PAINT EMULSION INDUSTRY

NIKHIL RAONIRALI SHAHSHILPA GANESHMEGHA NATARAJAN

SIEMENS

Business Problem

A paint manufacturing company has approached Siemens India to study and automate their process which has a legacy system in place and increase the current production value. Client has maintenance issues with no process visualization tool to monitor runtime process and check alerts or trends.

Project goals

• This project aims at developing a logic for an automated paint emulsion industry using ladder networks in Siemens Simatic Manager

• The simulated and tested logic is practically realizable on the Siemens S7-300 series PLCs a much advanced version PLC

• It provides a process visual display of the real-time field process on a SCADA screen using Siemens WinCC

• The automated solution will improve productivity • The maintenance issues will be resolved with

both automatic and manual set up provided

Technology Used

•Simatic Manager•WinCC SCADA•MS Office •Windows Paint•VMWare•Ladder, FBD etc.

S7-300 SERIES PLC

SIMATIC MANAGER

• Core of every SIMATIC S7 project .• Objects used:

Organization Blocks Function Blocks Data Blocks Variable Tables

• The ladder networks make use of NO/NC contacts, Counters, Timers, Comparators

WinCC

• Powerful HMI system• Used to visualize the

process and develop the graphic user interface for the operator. • Allows the operator to

observe and control the process.

1. Graphic Designer: The SCADA screens depicting the process in runtime are created with the help of the Graphics Designer tool of WinCC. It enables a visual display of the plant process by means of various objects and animations

2. User Archive: The quantities of the ingredients to make different emulsions is stored in the form of recipes in the archives.

3. Alarm logging: The editor for configuring the alarms is named Alarm Logging. Alarms inform the operator about process malfunctions and errors. Alarm Logging is used to define when and what type of an alarm is to be displayed with what content.

4. Authorization/User Administration: The User Administrator is used to issue and control access rights to users. The main task of the User Administrator in runtime is to monitor system logins and access rights

SUBSYSTEMS OF WINCC

5. Tag Logging: Selection and configuration of the process values to be archived is done using Tag logging. It enables archiving the process values during runtime and reading them.

6. Trend Control: It displays process data as a trend in graphic form. The trend type to be used may be selected. There is also an option of displaying current or archived values.

7. WinCC Runtime: With the runtime software, the operator can run and monitor the process. In particular, the runtime software has the following tasks:• Reading of the data stored in the

database.• Archiving of the current runtime data such

as process values and alarm events.• Running of the process, e.g. through

specified set-points or activation/deactivation.

DIAGRAM

INPUT VARIABLES

ALGORITHM

LADDER LOGICADDITION OF DMWATER CALCULATION OF SETPOINT

ADDITION OF SURFACTANT

MIXER WEIGHT INCREASE INDICATION

MIXER AGITATOR STARTS

ADDITION OF MONOMER FROM MIXER TO REACTOR

EMULSIFICATION FOR 1Hr

SCADA DISPLAY

AUTO MODE

Testing and results• The simulated automation logic was tested• It increased productivity by 52%• Saved process time by increasing cycle time by

35%• Process and runtime visualization provided

alerts and precision• Used to monitor and control the actual field

process, see its real-time status, read the alarms, service them and test all field components for failure, thereby providing a strong HMI system.

• Maintenance was easier with new set ups

References and Citations

• SIEMENS Trainee Manuals:• Totally Integrated Automation – I• Totally Integrated Automation – II• Course Material on SIMATIC HMI WinCC

THANK YOU