODUCTION TO BRAUMAT ............................................................................................................ 5

1.1 GENERAL ................................................................................................................................................. 5

2 HIERARCHY................................................................................................................................................ 6

2.1 AUTOMATION HIERARCHY....................................................................................................................... 6

3 ARCHITECTURE HARDWARE ............................................................................................................... 7

3.1 SYSTEM ARCHITECTURE .......................................................................................................................... 7

4 ARCHITECTURE SOFTWARE ................................................................................................................ 8


5 PROCESS DISPLAYS.................................................................................................................................. 9


6 SYSTEM MODULE ICM .......................................................................................................................... 10

6.1 MODULES .............................................................................................................................................. 10 6.1.1 System Module .............................................................................................................................. 10

7 SYSTEM MODULE CONTROLLER ...................................................................................................... 11


8 PROCESS DISPLAYS................................................................................................................................ 12


9 TOOLS......................................................................................................................................................... 13


10 ORDER SYSTEM................................................................................................................................... 14

10.1 MODULES .............................................................................................................................................. 14 10.1.1 Technology Modules ..................................................................................................................... 14

11 RECIPE SYSTEM .................................................................................................................................. 15


12 OPTIONS TO BRAUMAT .................................................................................................................... 17


13 EVENT AND TROUBLE SHOOTING ................................................................................................ 18


14 STEP LOGS............................................................................................................................................. 19


15 MAINTENANCE .................................................................................................................................... 20


16 TRENDING ............................................................................................................................................. 21 BRAUMAT Classic 2 / 52 Automation and Drives Control System Siemens A&D CC F&B / Germany 03-03-14_Functionality_BRAUMAT_Classic.doc 14/03/03

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17 SYSTEM CONFIGURATION............................................................................................................... 22

17.1 CONFIGURATION.................................................................................................................................... 22

18 COMMON FUNCTIONS....................................................................................................................... 23

18.1 FUNCTION RELATED MAIN MENU ......................................................................................................... 23 18.2 LOOP-IN ALARM .................................................................................................................................... 24 18.3 ADDITIONAL ATTRIBUTES TO BRAUMAT OBJECTS............................................................................. 24 18.4 GRAPHICAL SOURCE VIEW .................................................................................................................... 25 18.5 ADDITIONAL INTERVENTION AND CHANGE LOGS.................................................................................. 26

18.5.1 Open change log ........................................................................................................................... 26 18.5.2 Change log view............................................................................................................................ 26

18.6 ENTITIES / DEVICE MODES .................................................................................................................... 27 18.6.1 Entity Groups ................................................................................................................................ 27 18.6.2 Additional ICM Mode Description................................................................................................ 27 18.6.3 Group and Individual Device Modes ............................................................................................ 27

19 ENGINEERING...................................................................................................................................... 29

19.1 PLANT DIGITALS.................................................................................................................................... 29 19.1.1 Trending tab .................................................................................................................................. 29 19.1.2 Parameter tab................................................................................................................................ 30

20 VISUALIZATION .................................................................................................................................. 31

20.1 PROCESS IMAGES ................................................................................................................................... 31 20.1.1 Real Values in Process Images ..................................................................................................... 31 20.1.2 Dynamic Application Call ............................................................................................................. 31 20.1.3 Faceplates ..................................................................................................................................... 31

20.1.3.1 Plant ICM Faceplate.............................................................................................................................. 31 20.1.3.2 Plant Analog Faceplates (analog input)................................................................................................. 33 20.1.3.3 Plant Analog Faceplates (analog output)............................................................................................... 34 20.1.3.4 PID Controller Faceplate....................................................................................................................... 35 20.1.3.5 Message Faceplate ................................................................................................................................ 36 20.1.3.6 Status-byte Faceplate ............................................................................................................................ 36 20.1.3.7 Entity Faceplate..................................................................................................................................... 36 20.1.3.8 Unit Control Faceplate .......................................................................................................................... 37

20.1.4 Indirect Addressing of Faceplates................................................................................................. 39 20.1.5 Tags in Process Images................................................................................................................. 39 20.1.6 Image Variable View..................................................................................................................... 40

20.2 TAG SEARCH TOOL (GLOBAL VARIABLE SEARCH) ................................................................................ 41 20.3 PROCESS IMAGE EDITOR........................................................................................................................ 42

20.3.1 General.......................................................................................................................................... 42 20.3.2 File - Menu.................................................................................................................................... 42 20.3.3 Edit Menu...................................................................................................................................... 42 20.3.4 Resources - Menu.......................................................................................................................... 42 20.3.5 Variable - Menu ............................................................................................................................ 43 20.3.6 Tools - Menu ................................................................................................................................. 43 20.3.7 Align and Distribute Variables...................................................................................................... 43 20.3.8 Copy Variables.............................................................................................................................. 44

21 RECIPE SYSTEM .................................................................................................................................. 45

21.1 RECIPE HIERARCHY................................................................................................................................ 45 21.1.1 Area............................................................................................................................................... 45

21.2 RECIPE CATEGORY ................................................................................................................................. 45 21.3 MASTER RECIPE..................................................................................................................................... 45 21.4 SEQUENCE OVERVIEW ........................................................................................................................... 47 21.5 STREAMS ............................................................................................................................................... 48

21.5.1 Open an Order List ....................................................................................................................... 49 21.5.2 Create a new order........................................................................................................................ 49


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21.5.3 Release Batch ................................................................................................................................ 50 21.5.4 Change a stream for a given batch ............................................................................................... 51

21.6 VESSEL Q_ING ....................................................................................................................................... 52


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1 Introduction to BRAUMAT Classic 1.1 General

BRAUMAT is a powerful process management and information system for breweries. It is optimized for automation and supervision of processes in the batch processing industry. It was developed by BRAUMAT PCU (Process Control Unit) for the process control level and BRAUMAT IOS (Information and Operation System) for process management. The system guarantees operational reliability as well as the protection of your investment. Operational reliability

• Back-up strategy (recipes, archives, reports, configuration data... are stored redundantly on two IOSes)

• Log function • Extensive on-line help system • Password (levels 2 ... 255) • Presentation close to reality via a high graphical resolution (1024 x 768 pixel) • Process-oriented

Protection of your investment

• Worldwide deployment of BRAUMAT systems • Adaptable system scope • Network-able, distributed system, possibility of modular expansion • Use of international standard hardware (Intel-PC, TCP/IP, SIMATIC) • Open system (Windows NT) • User-friendly recipe generation according to ANSI/ISA-S88.01 standard • Modern user interface (Windows Standard) • Integration of Windows TM applications ( WORD, EXCEL, ACCESS, …) • Use of all standard graphics tools (Corel DRAW, DESIGNER, …) • Networking via TCP/IP and SIMATIC NET - Industrial Ethernet - H1 • Development and transfer to SIMATIC S7 and the use of standard function blocks of S7 library • Combination of SIMATIC S5 and SIMATIC S7 in one installation


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2 Hierarchy 2.1 Automation Hierarchy

A Company has to handle diverse tasks of automation and organization. For these different tasks, integrated systems are used. The automation hierarchy and the corresponding BRAUMAT systems represent these levels.


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3 Architecture Hardware 3.1 System Architecture

Process management level BRAUMAT-IOS The process management level uses BRAUMAT IOS systems for monitoring and archiving process data. The systems are based on standard components such as PC hardware and WINDOWSTM operating systems completed with BRAUMAT system configuration software. BRAUMAT combines user-friendly, intuitive operator control and a wide range of functionality. On-line connection to other WINDOWSTM applications (MS-EXCEL, MS-ACCESS, ...) is easily done. Process control level BRAUMAT-PCU For process control, BRAUMAT PCU systems are installed. They consist of the programmable controllers SIMATIC S7-400 (CPU 417-4DP) and the appropriate technological modules. They are responsible for control and supervision of processes and acquisition and processing of measured values. Communication systems Communication between BRAUMAT systems is done by using an efficient industry bus based on SIMATIC NET - Industrial Ethernet - H1. Additionally, the PC-based BRAUMAT - IOSes can use all types of TCP/IP communication systems. This ensures a maximal open system that can be integrated into existing computer networks. Back-up devices Back-up devices are used to avoid a breakdown of the system.

• All process displays are kept redundantly on every IOS

• Message log, step logs and batch data are stored in 2 IOSes

• The decentralized structure (Industrial Ethernet) guarantees high reliability

Configuration BRAUMAT is configurable and integrates an engineering tool to support the generation and documentation of application components. For project engineers and operators, BRAUMAT offers standardized process control objects for a clear and reproducible structuring of the system. It is a uniform system throughout the plant with technological functions. The BRAUMAT configuration of the communication between technological objects in IOS and PCU is completely independent (Plug and Play solution).


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4 Architecture Software 4.1 System Architecture

User interface The user interface follows generally accepted guidelines for user interfaces on WINDOWSTM. Operating elements such as windows, menus and icons are used. Operations are made via keyboard and mouse, control panels and dialog boxes. This leads to a uniform user interface that makes learning and operating as easy as with other WINDOWSTM programs. Important frequently used functions are shown in the symbol bar and are also accessible via function keys.


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5 Process Displays 5.1 System Architecture

Process displays Full graphics and high-resolution display of process images make them appear very close to reality. Background images are designed by using any graphics tools that are compatible to Windows and that are able to create bitmap files. Display generating superposes these background images with dynamic objects representing on-line process data and technological objects. Technological objects are operated via special dialog boxes.


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6 System Module ICM 6.1 Modules

6.1.1 System Module

Individual control modules (ICM) For ICMs, BRAUMAT contains standard objects for control, locking and monitoring of actuators, valves, motors, slide valves, etc. The configuration of ICMs generates the corresponding messages and a detailed display with the following functions:

• Status display of ICM • ON-OFF signal using manual mode • Acceptance of faults/messages • Note function • Diagnosis of the corresponding interlocks (PLC program code) via display of 'block status' • Standard objects for controllers are also available. They are designed as PID or a three-step

software controller. Standard loop displays with suitable graphic primitives and operator panels are available as well.


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7 System Module Controller 7.1 Modules

7.1.1 System Module

PID / STEP - Controller

• Standard objects for controllers are available. They are designed as PID or a three-step software controller. Standard loop displays with suitable graphic primitives and operator panels are available as well.


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8 Process Displays 8.1 Modules

8.1.1 System Module

Process displays and their generation The plant's on-line process data is displayed in full graphics.

• Operation of technological objects by using particular dialogs. • For the selection of other process displays, panels, objects or menus are used. • Of course 'freezing' and printing of current process images are possible. • Arbitrary Windows programs (exe-files) can be started out of process displays • Background images can be designed using all Windows-compatible tools that create bitmap

files (*.bmp). • Symbols for ICMs are available in the extensive symbol library that can be freely extended by

the operator.


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9 Tools 9.1 Modules

9.1.1 System Module

Integrated PCU-Engineering Tool BRAUMAT is configurable and includes an engineering tool to support generation and documentation of application components. For project engineers and operators, BRAUMAT offers standardized process control objects for a clear and reproducible structuring of the system.

• Status display of all SIMATIC blocks (OB, PB, SB. FB, FX) • Program blocks are stored on hard disk. The on-line status information is continuously

updated by PCUs. • Editing of all PCU data blocks (DB/DX) throughout the network • Storing / loading of recipes or any STEP 5 blocks from IOS hard disk to PCU RAM or vice

versa.


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10 Order System 10.1 Modules

10.1.1 Technology Modules

Order System The order system offers:

• Easy specification of number and sequence of production orders and batches • Entry of additional production parameters with automatic adjustment of recipes to the optimum

batch size • Changes to defined order-specific production and process parameters • Display of batch sequence with the most important order parameters • Visualization of order status • Display of batch tracking


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11 Recipe System 11.1 Modules

11.1.1 Technology Modules Graphical Recipe System according to S88.01 standard The recipe system concentrates on the following elements:

• The basic recipes define process handling (sequences and alternatives) by grouping diverse basic operations (what's to be done). In the list of components (parts list), raw materials required for producing a recipe are described (what's to be taken).

• The component list describes the components of raw material (list of pieces) that are used for productions according to a special recipe.

• The master recipe characterizes processing parameters (time, temperature, pressure, etc). These parameters for basic operations can be entered dynamically (by orders, recipe types, manual input).

• Integration of user-friendly, extensive recipe generation and management systems. The recipe system is standardized according to ANSI/ISA-S88.01 standard. Operator control and visualization is done graphically and in list form.


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12 Options to BRAUMAT 12.1 Modules

12.1.1 Technology Modules Silo / Tank Data Management

• Assignment of raw material to silos and tanks. • Balancing of raw materials and components of silo and tank farms. • Specification of silos and tanks to be used by weighing systems. • Visualization of important silo and tank states. • Archiving of historical silo and tank data.

Weighing and Proportioning

• Fully automated weighing of several components. • Reproducible accuracy. • Uniform operator control of different weighing systems (i.e. SIWAREX, Toledo, HBM). • Specification of components for silos, weighing systems. • Definition of weighing parameters (i.e. set-point: Coarse / fine dosing, tolerances,

calibration...). • Proportioning via volume and flow meter.

Route Control Production plants often have numerous production routes. CIP programs must be controlled concerning their production course. The module route control offers:

• technological engineering of production and CIP routes • a diagnostic overview for service and operation • documentation of all routes using cross-reference lists

When planning sub-routes, the application itself generates the necessary interlocking programs for ICMs.


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13 Event and Trouble Shooting 13.1 Modules


Event and Trouble Shooting Faults and process signals can be displayed and selected by types. Comments can be added to faults. Event Logs Events are all faults and manual interventions by the operating staff. Messages and faults are stored in day-specific files and can be evaluated by different criteria. Message Log All faults, events and manual interventions of each batch can be displayed and are stored in daily files. The selection of messages by different criteria is possible. These daily files can be used for any other evaluation purpose as well.


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14 Step Logs 14.1 Modules


Sequence Step Logs Configurable data of current recipe processing in plant sections are stored and can be printed out (list of basic operations - date, starting time, setpoint and real values).


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15 Maintenance 15.1 Modules


Maintenance Data Preventive maintenance leads to increased operational reliability. The maintenance module offers:

• Registration and visualization of operating hours and switch cycles • Supervision of freely-configurable maintenance intervals with user-defined messages


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16 Trending 16.1 Modules


Trending System All measured values (related to batches or orders) can be stored in a curve archive. The curve archive offers the following functions:

• Process-oriented, trigger-able and batch-specific archiving of measured values in short-term (RAM) or long-term archives (files)

• Time-dependent storing of non-batch values • Fade in of set-point curves to evaluate actual value curves • Visualization and logging as full graphics curves with variable (manual) or automatic scaling of

axes • Selection of different analog/digital values per group to be displayed • Integrated tools like a curve ruler for better readability

Editing of set-point curves (graphical or via tables)


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17 System Configuration 17.1 Configuration

System configuration BRAUMAT can be adapted to any size of installation - from a stand-alone to a company-wide extensive network system. The configuration can be changed and expanded. The BRAUMAT client-server structure allows an expansion by any amount of PCs and PLCs.

Fast Ethernet 100MHz Fiber Optic

Fast Ethernet 100MHz Fiber Optic

Operator Terminals Client Operator Terminals Client

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Primergy

Process Data Management

TCP/IPServerredundant

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FILLING

FILLING


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18 Common Functions

18.1 Function Related Main Menu

The main menu is designed and structured as follows:


SIEMENS 18.2 Loop-In Alarm

Depending on the selected message in the alarm window, the program automatically calls a pre-defined process image for this BRAUMAT object. 18.3 Additional Attributes to BRAUMAT Objects

Each BRAUMAT object contains the following additional standard attributes:

Description of the functionality (Inlet Valve on T45 for CO2 Supply) Physical location in the plant (On Gas Block 4, underneath Tank FV1) I/O Address (I 25.2/Q 25.2)


SIEMENS 18.4 Graphical Source View

In the BRAUMAT Parameterization it is possible to fetch data from one module to another module without using program code. The following example shows a typical BRAUMAT module link documentation. CIP: Speed Control CIP Pre Run Pump

Functionality: Depending on the status of two different flags the CIP pump will fetch the actual speed setpoint for the frequent converter from three different sources. Starting from an analog/digital signal the graphical source view will show where and how the value is used in the different BRAUMAT modules. For example: The wort heater is controlled by a PID temperature controller. This controller will receive the process setpoint from a Digital Function Module (DFM) which is used from the Basic Operation “Heating”. This BOP is part of the Recipe Procedure “Wort Production” and is used within different brands. The explorer tree shows always the fetch direction, this means BRAUMAT shows the source.


SIEMENS 18.5 Additional Intervention and Change Logs

The functionality of logging all events, alarms, operator interventions or parameter changes during production is very important for all food and beverage producers, specially for a brewery. The intervention and change log program is developed in such a manner, that it is possible to add this functionality to previous BRAUMAT versions without interrupting the production. The log archive is daily structured. 18.5.1 Open change log

Example of the open dialog of change logging:

18.5.2 Change log view

The user can change the layout of the change log. Each column of the archive can be selected or deselected. Example of change logging view:


SIEMENS 18.6 Entities / Device Modes

18.6.1 Entity Groups

The entity engineering function allows additional to the definition of device groups, the definition of entity groups. Entities are used for maintenance interlocking functions and for process interlocking functions. A section of plant can only be a part of one entity, i.e. a portion of line can only be in one entity, and it cannot be a member of two entities. However any device may be a member of two entities. The entities should be defined according to the following two main criteria:

Device (Valves/Motors) and units can be part of an entity group. One device can be member of maximum two entities.

18.6.2 Additional ICM Mode Description

Icon view The icon view of an ICM displays the actual state of the ICM. Eight states can be displayed. Additional to these states the mode can displayed in two different styles. Style Example description Mode border

For each ICM mode a separate color can be defined. The width of the border can be defined.

Mode signal

The signals are stored in the system. For each mode a special signal is defined. The automatic mode has no signal.

Both

The two styles can be used at one time.

18.6.3 Group and Individual Device Modes Maintenance Mode The operator can set an ICM in maintenance mode, e.g. when the ICM is not available or defect. Once in maintenance mode the device cannot be activated either manually or automatically by the control system. For safety reasons the maintenance mode should be used as an administrative tool only. Affected by Maintenance If an ICM is set in maintenance mode, the rest of the devices that belong to the same entity are in maintenance mode as well. The device can be used in off/de-forced position.


SIEMENS Reserved for Automatic One ICM can be used by two different routes. So in the ICM faceplate two route ID's can be displayed. If the ICM is not used by RCS the fields will be empty.

A typical faceplate example:

Individual Device Modes The amount of ICM modes are increased to following modes:

Individual Device Mode “Forcing Enable” If the valve/motor is in a mode that allows the system to override a programmed interlock, great care should be taken when using this override.

Individual Device Mode “Simulation” This mode sets a valve/motor in a mode that allows an automatic program to operate when a valve or motor has reported an error or failure.


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19 Engineering

19.1 Plant Digitals

This Faceplate is a BRAUMAT standard module to display digitals. BRAUMAT uses TIMER modules for digital input/output signals. The faceplate can be used in the process images. 19.1.1 Trending tab

Within the digital faceplate a trending function is realized. The three signals are:

Digital input Delayed positive output signal Delayed negative output signal

A typical faceplate example:


SIEMENS 19.1.2 Parameter tab

In this tab the normal parameterization of the digital can be done. The values can be changed after the CheckBox "Change" is active. For this function a high user level is necessary. A typical faceplate example:


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20 Visualization

20.1 Process Images

20.1.1 Real Values in Process Images

Application Data in S7-Real (Floating Point -) Format can be shown in the process images. 20.1.2 Dynamic Application Call

BRAUMAT delivers the possibility to start applications via activating special variables in the process images. The application itself and call parameters can be defined. The parameters can be dynamic. A typical example is given in the trend application. It is possible to start an unit related trend application depending on the actual batch number. 20.1.3 Faceplates

BRAUMAT offers following faceplates: ICM, PID, analog input/output, digital input/output, Entities, unit control, status byte and message faceplates. 20.1.3.1 Plant ICM Faceplate


SIEMENS Icon ICM - State There is one bitmap selectable for the ICM Icon-state. The 3 status bits (activated, feedback OFF and Feedback ON) derive eight states (state 1 - 8). Eight different bitmaps are assigned to these eight states. Activated Feedback OFF Feedback ON Watchdog Time

Running Action

Comment State 1 no yes no no Not Active

State 2 yes - no yes During Opening

State 3 no no yes yes During Closing

State 4 yes no yes no Active

State 5 no no - no error

State 6 yes - no no error

State 7 no no - no error

State 8 yes yes/no no no error

Icon ICM - Mode Mode indication via icon frame The ICM Mode is displayed by the color of the frame. The colors and the width of the frame are free selectable:

Maintenance Affected By Maintenance Reserved By Automatic Idle/Automatic Manual

Mode indications via separate symbol Alternative the mode can be indicated via a symbol next to the icon on the right hand sight:

Maintenance (wrench in red color) Affected By Maintenance ( wrench in white color) Reserved By Automatic (gearwheel) Idle/Automatic (no Symbol) Manual (Hand)


SIEMENS 20.1.3.2 Plant Analog Faceplates (analog input)

Additional Functions: Icon flash: In case of simulation, the faceplate flashes during icon state. Trending: The "Trend-tab" shows the actual analog value. Addressing: The "About-tab" shows the address, location and description information of

the device.


SIEMENS 20.1.3.3 Plant Analog Faceplates (analog output)

Trending tab of the faceplate

Additional Functions: Icon flash: In case of simulation, the faceplate flashes during icon state. Trending: The "Trend-tab" shows the actual analog value. Addressing: The "About-tab" shows the address, location and description information of

the device.


SIEMENS 20.1.3.4 PID Controller Faceplate

Extended view of the controller faceplate In this tab some parameters of the PID controller can be changed. For the change a high user level is necessary. Trending tab of the PID controller faceplate

Additional Functions: Icon flash: Actual value out of limit value causes the faceplate flashes during icon state. Trending: The "Trend-tab" shows the actual, setpoint and output value Addressing: The "About-tab" shows the address, location and description information of

the device.


SIEMENS 20.1.3.5 Message Faceplate

The Faceplate shows selectable Alarms, Events and Messages in process images.

20.1.3.6 Status-byte Faceplate

The status-byte Faceplate allows visualizing up to 255 bit maps. The visualized bitmap depends on the value of the status byte. 20.1.3.7 Entity Faceplate

The entity faceplate is used for parameterization and adjustment of an entity. An entity is described as a data set in the PCU. For this data set a template is engineered on the IOS for the faceplate. One value of the data set can be defined as a status variable. For this value for each bit can be set a name. Entity-related data may be displayed and/or edited, by using an Entity Online Data Editor. A standard dialog is available, to view and/or change data related to every Entity. E.g., a tank Entity may have values like material, filling status, etc. A typical example: by clicking on the i-Button of Kettle-Whirlpool 6, the dialog opens showing the corresponding Properties. By clicking on the Status-Tab, a list of all status signals is presented.

Example for tank entity data


SIEMENS 20.1.3.8 Unit Control Faceplate

Icon view The icon representation type contains:

a bitmap with representation of the sequencer status the operation dialog

In the process diagram the selected bitmap is represented. Via the Bitmap the status of the sequence is indicated in the right lower edge.

Idle run

Current

Starting is not indicated

Re-Starting

Intermittent

Interrupting

Stopped

Stopping

Broken off

Interrupting

Stopped

Stopping

Ready

After the pressing of the left mouse button the operating dialog opens itself. Operation dialog Overview

The operating dialog divides into 3 parts:

1. Global functions

2. Allocation and calls to the batch

3. Sequence control

4. Recipe operation and their operation

Two more windows for the setpoint displays can expand the dialog.

The operating dialog is possible in the representation type 'icon' only.


SIEMENS Display

In this version without importance

Call of the application plant overview

In this version without importance Allocation Here the current allocation of the unit is displayed.

Call of the control recipe view for the current batch of the unit

Signaling of the process parameters for the batch

Signaling of the input list of the batch

In this version without importance

The operating dialog is expanded by the sequencer-related set points.

Sequence The name of the sequence is indicated. Status The status of the sequence is indicated. Signaling The status display of the sequence is indicated.

Start of the sequence. After pressing the button the dialog recipe selection is opened.→ Plant overview

Abort of the sequence

Sequence re-starting

Stopping sequence

Step selection; After pressing the button the dialog step selection is opened → System equipment list

Skipping over synchronization

Recipe operation The dates are indicated for the current step. Step operation

Restarting step

Stopping step

Switch operation step to pause

Stopping step

Abort step

Acknowledge operating request the text of the operating request is indicated in the display field above the recipe operation

Only relevant for the variant with EPE creating as FC. It is branched out to the status program for the block.

The operating dialog is expanded by the step-related set points.


SIEMENS Setpoint window

The sequencer setpoints or the step-related setpoints are indicated in the window. The setpoint can be changed directly in the window. If the setpoint SP is a type of "text", a dialog for the further selection of the setpoint cell can be opened. The size and column width of the setpoint windows can be changed. The concerning adjustments are stored. The windows for the setpoints of the step and the sequencer have different adjustments. Line view with title This view shows a sequence corresponding to the plant overview. It is not distinguished between 'Iconized view' and 'Operating dialog'

Overview

The buttons correspond to those of the operating dialog. Line view This view corresponds to the view 'line with title', however without the heading. The two views are for a table provided within the process figure. The setpoint windows are opened always only for a sequence. If the setpoint window is opened for a further sequence, the currently opened one is closed so before. Window view In this view the operating dialog is displayed immediately. In the view no header line is indicated and the dialog is not movable. Otherwise the signaling and the operation are just the same as in the operating dialog. 20.1.4 Indirect Addressing of Faceplates

A faceplate address subscribing is possible similar to indirect addressing in the process images. 20.1.5 Tags in Process Images

Process images should not be overloaded with information. But it is also important to get more information if required. BRAUMAT has a second layer including tag names of the designed variables. This information can be shown on screen alternatively or print out if required.


SIEMENS Example for tags in the process image

20.1.6 Image Variable View

An user dialog which provides all information of the existing variables in the image can be called. If selecting one variable in the table, the relating variable will be shown with a blue frame. The operator can set a filter for the variables in the image (for example only ICMs). The actual selected tag in the list is flashing on the image. Example of image variable view


SIEMENS 20.2 Tag Search Tool (Global Variable Search)

The tag search function allows the operator to search for a specific BRAUMAT object. The object can be assigned to a specific process display. After a successful search the related picture will be called and opened.


SIEMENS 20.3 Process Image Editor

20.3.1 General

Definition of the visualization surface Administration of static background images Connect process variables Create executable process diagrams While processing the same file of several users (IOSes) simultaneously the consistency of

the dates is guaranteed when the last storing attains validity in each case. Every IOS has its own images; i.e. it is independent of different IOSes (Redundancy). The

images can be loaded by a different IOS after having requested.

20.3.2 File - Menu

New

- Create a new document Open

- Open an existing document Save

- Safes open document under same file name Print the active document Switch in the runtime system

20.3.3 Edit Menu

Cut

- Removes selected texts or graphics from the document and copy them in the clipboard. Select all

- Select the entire list of variables Align

- as stated below Copy

- Copy selected objects

20.3.4 Resources - Menu Background image Loading

- Load a background image which has already been created


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Dyeing - Dye the current background image.

20.3.5 Variable - Menu Selection

- In this condition object can be dialed or selected. Information

- The information can be made visible in the application process diagrams in the menu Process images\Variables information.

Image change - Determining alternation to different process diagrams

Exec-FB - Connect executable Function block

Exec-IOS - Connecting executable PC file

Static text - Static assigned text

Value - Connect an integer variable or real variable

Hexadecimal - Connect a hexadecimal variable

Bit - Connect a bit variable

ICM - Boarded one of a single control element

Text - Connecting process value display through text outputs

Line - Connect a line

Bar - Process value display in the form of bars (level or upright)

Sound - Connect one variable with file *.wav

Control - Operation dialog Faceplate

20.3.6 Tools - Menu Via the item 'Configure tools' in the 'Options' Menu programs can be added which are

started via this menu later. Reference: Here graphics tools like Paint Brush or Micrografx Designer can be linked. If a background image is loaded in the image construction, these programs can be loaded by clicking the requested tool. Establish the option plotter program in the menu options under tools. The dialog enables to start graphic-independent application as for example MS-EXCEL without problems from this menu.

20.3.7 Align and Distribute Variables

The alignment of objects requires one dominant variable. This dominant variable will be the last selected.

Left - Shift variables, that the left border lines will be arranged in one vertical line

Top - Shift variables, that the top border lines will be arranged in one horizontal line

Bottom - Shift variables, that the bottom border lines will be arranged in one horizontal line


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Right - Shift variables, that the right border lines will be arranged in one vertical line

Center horizontal - Shift variables, that the objects will be centralized in one horizontal line

Center vertical - Shift variables, that the objects will be centralized in one vertical line

Distribute horizontal - Shift variables, that the objects between the left and the right in the row, will have the same horizontal distance

Distribute vertical - Shift variables, that the objects between the bottom and the top will have the same vertical distance

The alignment functions can be used via menu or toolbar.

20.3.8 Copy Variables

It is possible to copy variables including their properties in the images editor. The variable image will be placed next to the source variable.


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21 Recipe System

The BRAUMAT Recipe System is modular in structure and comprises a number of interfaces that provide the user with the necessary tools to create, organize and review the recipes. Furthermore, the recipe system provides the user the ability to monitor control recipes during execution. The recipe system generates unit dependent control recipes in conjunction with the batch system, which are loaded into the PCU at the start of the corresponding sequence. 21.1 Recipe hierarchy

21.1.1 Area

The highest level in the physical structure defines the area. For each area one BRAUMAT recipe server is needed (or with redundancy a server pair). 21.2 Recipe category

The highest hierarchy level for the recipe is the recipe category. One recipe category combines all master recipes (brands) that have similar functions e.g. the lager-wort production in the brewhouse, CIP brewhouse. All master recipes of one category share the same set of process parameters (values are master recipe specific) but not necessarily the same recipe procedure. There is no 1:1 relation required between recipe categories and process cells. The recipe categories are defined global for the complete beer production. Maximal 255 categories per site can be defined; the recipe categories shall be unique numbers in the complete brewery (1-255). For all batch processes the category, the recipe, order number and batch number serve as key for data archiving. Since most of the data selections work with these keys, a structured definition of categories is required. 21.3 Master Recipe The master recipe is an object that combines the process inputs, process parameters and recipe procedure. On starting a batch, a runtime version of the master recipe is constructed (control recipe) from the various components and is downloaded to the PCU for execution. The master recipe can be designed and tailored to suit the process and plant. At minimum it will comprise of a recipe header and a recipe procedure. Depending on the design, it may also include process parameters and a process input.

• Recipe Header: The header defines the relationship between the recipe procedures and process parameters.

• Recipe Procedure: The recipe procedure provides the structure for storing the operations or steps that have to be executed at run time in a chronological manner. It also stores parameters relating uniquely to this recipe procedure.

• Process Parameters: The process parameters can be used to store process values (time, temperatures etc) that are specific for a master recipe but not for the recipe procedure. BRAUMAT allows different recipe procedures to access these parameters by symbolic referencing.

• Process Input: The process-input function can be used to separately store quantity values of specific ingredients that are required to process a varying amount of a product. Again, this allows different recipe procedures to


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access these parameters by symbolic referencing. Component List is also known as Process Inputs.

The example below shows how different process parameters can be used with a common recipe procedure to make up different master recipes. Component lists are not considered in this configuration.

Process Parameters X

Recipe Procedure A

Process Parameters Z

Process Parameters Y

Master Recipe 1Master Recipe 2

Master Recipe 3

It is also possible to design the master recipe using a one to one ratio of procedures and parameters.

Master Recipe 2

Recipe Procedure B Process Parameters Y

Process Parameters XRecipe Procedure A

Master Recipe 1

Alternatively, the master recipe can be designed with a single recipe procedure component.

Recipe Procedure B

Recipe Procedure A

Master Recipe 1

Master Recipe 2


SIEMENS 21.4 Sequence Overview

Detailed program monitoring is done via Sequence Overview. This application displays a list of sequences, with the actual step executing for every sequence. There will be several lists that may be displayed. In the BH, lists for CIP and for each brewing line will be available. In Beer Processing, lists for CIP and for transfer programs will be available. There is a function, which allows showing only the running sequences in the actual view. The actual set points and actual values for the running step, as well as the corresponding Event View Page of the selected sequence will be displayed, as shown.

Sequence Overview application


SIEMENS 21.5 Streams

At the present planning state for the brewery, there is no need to implement streams. The reason is that e.g. in the brewhouse two lines work independently. The vessels and devices that serves both lines (e.g. hops extract dosing) also not offer alternatives for the two lines, since all these devices are unique. The stream function is therefore not required. Nevertheless if changes of the planning will be done this feature can gain importance and is therefore shortly described. Recipe Procedures are made up of Recipe Unit Procedures, which are linked together by synchronizations and alternatives. In the following example, EOP124 (SB124) of the mash tun reaches Alter.10 and starts kieve 1 (Sequence 10) or kieve 2, depending on the alternative value supplied by EOP124..

Example of synchronization in a Recipe Procedure As shown in the example, if there is more than one option to start a sequence then an alternative is needed. Although only one sequence, either unit 10 or unit 12 will be executing at runtime, all sequences will be shown in the recipe. The streaming function activates a filter on the recipe, so that for a given stream, only the relevant sequences will be shown. A stream must be selected before starting any given batch with any given recipe. The stream tells the recipe, which sequences are going to be used in production of that batch. It is possible to change the stream for a given batch at runtime. Only those streams that are possible at that time are shown for selection. E.g., before EOP124 starts either one of the kieves, both corresponding streams will be exchangeable. The following screenshot sequence shows the procedure to create a new order in the Batch Schedule application to start a batch in the Brewhouse. A stream is selected and changed for this batch.


SIEMENS 21.5.1 Open an Order List In the following Figure, the Order List for Production is opened.

Open Order List for Production (Brewhouse). The following Figure shows the opened Order List (Production).

Display of Order List for Production. 21.5.2 Create a new order

In the following Figure, a new order to produce batch number 00001 is created, using Recipe HG1072 and Stream M2. The corresponding bitmap for this Stream is displayed on the right side, including BRAUMAT Classic 49 / 52 Automation and Drives Control System Siemens A&D CC F&B / Germany 03-03-14_Functionality_BRAUMAT_Classic.doc 14/03/03

SIEMENS M2, MV-2, K7, UB-7 and WHP-7. In this dialog, only primary streams (designed for start) may be selected.

Create a new order and select a Stream. 21.5.3 Release Batch

The following Figure shows how the new batch, which is initially locked, is released. The first sequence of the Stream will be started, as soon as the Start Mode Conditions are met (“as soon as possible”).

Release the order, so that the system can start the batch.


SIEMENS 21.5.4 Change a stream for a given batch

A Stream for a given batch may be changed by clicking on the Line Name (“M2”) as shown in the following Figure.

View the actual stream (M2) If the batch is not running, only the primary streams may be selected. If the batch is running, only streams may be selected that fulfil the following rule: “All running units must be in the actual and the new stream”. By selecting “M3” in the following Figure, the corresponding bitmap for that Stream will be shown.

Change from stream M2 to stream M3.


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21.6 Vessel Queuing

The functionality of “Queuing” defines possible sources and possible targets of transfer processes. In all processes, not only in the brewing industry, we will find transfers between tanks or vessels with:

one source and more than one target more sources and one target more sources and more targets more sources and more targets

and additionally you can have one or more dosing processes, we call this

secondary sources (one or more parallel)

CWS1 Y1

P1

P2

Brewhouse output area Yeast tanks

Fermentation tanks

V1 V2

V3

V4

V7

V8V9 V10

V12

Y2

F1 F2

V11

F3 F4

Y3 Y4

Gully

Water

V5

V6

V13

V14 V15 V16 V17

V18

CWS2

Water

V30

Documents

03-03-14 Functionality BRAUMAT Classic