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Production Process Automation

1. Data sheet Solenoid valves type EV220B 15 EV220B 50 Capacity diagrams Example water 40777777 CT I T Capacity for EV220B 158 at differential pressure of 3 bar 2 30 41 I HH I H FH ae H 20 10 HEHE HH 6 SH H HH rH HH 3 abl Sa y E H S Ny 1 Wa 0 8 II 0 54444 0 4 0 3 0 2 01 HH HH 04 06081 2 34 6 810 20 3040 60 80100 200 m h Example air Capacity for EV220B 15B at inlet pressure p of 5 bar and outlet pressure p of 3 5 bar Approx 245 Nm h o o N WV o e n mM N N a a a a a a o o o o o o N N N N N N N N N N N N py bar 6000 rH 5500 i a TT H DO 5000 4500 4000 3500 H 3000 2500 co 2000 1500 5 1000 200 AT 500 0 1 2 3 4 5 6 8 9 10 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S Al
2. Data sheet Solenoid valves type EV220B 15 EV220B 50 Spare parts kit NC Brass versions DZR brass and stainless steel versions Type Seal material Code number Type Seal material Code number EV220B 15 EPDM 03201071 EV2208 15 EPDM 032U6320 EV2208 15 FKM 032U1072 EV220B 15 FKM 032U6326 EV220B 15 NBR 03206013 EV2208 20 EPDM 032U6321 EV2208 20 EPDM 032U1073 EV2208 20 FKM 032U6327 l 1 rese FKA 03201074 EV220B 25 EPDM 032U6322 EV2208 20 NER 03206014 EV2208 25 SRM 23240328 EV220B 25 EPDM 032U1075 EV2208 32 EPDM 032U6323 EV2208 25 FKM 032U1076 EV2208 32 FM CAES EV2208 25 NBR 032U6015 EV220B 40 EPDM 032U6324 ev220832 EPDM 03201077 EV220B40 FA 032196330 n RER FRM 03201078 EV220B 50 EPDM 03206325 EV2208 50 FKM2 032U6331 EV220B 32 NBR 03206016 EV220B 40 EPDM 032U1079 EV2208 40 FKM 032U1080 EV220B 40 NBR 03246017 EV220B 50 EPDM 032U1081 EV220B 50 FKM 032U1082 EV220B 50 NBR 032U6018 n Approved by pomos Sind The kit contains pproved by Attestation de A Conformite Sanitaire ACS Locking button and nut for the coil EPDM is recommended for water Steam max 140 C 4 bar Armature with valve plate and spring 2 FKM is suitable for oil and air For water at max 60 C O ring for the armature tube NBRis suitable for oil water and air Dezincification resistant brass 2 O rings
3. 5 21 SySleMteguire mentis lapilli case ee eee 5 celebrare 6 2 2 E m 6 22 1 Waiting tank PERS 7 22 2 E 9 223 Filter Cleans DypasSSu u au 22h a ea eae 10 2 3 Programmable Logic Controller 12 2 3 1 Programming environment i 14 2 3 2 Internet Connect 14 Z4 SEN SOUS Ss Sardis te RL Ls e e edis 15 DAM dinge d ii 15 p NEM du d 18 24 37 Tone O MEUS rue 19 25 AMO ne 2 2 5 1 Electronic valves icio ret a 21 2 5 2 Pumps and motor controllers iii 23 ZO Fenes se 24 2 7 Other components Lasses 25 3 Development Status iare ted In Eb ena 27 3 1 Prototype 1 flow monitoring 21 SS metet Zst RS 27 312 zelo Smart RT spa 27 3 22 Prototype 2 Sambas a oec a RPM NO Kio FSR 28 3 2 1 Navigation panels susanne ka 20 322 Internet connectivity sos 29 32 3 Phasel Watne kor 30 3 2 4 Phase 2 Concentration 31 3 3 Remaining Development nie 32 3 3 1 Serial communications flow sensor 33 33 2 Phase Su 33 xi 33 3 Byac atiOnD Eee et te da 34 534 Filter cleaning hp se ass 33 3 3 5 Batch mode res reete a san 35 3 3 6 Electrical enclosure tes nib ame nn 35
4. gt sem ee ep od ql I I 1 I I eae BES IC PD 200 D8 02 52086672 8 68 Data sheet Manuel override unit tool operated Manual override unit hand operated Isolating diaphragm kit Dar Material Code number Used for manual override in event of power failure Note Valve height is increased by 16 mm Solenoid valves type EV220B 15 EV220B 50 Brass size DN 15 32 seal NBR 032U0150 Stainless steel seal NBR 03200149 The unit consists of Media temperature 10 90 C Manual override body 4 screws 3 o rings Material Code number Used for manual override in event of power failure Stainless steel seal EPDM 03207390 The unit consists of Media temperature 30 120 C Armature incl closing spring Armature tube Stainles steel valve body e EI o O ring 3 68 x 1 78 O ring 19 x 1 5 O ring 5 x 2 5 4 screws 4nuts for transportation purpose only Seal material Code number The isolating diaphragm design ensures that no EPDM 642010609 fluid enters the armature area which gives the following advantages FKM 04201010 The valve is resistant to aggressive fluids impurities Media temperature 20 50 C in the fluid and to calcarous and scale deposits Media temperature 0 50 C The kit contains Assembled isolating unit O ring 4 screws Locking button Nut for the coil Ieo IC PD 200 D8
5. Production Process Automation Xabier P r Tejero Landa Final thesis for B Sc degree in Mechatronic Engineering Technology Faculty of Electrical and Computer Engineering School of Engineering and Natural Sciences University of Iceland Z Keilir SEX A T knifr i SENA H SK LI SLANDS y A 33 K s Production Process Automation Xabier P r Tejero Landa 24 ECTS thesis submitted in partial fulfillment of a Baccalaureus Scientiarum degree in Mechatronic Engineering Technology Advisor Burkni P lsson Final thesis for B Sc degree in Mechatronic Engineering Technology Faculty of Electrical and Computer Engineering School of Engineering and Natural Sciences University of Iceland Reykjanesbaer May 2015 Production Process Automation 24 ECTS thesis submitted in partial fulfillment of a Baccalaureus Scientiarum degree in Mechatronic Engineering Technology Copyright 2015 Xabier P r Tejero Landa All rights reserved Final thesis for B Sc degree in Mechatronic Engineering Technology Faculty of Electrical and Computer Engineering School of Engineering and Natural Sciences University of Iceland Graen sbraut 910 235 Reykjanesbaer S mi 578 4000 Bibliographic information Xabier P r Tejero Landa 2015 Production Process Automation BSc thesis Faculty of Electrical and Computer Engineering University of Iceland pp 99 Printing H sk laprent ehf F lkagata 2 107 Reykjav k Reykjav k Iceland May 201
6. 0 000229 0 23mbar This resolution is well above estimated minimum requirements and will prove extremely useful for the application of the pump s PID controller as later explained in chapter 2 5 2 The sensor can be connected by a two wire or three wire interface being the latter the chosen one for the project which powers the device by its own power lines and leaves one output exclusively for transmitting the signal Figure 2 12 Figure 2 12 PM2653 For more details on technical information refer to the datasheet connection diagram 30 in Appendix C To take advantage of the hygienic design feature a special mounting adapter is required Different versions are available which vary in shape and fitting It is not clear at this point which is more suitable for fitting into the system at hand and the assistance of a plumbing specialist might be required This presents no issue whatsoever for a plumber is present within geoSilica s staff who has been confirmed to be available to carry on this task The price of one such fitting the one currently available at the distributor s store is 15 903 ISK VAT and pricing for the other adapters should not vary much from this one s 18 2 4 3 Flow Flow meters are available in several designs ranging from mechanical to contact free devices Given the nature of the project a mechanical sensor is not viable for besides the pre requirement of being food approved as it would be in cont
7. analog output Table 2 2 Waiting tank I Os 1 0 Amount Description Digital Input 2 Level switches Relay output 1 Solenoid valve Analog output 1 Pump control The hot water being taken into the waiting tank must never be still in the pipes for during winters it could freeze as well as silica could sediment and affect the end product Therefore when the tanks are not being filled water must flow into another system This is easily accomplished by implementing a bypass with a smaller diameter than the valve used to allow water into the tank While the valve is closed water flow is forced through the small opening to the bypass Figure 2 3 but while the valve opens the liquid tends to flow through the point of less resistance the larger diameter outlet Figure 2 4 Once the tank is full and enough time has passed for the silica cli molecules to grow the pump can then start pushing the fluid into the recirculation system Figure 2 3 Bypass active Figure 2 4 Bypass inactive 2 2 2 Filtration circuit Built upon the original system made by geoSilica the core functioning remains the same Devices such as valves and pressure sensors are replaced with their respective electronic versions and some minor modifications are implemented An isolated diagram of the filtering loop can be seen in Figure 2 5 From waiting tank Figure 2 5 Filtration circuit diagram An air drain valve is added to the highe
8. min max bar min to max C Code number EPDM 03 16 30 120 032U8500 Gh 15 4 FKM 03 10 0 1009 032U8506 EPDM 03 16 30 120 032U8501 Gu 20 8 FKM 03 10 0 100 03208507 EPDM 03 16 30 120 032U8502 G1 25 1 FKM 03 10 0 1009 032U8508 EPDM 03 16 30 120 032U8503 GIA 32 18 FKM 03 10 0 1009 032U8509 EPDM 03 16 30 120 032U8504 G11 2 40 24 FKM 03 10 0 1009 032U8510 EPDM 03 16 30 120 032U8505 G2 50 40 FKM 03 10 0 100 032U8511 EPDM is recommended for water steam max 140 C 4 bar FKM is suitable for oil and air For water at max 60 C Low pressure steam 4 bar Max 140 C BA AC DC and BB BE DC coils Max 100 C BO and BP coils Max 90 C For water Max 60 C BO and BP coils Max 90 C Main type Time to open ms EV220B 1555 EV220B 2055 EV220B 2555 EV220B 3255 EV220B 4055 EV220B 5055 350 Time to close ms The times are indicative and apply to water The exact times will depend on the pressure conditions Closing times can be changed by replacement of the equalizing orifice Installation Optional but vertical solenoid system is recommended Max test pressure 25 bar Viscosity Max 50 cSt Valve body Stainless steel W no 1 4581 AISI 318 Armature Stainless steel W no 1 4105 AISI 430 FR Armatur
9. 1 86 421 Flow meter Modbus cable 2 000 est 1 2 000 Serial com cable PM2653 88 489 2 176 978 Pressure sensors Sensor adapter 15 903 2 31 806 Pressure sensor adapt CYJV2 3 000 est 2 6 000 Pressure sensor wire EV220B 20 000 est 2 40 000 2 2 valve Solenoid coil 5 000 est 2 10 000 To actuate valve Total 353 205 4 3 Evacuation The evacuation phase is composed of a simple design with few components Given the simplicity of the programming the development is estimated to last for two working days Table 4 4 presents the estimated workforce cost Table 4 4 Evacuation workforce cost estimate Reason Hourly cost ISK Hours Total ISK Workforce 5 000 16 80 000 Table 4 5 sums up the component s prices 38 Table 4 5 Evacuation component cost estimate Component Unit price Quantity Total price Description ISK no VAT ISK no VAT MHF15 27 781 1 27 787 Level sensors 21NG1HSM M12x1 4 pin 2 260 1 2 260 Level sensor cable connector EV220B 20 000 est 1 20 000 2 2 valve Solenoid coil 5 000 est 1 5 000 To actuate valve Total 55 047 4 4 Filter cleaning bypass The filter cleaning bypass requires the construction of the pipe section which constitutes the second recirculation system used exclusively for this purpose The sourcing of the materials machining and assembly are not part of the automation project itself thus it is not accounted for in the cost estimation Given that the system can contr
10. 2 HMI main Sak 29 Figure 3 3 HMI waiting tank screen ares actio e oed ca 20 Figure 3 4 HMI concentration screen 20 FiQUte 3 35 gt HMI trendine en mta vtt itus ba A ui hoa as 20 xiii Figure 3 6 Waiting tank process logic diagram eee esee eee Figure 3 7 Concentration process logic diagram eeen Figure 3 6 Purification process logic diagram xiv List of Tables Table 2 1 Symbol descriptions for system diagram 7 Table 2 2 Waiting tank LOSE EEE ER Ian 8 Table 2 3 Filtration circuit I OS Erin ill diodi Saeed 10 Table 2 4 Filter cleaning bypass IOS usus da dude el 12 Table 2 5 Unitronics Samba and Vision compared 12 Table 2 6 Price comparison of PLCs with expansions 13 Table 2 7 Level sensor types comparison EHI UR ann 17 Table 4 1 Waiting tank component cost estimate iii 37 Table 4 2 Concentration and purification workforce cost estimate 38 Table 4 3 Concentration and purification component cost estimate 38 Table 4 4 Evacuation workforce cost estimate eese esee eene 38 Table 4 5 Evacuation component cost estimate eese eene nennen 39 Table 4 6 Filter cleaning bypass workforc
11. 4 10 presents all the workforce related costs and sums them together Table 4 10 Total workforce cost estimate Workforce section Hourly cost ISK Hours Total ISK Concentration purification 5 000 330 1 650 000 Evacuation 5 000 16 80 000 Filter cleaning bypass 5 000 165 825 000 Batch mode 5 000 40 200 000 Electrical enclosure 5 000 120 600 000 Total 671 3 355 000 Table 4 11 presents all the components needed for the full project with the exception of the electrical enclosure air filter and air drain and diaphragm valves and adds their prices together 41 Table 4 11 Total component cost estimate Component Unit ISK no VAT price Quantity Total ISK no VAT price Description 42 V350 35 RA22 EX A2X 10 RO8 LRF 2000M Modbus cable MHF15 21NG1HSM M12x1 connector 4 pin EV220B 3 way valve Solenoid coil PM2653 Sensor adapter CYJV2 79 165 1 8 737 1 13 004 1 86 421 1 2 000 est 1 27 787 3 2 260 3 20 000 est 7 40 000 est 3 5 000 est 10 88 489 3 15 903 3 3 000 est 3 Total 79 765 8 737 13 004 86 421 2 000 83 361 6 780 140 000 120 000 50 000 265 467 47 709 9 000 912 244 PLC PSU available at geoSilica Local expansion adapter 8 relay expansion module Flow meter Serial com cable Level sensors Level sensor cable 2 2 valve Rough estimated cost To actuate valve Pressure sensors Pressur
12. Electrical enclosure As mentioned earlier the high levels of sulfide gas in the environment corrode and degrade the copper within electronic components Therefore the PLC power supply and other modules should be enclosed in a sulfide free casing To achieve this a modified electrical Electronics enclosure may be designed By Air Filter Box implementing a suitable air filter through which air is cleaned before being fanned into the box it is ensured that all air within the box is free of corrosive gases Figure 2 17 Different filter materials have been investigated e Activated carbon is a very common and cost effective material to filter hydrogen sulfide Carbon grains undergo x a process which opens micro pores and fissures on its A x ari surface increasing the internal surface area and thus E enhancing the material s adsorbent properties 26 Figure 2 18 e Specialized filtering materials are offered by Purafil a US A based company which focuses on the engineering of specialized filtering products 27 Their product Purafil Figure 2 18 Internal Odorcarb Ultra Media is specifically engineered for the structure of activated filtration of hydrogen sulfide and it is composed of ri activated carbon activated alumina and other binders resulting on a high reserve alkalinity product which provides the maximum neutralization potential available and assures the highest overall performance
13. e Design of automation system Overall system design including placement and type of sensor and actuators logic diagrams and general functionality e Selection of components on minimal budget Specific models and pricing for control unit sensors actuators and other components Low cost is a must e Implementation of remote access to PLC Remote access to the system both for monitoring and process control e HMI design Design and programming of the UI e Logic programming The implementation of the functionality within the control unit s o Waiting tank filling and timing Concentration process Purification process Evacuation process Filter cleaning process Batch process all previous processes in one o System configuration options e Design and construction of air filtration system Electronics will be placed in a copper abrasive environment thus must be enclosed into a safe cabinet with proper filtration e System installation Once the system is prepared it must be installed on site tested and adjusted as needed O OO OO It is not expected to complete all of the project milestones during the course of the project here presented as more time is estimated to be required to fully complete the development of the system Appendix A presents both the original and reviewed time plans of the project 2 Automation system design A well defined project starts with a good design To be able to develop the system with a minimal amo
14. pL ST v 9c UNS ST vV Hid STY TC ONL STY Te NL STE 9 nul ste 9 nul ste 9 nul SU 07 Hd ST E OT HJ SUC E an SUT EZ Mj ST T s UON SunuA 110day uonejje1su xoq JO U01 9a as xoq s3luo1132 dn 1eg 014U09 IAEA SJOSUAS A 1 Ae ds p INH suoneoiunuJulo2 SYdD SuiuueJ804d Jld 1 efoud 01197 uoneje1sul Ja MOJH u isap Y YIJEISIY el v eoe et 9 Dejez 91 62 Rm 6 ra ze lel S 6 SL en SL dy dex EN 194 1192X SLJEN SL 924 SL ver ysiul4 Dez lod Jalgexy FT Jog saiqex L STT TERS ST T GUONN HEIS uoneung STSOCPSM STYITNYL STHST PAM STETESNL ST ETE ONL STE ET UON STETTUNS ST E GUOW ST E B UNS STTIT UON ST ETE NL ST Z 9T UON STTSTUNS STTTEIS awen YSEL Sunum poday SuinoJdwii 9 Susa Sulodad 9 x99up 10413 Sulwwessoud ajnpow WUeJ8oJd 310 SurwwueJ8014 Wajs s JO usisaq SJOSUAS pue 1d UO YMEISIY sLoz Ken S1OZ Judy SLOZ YueW 0112 1 Bascjez6VoLELOU L v 1 6zozlecoze pL Lis S e Leve iz gusti 6 9 Legeseec oL oL EDU Lv 102 Aenigay 6102 Auenu QUEN Xse 51 52 Appendix B MHF15 data sheet extracts Detailed technical data Features Medium Measurement Light source Type of light Wave length Process pressure Process temperature GOST approval UL approval RoHS certificate Performance Response time Mechanics Wetted parts Process connection Housing material Electronics Supply voltage Resi
15. project and although the price appears to be much higher at first sight it reduces the overall cost of development It also includes the much preferred analog inputs which in the Samba are not present thus requiring an expansion module from early stages 2 3 1 Programming environment Both the V350 and Samba PLCS are configured through the royalty free software Visilogic by Unitronics This On button Off button software includes the programming environments for both the logic and HMI parts in one project making the Contact A development easy and dynamic The programming language is Ladder a standard in the industry This language is built around relay logic representing the program by a graphical diagram based on circuit diagrams of such systems Figure 2 7 Figure 2 7 Industrial on off switch in ladder language Unitronics offers great educational tools through example programs videos and webinars allowing the programmer to easily familiarize himself with the environment The help files give extensive information about the different features available plus they offer free professional online assistance to solve any given complications Overall programming with Visilogic is relatively easy and hassle free 2 3 2 Internet connectivity To connect remotely to the PLC a wireless data connection is utilized Several industrial grade modems are available but are very costly compared to a standard 4G consumer modem Th
16. this menu 25 in the controller will display the required distance between transducers which need to be installed accordingly e Lastly the parameters must be solidified permanently stored on the controller While the sensor is designed to function as a stand alone device it can also transfer the measurements to a PLC via the analog output and or serial bus The analog output can be configured to output any of the different measurements which the meter can monitor flow PT100 etc and is able to do so by different methods 0 20mA 4 20mA 20 4 20mA 0 4 20mA 20 0 20mA as selected by the user The range of the measurements is also configurable where it is possible to choose the values corresponding to the low and high ends of the analog output The RS485 serial communications port can be used both to read and write registries from and to the module It supports both Modbus ASCII and Modbus RTU protocols and allows to configure the baud rate parity data bits and stop bits making it compatible with most PLCs in the market Using this method of communication although much more time consuming than the analog option is a powerful solution which effectively transforms this sensor into a full expansion module for the PLC connected to it 20 By transmitting data through a serial connection it is possible to access several extra functions built into the controller 17 The most interesting ones for this project are Time period flow
17. ub tarefni Framlei slukerfi samanstendur af bi tanki ar sem k silkornum skiljuvatninu er leyft a fj llidast og vaxa og af hringr sarkerfi par sem k silmagni v kvanum er auki og hann svo hreinsa ur Fyrirliggjandi kerfi er einnig endurb tt me sj lfvirkri losun tilb inni afur r kerfinu samt v a gera hreinsun rs u kerfisins sj lfvirkari Framlei slan fer fram frekar afskekktum sta svo br n rf er a gera a m gulegt a stj rna og fylgjast me kerfinu me fjara gangi e remote access um interneti etta gerir stj rnendum kerfisins kleift a fylgjast me og stj rna kerfinu fr h fu st vum fyrirt kisins og ar me a l gmarka vi veru framlei slusta Verkefni er unni fyrir sprotafyrit ki sem ekki hefur miki fj rmagn og v er l g mikil hersla 4 a l gmarka kostna me v a velja eins kostna arlega hagkvema hluti og m gulegt er sem samr mast llum eim kr fum sem ger ar eru til kerfisins Dedication To my soulmate Kriselle Lou and my son Lawin P r It is your love what motivates me to do my best v Table of Contents List of Heures eX cc xiii Last of Tables ine deseas a u L e 8 XV Abbrevationis aerei xvii Acknowl dgements unire xix A a 1 LE The systemi to Automatize assi eet el 1 1 27 lt Broject mulestotie Sos eee Ru 3 2 Automation system desisn
18. 02 52086672 9 69 Danfoss Data sheet Solenoid valves type EV220B 15 EV220B 50 Equalizing orifice The kit comprises An equalizing orifice includes 2 O rings The valves A shorter closing time is obtained with a larger closing time can be changed by installing an orifice the shorter closing time the greater risk equalizing orifice of a size which deviates from the of water hammering standard valve Alonger closing time is obtained with a smaller orifice Equalizing orifice DZR brass size mm Seal material Applicable in Brass Stainless steel n EV220B 15 05 EPDM ERU 032U0082 032U6310 EV220B 25 08 EPDM EV2208 32 032U0084 032U6311 EV220B 40 P EV220B 25 1 2 FKM EM 032U0085 032U6314 12 EPDM EV220B 50 032U0086 032U6312 EV220B 40 14 FKM B D 032U0087 032U6315 Adjustable orifice The kit comprises An adjustable orifice including O ring and gasket The valves closing time can be adjusted by turning the setting screw Applicable in Adjustable EPDM Brass 032U0682 S I All EV2208 15 EV220B 50 valves Adjustable FKM Brass 032U0683 Approved by WRAS Approved by Attestation de Conformite Sanitaire ACS EPDM is recommended for water Steam max 40 C 4 bar FKM is suitable for oil and air For water at max 60 C Dezincification resistant brass IC PD 200 D8 02 520B6672 10 70 Dark
19. 03 16 10 90 03207175 FKM 50 40 03 10 0 1009 03247151 Brass valve body NO EPDM 032U7117 NBR 032U7180 FKM 0 1009 032U7118 EPDM 30 120 032U7122 NBR 20 75 03 16 10 90 032U7181 FKM 20 8 03 10 0 1009 03207123 EPDM 25 11 ili 03 16 30 120 032U7127 NBR 25 11 03 16 10 90 032U7182 FKM 25 n 03 10 0 100 032U7128 EPDM 32 18 03 16 30 1209 032U7134 NBRY l 32 18 03 16 10 90 032U7183 FKM 32 18 03 10 0 100 032U7135 wow 4 2 03 10 30 120 03207142 NBR 40 24 03 10 10 90 032U7184 FKM 40 24 03 10 0 1009 032U7143 EPDM 50 40 03 10 30 120 032U7152 NBR 50 40 03 10 10 90 032U7185 FKM 50 40 03 10 0 100 032U7153 EPDM is recommended for water NBRis suitable for oil water and air FKM is suitable for oil and air For water at max 60 C Low pressure steam 4 bar Max 140 C BA AC DC and BB BE DC coils Max 100 C BO and BP coils Max 90 C 5 For water Max 60 C BO and BP coils Max 90 C Only 10 bars on liquids NO IC PD 200 D8 02 520B6672 2 63 Data sheet Solenoid valves type EV220B 15 EV220B 50 Dezincification resistant brass DZR valve body NC 032U5820 EPDM 30 120 03205832 032U5850 EPDM is recommended for water Low pressure steam 4 bar Max 140 C BA AC DC and BB BE
20. 0L h 5000L h was determined for measuring thus the sensor was configured to output 4mA 20mA based on those limits 3 1 2 Zelio Smart Relay Schneider s Zelio is a so called smart relay a low end PLC which offers the possibility of controlling basic systems One such Zelio model SR3B101BD was purchased by geoSilica in the past and was decided to use in combination with the flow meter to monitor the flow and stop the system if errors were diagnosed A suitable power source accompanied this controller which can also be used later to power the Unitronics PLC when purchased This would be sufficient to connect the flow meter but it was found out that the analog input there present only supported OV 10V analog signal while the meter works with current output as previously stated 27 To overcome this issue an analog converter was borrowed from KIT which reads the current analog signal from the meter and outputs a voltage analog signal to the Zelio This isolated analog converter is manufactured by Schneider model RM CL55BD A wiring diagram and terminal description can be found in Appendix E A GSM terminal was also borrowed from KIT along the required SR2 COMOI module which allows the system to send SMS alerts to geoSilica s staff upon an alert is triggered accompanied of a short text describing the error abnormally high or low flow Besides alerting via SMS the controller stops the pumping from the waiting tank if the flow is
21. 2015 Longrun industrial instrument CO LTD Ultrasonic flow meter user manual Type LRF 2000M n a Online Available http www ultrasonicscn com Download User manual LRF 2000M 20User 20Manual pdf Accessed 29 April 2015 Longrun industrial instrument CO LTD Ultrasonic Flow Module LRF 2000M Longrun industrial instrument CO LTD n a Online Available http www ultrasonicscn com Products Ultrasonic flow meter LRF 2000M html Accessed 07 May 2015 Innanr kisr uneyti Reglugerdasafn Regluger um neysluvatn 2008 Online Available http www reglugerd is reglugerdir allar nr 536 2001 Accessed 15 May 2015 Danfoss A S Data sheet Servo operated 2 2 way solenoid valves Type EV220B 15 EV220B 50 n a Danfoss A S 2015 V sindavefurinn H sk li Islands Hva er a helst sem getur spillt neysluvatninu og hvernig komum vi veg fyrir a a gerist 2012 A neti Available http www visindavefur is svar php id 62801 Skodad 15 May 2015 A Andersen F Fontenay L R Hilbert and F Technology Corrosion of brass in drinking water with high alkalinity EUROCORR Denmark 2011 Wellington Rubber Co Ltd Material safety data sheet Material safety data sheet Wellington 2012 24 25 26 27 28 29 30 Stutzman Services Inc Introduction to constant pressure systems Stutzman Services Inc 2015 Online Available http www stutzm
22. 28 _ Activated Prices for these materials need to be further researched as well as the lifespan per volume unit given the average levels of airborne hydrogen sulfide in the Hellishei i area Ideal flow rates need to be calculated once the enclosure is chosen what should also be taken into account for the calculations A suitable container for whichever filtering product is selected needs to be either sourced or designed Different formats are possible such as cylindrical and slot based with no known performance differences between them 24 2 7 Other components A few minor components remain to be selected for the system to be completed These components are not electronically controlled and thus are somewhat outside of the scope of this project Regardless it is crucial to acquire the appropriate models ensuring they meet the requirements of the system Such components are e Air drain valve found on the recirculation system e Diaphragm valves found on the cold water inlets These components would be relatively easy to acquire with the assistance of a professional plumber or plumbing company salesperson 25 26 3 Development status The development of the control system is currently on the second prototype stage The following subsections present the different prototypes built and their various fragments In this chapter further development is also analyzed and planned With this information it is possible t
23. 4 Cost CS HMAC ioco On u ne UIN te aids rl At Watne tankini a RO RTC AD R ss 37 4 2 Concentration and purification 37 4 37 38 44 Filer ele anime Dy Pass na sanieren 39 AS Batch mole svale else 40 4 6 Electrical nclOsufe nuy sua usu sa Sa aa asus 40 4 7 Total cost SUMMARY ne abeti illo ia ba 41 5 Discussion 43 GCM CISION oer L u aS A A E AE tO Referei tess Appendix A Project time plan D Appendix B MHF15 data sheet extracts II Appendix C PM2653 datasheet 57 Appendix D EV220B valve datasheet 61 Appendix E RM CL55BD user guide 75 Appendix F Zelio program 77 Appendix G V350 connection diagram 79 xii List of figures Figure 1 1 The filtering unit to be automatized ic esse 2 Figure 2 1 Full system ns conse ae RR EE RANG dA 6 Figure 2 2 Waiting tank d
24. 5 Abstract An automation system for an existing production line is designed in this thesis This production line processes separated geothermal water to generate potable water with a high concentration of silica meant as a dietary supplement for human consumption The different system sections and their relevant processes are to be controlled by means of an industrial computer a Programmable Logic Controller flow pressure and fluid level sensors and actuated by means of electronically controlled valves The production is conducted in a remote location thus the need of implementing an automation solution with remote access This will allow the operators to control and monitor the production line from the company s offices minimizing the need to be present on site The project is made for a start up company thus emphasis is placed on minimizing costs by sourcing the most cost effective components that comply with the system s requirements Most of the components have been carefully selected and two initial prototypes have been built The plans for the final prototype are also presented with cost estimates made Utdr ttur bessi ritger fjallar um h nnun og kostnadargreiningu sj lfvirkri styringu e automation system fyrirliggjandi framlei slukerfi Framlei slukerfi er rs unarkerfi sem me h ndlar k silr kt skiljuvatn fr jar varmavirkjun til a framlei a mj g k silr kt vatn sem tla er til innt ku sem f
25. 8 8 Analog Outputs 0 2 Local expansion module No Yes Ethernet Optional Optional Web Server No Yes SD Card Support No Yes Remote operation Yes Yes Permeability IP66 IP65 NEMA4X IP66 IP65 NEMA4X App Logic MB 0 5 1 Memory Bits 512 8192 Memory Integers 256 4096 Long Integers 32 512 Double Word 32 256 Memory Floats 24 64 Timers 32 384 Counters 32 22 With the V350 being an advanced version of the Samba it is obvious that it is a better product although much more costly A Samba PLC was borrowed from the distributor for evaluation purposes and over the remaining length of this chapter it is analyzed and decided whether this cheaper PLC is sufficient and or ideal for this project Given the design of the system at least two analog inputs are required to begin with pressure sensors as well as several digital level switches and relay outputs solenoid valves An analog output is optional but recommended for it permits an easy implementation of a PID controller for the pump between the waiting tank and filtering unit thus optimizing pressure stability in the system and minimizing stress on the motor In later stages as when developing the cleaning bypass more analog I Os may be required These can be added by implementing an expansion adapter which bridges the PLC with a dedicated I O module Two kinds are available e Local expansion adapters are connected side by side to the PLC 5 e Remote expansion adapters utilize a serial po
26. By this method it is possible to allow a constant flow out of the system if the previously explained method proves to be non ideal By doing so the cleaning fluid might not be fully saturated once expulsed from the system thus making the process more expensive but it is left to determine which method is more effective Table 2 4 presents the additional I Os required for this part of the process 11 Table 2 4 Filter cleaning bypass I Os 1 0 Amount Description Analog input 1 Relay output 7 Analog output 1 Backflow pressure sensor Three way valves 3 two way valves 3 cleaning fluid pump 1 possible to use analog Cleaning fluid pump 1 instead of relay 2 3 Programmable Logic Controller A PLC was decided to be the best choice for a control system 1 Several PLCs were considered finding out that the Vision line from Unitronics was the best choice 1 Upon a closer inspection two models seemed to be the most appropriate ones the enhanced Vision 350 and the low budget Samba Both these controllers present an embedded full color 3 5 touchscreen and an array of choices of built in I Os Table 2 5 compares the two models considered 12 Table 2 5 Unitronics Samba and Vision compared Samba SM J R20 Vision V350 35 RA22 Price ISK no VAT 29 900 79 765 Digital Inputs 10 total 12 total Analog Inputs 2 8 digital remaining 2 10 digital remaining Analog Resolution bits 10 14 Relay Outputs
27. DC coils Max 100 C BO and BP coils Max 90 C Technical data dezincification Main type EV220B 15BD EV220B20BD EV220B 25BD EV2208 328D EV2208 40BD EV220B 508D resistant brass DZR valve body Time to open ms 40 40 300 1000 1500 5000 NC Time to close ms 350 1000 1000 2500 4000 10000 The times are indicative and apply to water The exact times will depend on the pressure conditions Closing times can be changed by replacement of the equalizing orifice Installation Optional but vertical solenoid system is recommended Max test pressure 25 bar Viscosity Max 50 cSt Valve body Dezincification resistant brass DZR CuZn36Pb2As CZ132 Armature Stainless steel W no 1 4105 AISI 430 FR Armature tube Stainless steel Wano 1 4306 AISI 304 L Armature stop Stainless steel W no 1 4105 AISI 430 FR Springs Stainless steel W no 1 4310 AISI 301 Materials Orifices Stainless steel W no 1 4404 AISI 316L Valve seat Stainless steel W no 1 4404 AISI 316L O rings EPDM Valve plate EPDM Diaphragm rom IC PD 200 D8 02 520B6672 4 64 Data sheet Stainless steel valve body NC Technical data stainless steel valve body NC Solenoid valves type EV220B 15 EV220B 50 Darf Connection Seal Orifice Ky value Differential pressure Media temperature 150228 1 material size m h
28. The filter cleaning bypass is an optional feature of the system which can be left for development once the rest of the design is completed On the meantime the filter can be monitored by the alert system and the process may be paused until the operators clean it by hand The logic design of this part of the system is thus left for future stages of development which also implies a lower cost of development while achieving all of the requirements 3 3 5 Batch mode Once all individual parts of production are automatized an option for batch production needs to be set This option will begin with filling the waiting tank followed by concentrating rinsing and possibly evacuating the product The number of batches should be configurable by the operator especially when the storage tank for the final product is large enough for holding several batches allowing for a constant production with minimal human interaction The filter cleaning bypass is highly recommended for being able to perform several batches in arow otherwise an operator would have to perform such operation whenever the necessity arises It is estimated that the development of this stage would be trouble free and easy to implement for the different subroutines it handles are programmed in earlier stages 3 3 6 Electrical enclosure A priority part of the project involves the design of the air filtered electrical enclosure to protect the electrical components from hydrogen su
29. UOTIETNIUTIIY AUR M WOJ4 JaTTOJJUO dung I dundi MOTJYDE Josuas dansa ed OO ONO N g JOSUAS BUNSS8dd ed I1 Ssosso oud uorieo2rjrund 8 9 UOTZESZUIIUOI A ee SJATEA PTOUaTOS I JOsuas aunssaud d PaL 1 1 O dio 21 uoT endeAa 8 9 aseud TI y3ty T jue Tana G gt ur xyue3 M BATEA PIOUSTOS s MOT T Ue 9 9 3 ia Esa f ni 79
30. abilities of the Unitronics family of PLCs and has aided on determining the most suitable model for this system This has also allowed the author to familiarize himself with the programming environment what in turn allows for a faster development in the future Few components are left to be sourced while few others need to have their prices confirmed Nevertheless the cost estimate is presumed to be accurate enough as to give a good idea of the budget required for the different stages The time required to complete the project is a very rough estimate and costs involving workforce are listed only as a reference If the project is to be completed it is possible to lower costs by arranging different payment methods than the one presented in this report freelance engineer Regardless the effort placed in minimizing the cost of components allows for more resources to be placed on workforce what seems to constitute the greatest cost of development Overall the project is now well defined with schematics ready most components selected and the programming in development A solid project design is delineated making it possible to commence the construction of the system 45 46 References 1 3 10 11 X b T Landa Research and analysis for the automation of silica production n a Reykjanesber 2014 Umhverfisstofnun Brennisteinsvetni n a Online Available http www ust is einstaklingar loftgaedi brenni
31. abnormal To do so the pump is controlled by one of Zelio s relays It is possible to turn the pump on and off at will with one of the buttons on the Zelio A power surge recovery system was also designed where the Zelio would resume operations in case of recovering from a power loss The Zelio controller is programmed with the royalty free software Zeliosoft which gives the option to program either through Ladder or FBD languages FBD was chosen for this project as the author had more experience with such language Appendix F shows a snip of the program created Once the Zelio was ready it was connected to the modules as seen in Figure 3 1 installed on the system and tested thoroughly The results were positive and the installation functioned as desired for several productions 0 10V signal Al Converter OOOOO Flow meter Zelio SR2 COMO1 SR3B101BD AO AO IN r4 4 20mA signal Figure 3 1 Prototype 1 connection diagram 3 2 Prototype 2 Samba The Samba PLC was used to prototype the base functionality of the system Initially it was unknown whether this unit would suffice for the project and given the portability of the program over to the V350 development on this unit was considered to be a good start 28 Samey the official Icelandic distributor for Unitronics loaned the PLC and several components for the prototyping Thanks to this the evaluation of the unit was co
32. act signed by the designer appears to be required before such a system is put to operation Given the level of responsibility involved an official advisor should be offered by the regulatory body to assist on the creation of automated systems for food processing in the author s opinion The development of a high quality system such as the one here presented where the system to automatize is already built and in operation presents complications when testing and debugging the setup To ensure the automation system is fully functional by the time it 1s first used a prototype system is indispensable Otherwise development times would increase given that the system would not be readily available at all times for experimenting In the case of geoSilica an old proof of concept system is available which may be used to test and improve the automation setup In other situations test devices could be required such as analog I O simulators pressurized chambers etc This project has been an excellent educational one for the author which has opened his eyes to a whole field of specialty that he finds exciting and rewarding The experience and knowledge acquired will surely open a wide array of doors in the future 43 44 6 Conclusion The system design has been thoroughly reviewed and approved by the end users The control logic is robust and fully accomplishes the requirements of the production process The Samba prototype has proven the cap
33. act with the final product explained in section 3 1 it would also be prone to silica build up on the moving parts potentially loosing accuracy and eventually all functionality Being budget an issue the most cost effective solution was found to be an ultrasonic flow meter by the Chinese manufacturer Longrun model LRF 2000M Figure 2 13 Its price is 86 42 ISK VAT Chinese products are commonly known to be of low quality and or questionable efficiency yet Longrun is a company specialized in flow meter technology with over 12 years of experience in the sector 17 this suggests their products are up to European industrial standards The only issue encountered so far is the user manual which although thorough and detailed can be difficult to understand at some points Figure 2 13 Longrun LRF 2000M flow meter 17 It features an accuracy of over 1 of the measured range and a repeatability of 0 296 being able to measure flow rates as low as 0 001 m s 17 This sensor includes a full suite of I Os Upstream and downstream transducer ports One analog output loop powered Two PT100 temperature sensor inputs Three analog inputs One OCT output One relay One RS485 serial communications port customizable Two ultrasonic transducers must be connected to the relevant inputs for measuring the flow rate of a liquid through a pipe section Although it is possible to use customized transducers Longrun offers seve
34. anservices com en about news ssu_constantpressure html Accessed 06 May 2015 UnitronicsWebinars Webinar PID and autotune 3 April 2013 Online Available https youtu be EqEqEdOx x8 Accessed 06 May 2015 US Building Laboratories Inc Filtration machines US Building Laboratories Inc 2009 Online Available http usbuildinglabs com filtration machines html Accessed 12 May 2015 Purafil Inc Purafil Purafil Inc 2015 Online Available www purafil com Accessed 12 May 2015 Purafil Inc Product bulletin for purafil odorcab ultra media 2015 Online Available http www purafil com wp content uploads 2015 01 Purafil Odorcarb Ultra Media Bulletin pdf Accessed 12 May 2015 B P lsson and D sgeirsson Interviewees Various meetings with geoSilica s staff Interview 2015 IFM Electronic GMBH PM2653 26 March 2009 neti Available http tds ifm electronic com tentacle servlet PdfRequestServlet styleId2datasheet2 xhtml amp partN umber PM2653 amp pg 500 amp site uk amp lang ENGB amp locale en GB Sko a 15 May 2015 49 Project time p Revised time plan 18 03 2015 A Original time plan IX Append ST S 0 PAM ST v Sc 185 ST v H4 ST Y ST1ES ST v OT UON ST v OT UOIN st OC UOIN ste ST PIM ST t 0c UON ST c8uns ST TT UON STE OT Uy s ep yz ep T s ep sAep y s ep Sz shep Sz s ep Sz s ep s s ep Te s ep s s ep OT s ep
35. by geoSilica as seen in chapter 1 1 adding all necessary electronic components which will connect to the control unit as well as modifying certain parts such as air drain placement Figure 2 1 presents the system diagram with all components in place Table 2 1 gives an explanation of the symbols there used Figure 2 1 Full system diagram Table 2 1 Symbol descriptions for system diagram SYMBOL DESCRIPTION Two way solenoid valve Three way solenoid valve Diaphragm valve pressure regulator Air exhaust valve Level switch Pressure meter Flow meter OV 0 n Xi xxt Pump The system includes the waiting tank filtration circuit and filter cleaning bypass The following subchapters explain the functionality of these different sections and relevant components 2 2 1 Waiting tank The inflow of water into the waiting tank is controlled by a solenoid valve which in turn is activated by the control unit Two liquid presence sensors are placed on a wall of the tank one at the lowest level and the other at the highest By means of these sensors the control unit can determine if the tank is empty full or somewhere in between Figure 2 2 shows a closer look of the waiting tank Figure 2 2 Waiting tank diagram Table 2 2 summarizes the required I Os for this part of the process The pump could be controlled by a relay but it is a more efficient method to implement a PID controller on an
36. ce What did though come to light was that the regulations for potable water systems in Iceland follow European legislations which dictate certain limits for the amount of certain dissolved materials in this medium 19 Given that typically these valves are constructed of copper it is of most importance to note that the maximum allowed presence of copper in drinking water is 2 0 mg l 19 Two engineering firms F lkinn ehf and Samey ehf were enquired for a solution to the problem It was suggested that stainless steel 316 would be the material of choice for this application A SI316L stainless steel is a chemically inert metal which is resistant to aggressive media 20 which makes it ideal for food processing applications On the downside components built of this material when compared to copper or brass are very costly thus great effort needed to be placed on research to try and keep costs to a minimum 21 Different sources point at the use of DZR brass a copper alloy engineered to resist the effect of leeching or the absorption of metals from the alloy into the liquid medium water Danfoss a world wide specialist on water systems control devices was approached to enquire about the issue Danfoss Iceland recommended the use of the EV220B 032U 1256 valve Figure 2 16 This is a solenoid valve with a Kv value of 2 500 m h the flow through at I bar of pressure composed of a brass body material 20 Although the DZR version
37. ce is 27 787 ISK VAT A suitable cable is required which costs 2 260 ISK VAT Since two units are required for the tank the total price for such section of the project is 60 094 ISK VAT The sensor and cable for the evacuation section costs 30 047 ISK VAT 2 4 2 Pressure Pressure monitoring is critical for the correct functioning of the system The pressure sensors require to be in contact with the fluid thus need to be built of a suitable material as well as being constructed with a hygienic design The low pressure range at which the system functions and the importance of keeping the system within permissible operating ranges demand a high precision and reliability set of meters Considering these requirements a suitable sensor was found within an acceptable price range FM s PM2653 pressure sensor Figure 2 11 priced at 88 489 ISK VAT is able to measure ranges of 1 bar 25 bar with an accuracy of 0 6 and a repeatability of 0 1 15 Figure 2 11 IFM PM2653 pressure sensor 15 This sensor is programmable and can be purchased ready to output an analog signal of 4 20 mA over the desired range 0 3 bar for this project with no extra charge This feature grants a high resolution when reading the analog output with a PLC for all resolution bits are utilized to measure the specific range Given that the analog resolution in the V350 PLC is of 13107 units 16 for a range of 0 3 bar the resolution would be ET
38. dual ripple Power consumption Protection class Electrical connection Output signal Switching mode Signal voltage HIGH Signal voltage LOW Output current Switching frequency Enclosure rating V connections reverse polarity protected May not exceed or fall below U tolerances Output overcurrent and short circuit protected With light dark ratio 1 1 Ambient data Ambient operating temperature Ambient storage temperature Fluids Switch LED Visible red light 650 nm 0 5 bar 16 bar 25 C 55 C v v v 2ms Stainless steel 316L polysulfon FPM G 1 2 Stainless steel 1 4404 10 V DC 30 V DC lt 5V lt 30 mA at 24 V DC without output load II Round connector M12 x 1 4 pin 1x PNP gt 1x NPN depending on type Normally closed Normally open depending on type Vs 2 9V Approx O V PNP lt 2 9 V NPN lt 100 mA 250 Hz IP 67 EN 60529 IP 69K EN 40050 25 C 55 C 25 C 70 C LEVELS S MHF15 CD m Z 50F FLUID SENSORS SICK 3 53 MHF15 LEVEL SENSORS Type code Switch output 1xPNP transistor output normally closed 1xNPN transistor output normally closed 1xPNP transistor output normally open 1xNPN transistor output normally open lt z MHF15 2 1 N G 1 S M Ordering information Enclosure rating IP 67 EN 60529 IP 69K EN 40050 Process conn
39. e 100L Tank N Input Output AY Liquid Figure 1 1 The filtering unit to be automatized This filtering system was analyzed in a previous project by the author of this paper 1 where the process was investigated categorizing the procedure in three stages Concentration The system is filled with geothermal water from the waiting tank and recirculated through the system Arsenic salts and other pollutants are filtered out of the system diluted in water while silica remains in the system As waste mass flows out of the system more geothermal water is introduced keeping the pressure constant This process goes on for about two days Purification Remaining in the system is the high silica concentrate yet arsenic and other pollutants remain in undesired quantities Therefore fresh water is introduced in the circuit while recirculation continues efficiently removing pollutants off the solution The process is estimated to last for about a day after which the remaining solution is pumped off the system and into a collection tank Rinse cleaning The filter tends to obstruct over time with the buildup of silica It is therefore necessary to rinse the system with a silica solvent a heavily alkaline solution between cycles The rinsing is calculated to last for approximately an hour after which the filter is washed with fresh water 1 2 Project milestones For the completion of this project several milestones are determined
40. e 1 25 bar 15 363 psi 0 1 2 5 MPa Application Application Type of pressure relative pressure Hygienic systems viscous media and liquids with suspended particles Liquids and gases Pressure rating 100 bar 1450 psi 10 MPa Bursting pressure min 350 bar 5070 psi 35 MPa Medium temperature C 25 125 145 max 1h Electrical data eee Electrical design 3 wire DC 2 wire DC Operating voltage V 14 30 DC Insulation resistance MO gt 100 500 V DC Protection class Ul Reverse polarity protection yes AA Output Analogue output Output function 4 20 mA analogue Overload protection yes Analogue output 4 20 mA Max load 2 max Ub 13 V 20 mA 550 at Ub 24 V 57 PM2653 PM 025 REA01 E ZVG US P Pressure sensors Measuring setting range Measuring range 1 25 bar 15 363 psi 0 1 2 5 MPa Setting range Analogue start point ASP 1 0 18 8 bar 15 272 psi 0 10 1 88 MPa Analogue end point AEP 5 3 25 0 bar 76 363 psi 0 53 2 50 MPa in steps of 0 1 bar 1 psi 0 01 MPa Factory setting ASP 0 0 bar AEP 25 0 bar Accuracy deviations Accuracy deviations in 96 of the span Turn down 1 1 Characteristics deviation lt 0 6 Linearity lt 0 5 Hysteresis lt 01 Repeatability lt 01 Long term stability lt 0 1 Temperature coefficients TEMPCO in the temperature range 0 80 C in 96 of the span per 10 K Greatest TEMPCO of the zero point lt 0 1 G
41. e cost estimate 39 Table 4 7 Filter cleaning bypass component cost estimate 40 Table 4 8 Batch mode workforce cost estimate eese esee eene 40 Table 4 9 Electrical enclosure workforce cost estimate 41 Table 4 10 Total workforce cost estimate lucidi ria 41 Table 4 11 Total component cost estimal uus iie ae ale 42 XV Abbreviations DZR EPDM FBD HMI I O IP ISK KIT NPN OCT P amp P PID PLC PNP PSU SMS UI VAT VS Dezincification Resistant Ethylene Propylene Diene Monomer Function Block Diagram Human Machine Interface Input Output Internet Protocol Icelandic Kr na Keilir Institute of Technology A type of transistor NPN sensor outputs pull down to 0V Open Collector Transistor Plug and Play Proportional Integral and Derivative controller Programmable Logic Controller A type of transistor PNP sensor outputs pull up to the positive rail Power Supply Unit Short Message Service User Interface Value Added Tax Versus xvii Acknowledgements First and foremost thanks to all my classmates Something very special was born in our group that made us work together and help each other through tough times Without you I would have never made it this far I love you guys you are family to me Thanks to Ruben Mencos f
42. e evacuation process is fairly simple once the purification has been completed the outlet valve may be opened and the drainage valve activated until the level sensor there present determines the processing tank to be empty Since it is not decided whether the outlet will be connected to a large container tank which could hold several batches of product or a smaller one for one batch at a time the method of evacuation has not been fully designed It is possible to implement a user activated evacuation protocol as well as an automatic one which could keep track of the number of batches produced making sure the container is not overfilled In the latter case the operator would reset the batch count upon emptying replacing the storage tank This part of the development presents a minimal amount of programming effort and can be quickly implemented at any stage of development 34 3 3 4 Filter cleaning bypass One of the most complex and challenging parts of development is the filter cleaning bypass system This process should be activated whenever the filter is diagnosed to be clogged by monitoring the different pressures and flow rate in the recirculation system The logic involving cleaning and rinsing the filter needs to be recursively repeated until optimal measurements from the sensors are achieved Also the filter needs to be thoroughly rinsed before engaging once again into production to avoid the contamination of the final product
43. e sensor adapt Pressure sensor wire 5 Discussion The art of automation is a complex one when a given system needs to be upgraded all relevant aspects must be well researched to ensure the process is carried in a straightforward fashion as to minimize the amount of issues encountered while developing the solution When handed the project and its basic requirements many aspects were overseen For one the problem regarding airborne hydrogen sulfide and its corrosive nature was unknown to geoSilica this issue was found mostly by chance when a salesman in Samey who had work experience in the power plant pointed it out The discovery of this issue would most likely have happened at some point but it could have been catastrophic otherwise This taught a good lesson on the importance of researching the environmental conditions of the location where the control system is to be placed Another breakthrough discovery was the realization of the lack of strong regulations for food processing systems in Iceland Although the European law dictates the Icelandic rules there seems to be a lack of specialists on the field which in turn makes it very troublesome to reach for advice and possibly results in many such systems not being up to current standards Based on the information gathered during this part of the research it seems though as the designer himself is solely responsible for ensuring the system is up to standards A quality insurance contr
44. e tube Stainless steel Wino 1 4306 AISI 304 L Armature stop Stainless steel W no 1 4105 AISI 430 FR Materials Springs Stainless steel W no 1 4310 AISI 301 Orifices Stainless steel W no 1 4404 AISI316L O rings EPDM or FKM Valve plate EPDM or FKM Diaphragm EPDM or FKM IC PD 200 D8 02 520B6672 5 65 Data sheet Dimensions and weight Brass DZR brass and stainless steel NC and NO Mounting angle EV220B 15 Solenoid valves type EV220B 15 EV220B 50 B mm coil type EV220B 20 180 EV220B 25 220 EV220B 32 EV220B 40 EV220B 50 370 66 IC PD 200 D8 02 520B6672 Data sheet Solenoid valves type EV220B 15 EV220B 50 Below coils can be used with EV220B 15 EV220B 50 Darf Coil Type Power consumption Enclosure Features 9WAC IPOO IP20 with protective cap BA on 15WDC with spade connector IP65 with cable plug BB clip on 10WAC IP00 IP20 with protective cap Psp 18W DC with spade connector IP65 with cable plug a 10W AC BE clip on 18WDC 1P67 With terminal box n 10WAC a BF clip on 18WDC IP67 With 1 m cable 12WAC 3 R D BG clip on 20W DC IP67 With terminal box 20W Hum free gt BNR 26 VA 1267 With terminal box and 1 m cable Ice For explosion risk 10W only including seal kit EXP BO screw on 21VA 01820090 environment zone 1 With t
45. ection G Process temperature 25 C 55 C Process pressure 0 5 bar 16 bar Housing material Stainless steel 1 4404 Electrical connection round connector M12 x 1 4 pin Output signal Switching mode Model name Part no 1x PNP Normally open MHF15 21NG1HSM 1052273 1x NPN Normally closed MHF15 21NG1NSM 1052272 1x PNP Normally closed MHF15 21NG1PSM 1052237 1x NPN Normally open MHF15 21NG1TSM 1052274 Dimensional drawing Dimensions in mm inch MHF15 63 6 2 50 M12x1 O Ring 22 x 2 5 1 26 O Ring 0 87 x 0 10 Connection type and diagram Connector M12x1 4 pin 4 FLUID SENSORS SICK 8013868 2015 03 26 Subject to change without notice LEVEL SENSORS MHF15 Application information Use in tanks side mounting The distance A 2 40mm 1 57 Sensor prism B 8 mm 0 31 The conical prism is to project into the container Note Strong surface forming liquids can lead to deposits on the sensor and affect the function Applications with foam Foam with low density can t be detected by MHF15 Foam with high density can be detected by MHF15 and can lead to faulty operation 8013868 2015 03 26 FLUID SENSORS SICK 5 Subject to change without 55 56 MHF15 LEVEL SENSORS Recommended accessories Flanges Welded flange G1 2 Plug connectors and cables Cable M12 4 pin straight connector female with molded cable 2 m PVC Cable M12 4 pin straight connector female with m
46. ed materials and makes it prone to clogging due to silica sediment e Guided radar A low energy electromagnetic wave is pulsed through a probe inserted in the tank By monitoring the time it takes for the wave to return to the transducer the fluid level is calculated 13 This sensor is thus in partial contact with the fluid requiring specific build materials e Hydrostatic pressure A precise pressure transducer is submerged into the fluid which calculates the water level based on the pressure created by the liquid column above it 13 This sensor is in contact with the fluid and must be of a suitable material and constituted of a hygienic design e Photoelectric These sensors use a light beam to detect an object s presence within their operating space 11 More specifically a diffuse photoelectric sensor could be ideal for this project Such transducers emit light which is reflected on a nearby object or fluid and returns to the receiving end of it A small surface of contact with the fluid is required thus the build materials must be food approved e Ultrasonic Similar to the guided radar method ultrasonic transducers send a sound wave which bounces back on the material and based on the time it takes to return the distance is calculated 11 These could be ideal for the tank given that they are contact free but could not be used in the recirculation system e Vibration A tuning fork is piezoelectrically energized which makes it
47. erefore it was decided to configure the PLC to work within a network where the modem has a static external IP and the router actively forwards the connections to a specific port to the PLC Figure 2 8 An additional Ethernet port is necessary to accomplish this which is not too costly Static External IP ex o Ethernet N 2 a Port forwarding C to PLC e Static Internal IP Figure 2 8 PLC internet connection diagram 14 To access the system the free software Remote Operator by Unitronics is used Figure 2 9 This program connects to the modem s static IP through the port of choice and allows the user to virtually access the PLC by presenting the display on screen Interaction is processed with the computer s mouse where a simple click equals a panel touch action gt p Silica Insert Password System Status Idle SE unitronics Figure 2 9 Remote Operator interface The software can be configured to load all settings upon start up making it easy to use for the end user A special file can be exported from Visilogic which stores all pictures and functionality of the program into Remote Operator thus data transfers are minimal only variable updates and user interactions are exchanged This is ideal for the project as data connection in the Hellishei i area is limited to Edge which is about 10 times slower than 3G about 135 kbps 8 VS 1300 kbps 9 respectively 2 4 Sensor
48. erminal box and 5 m cable For further information and for ordering see separate data sheet for coils IC PD 200 D8 02 520B6672 7 67 Darf Data sheet Solenoid valves type EV220B 15 EV220B 50 Accessories Application Code number Cable plug GDM 2011 grey cable plug according to DIN 43650 A PG11 042N0156 Universal electronic multi timer type ETM Voltage Touse Ambient Application IV AC with coil temperature C Code number External adjustable timing from 1 to 45 minutes with 1 to 15 seconds drain open With manual override test button 24 240 BA BD BB 10 50 042N0185 Electrical connection DIN 43650 A EN 175 301 803 A Outside adjustments Light diodes for indication Light weight and small size Allin one unit External adjustable timing from 1 minute to 45 Manual override test button minutes with 1 to 15 seconds drain open One solid state timer fits all coil voltages from 24 to 240 V a c Technical data Type ET20M Voltage 24 240 V AC 50 60 Hz Power rating Max 20 Watt Enclosure IP00 IP65 with power connector cable plug Electrical connection DIN connector DIN 43650 A Ambient operating temperature range 10 50 C Function Start with pulse Interval timer 1 45 min On timer 1 15sec Weight 0 084 kg Dimensions 24 m T NES iI O i I i NI Jp Tee i 3 EE S l ie
49. ers and gather data from the pressure sensor connected to the analog input of the meter The LRF 2000M user manual includes a table of registries to be used in the communications thus once the Modbus protocol is configured on the PLC accessing the relevant data should be a simple process 3 3 2 Phase 3 Purification The rinsing process happens within the same recirculation system as the concentration Because of this both processes are quite similar and many of the features programmed in phase 2 can be reused in phase 3 The greatest difference between the two is the fact that the inlet is controlled through a solenoid valve instead of a motor controlled by PID Although the inlet s pressure is adjusted with a diaphragm valve it is possible that variations in the mains pressure would affect the pressure after the diaphragm Therefore the pressure in the system needs to be monitored closing the solenoid valve if necessary 33 A logic flow diagram for this system can be seen in Figure 3 8 upon which the development will be based on Open cold water inlet Close cold water Turn on inlet recirculation pump 4 Open cold water Iniet Close cold water Turn off Setrinsedbt ep inlet recirculation pump Figure 3 8 Purification process logic diagram The development of this part of the system should not require much effort as long as the concentration phase is mostly developed beforehand 3 3 3 Evacuation Th
50. es not require any additional parts Given the simplicity of the process it is estimated that one working week would suffice to complete this stage once all previous ones are completed Table 4 8 presents the estimated cost of development Table 4 8 Batch mode workforce cost estimate Reason Hourly cost ISK Hours Total ISK Workforce 5 000 40 200 000 4 6 Electrical enclosure The electrical enclosure s design and development is a delicate task A suitable enclosure needs to be selected with price ranges between 20 000 ISK to 50 000 ISK The cost of the filter and filtering material is yet unknown An estimate of 100 000 ISK is presumed but all the factors left to research will greatly impact the initial cost The level of maintenance required is unknown as well 40 Development of the electrical enclosure should begin right away for it is necessary in all stages of development Considering the research required calculations and building time an estimate of three weeks of work is expected to bring this part to completion Table 4 9 presents the estimated workforce cost involved in this process Table 4 9 Electrical enclosure workforce cost estimate Reason Hourly cost ISK Hours Total ISK Workforce 5 000 120 600 000 4 7 Total cost summary If the project is to be brought to a full completion the costs presented in the previous subsections must be added to contemplate the total expense of development Table
51. fferent models offered included a stainless steel AISI316L version Upon further research it was determined that DZR brass is not suitable in Iceland The high alkalinity of tap water 21 appears to be overly abrasive for the material resulting in corrosion and therefore contamination of the fluid 22 Given all this information it is highly recommended to utilize valves with conducts built of stainless steel A SI316L The increase of price compared with other solutions is justified by the insurance of a fully qualified material for food processing systems avoiding contamination of the product issues with the regulatory offices and the long lasting properties of the material Therefore the EV220B family of valves is chosen for the parts of the project where a two way valve is required The DZR body type is composed of A SI316L steel in all parts where there is contact with the fluid and the seal is built with EPDM rubber an approved material in food grade systems 23 Its price is yet unknown but it is expected to see over 100 increase in price or 20 000 ISK VAT The datasheet for this family of valves can be found in Appendix D 22 An equivalent three way valve remains to be found for the later stages of the project It is expected to see up to 100 increase in price or about 40 000 ISK VAT 2 5 2 Pumps and motor controllers As previously explained a portion of the control system involves the handling of water pumps Seve
52. for the equalizing orifice Spring and diaphragm 2 O rings for the pilot system OD ooo Spare parts kit NO Type A Code number The kit contains EPOR 03200286 Locking button and nut for the coil EV2208 15 NO actuator unit EV220B 50 ESN 93210295 O ring for the armature unit Gi NBR 032U0299 1 EPDM is recommended for water Steam max 140 C 4 bar 2 FKM is suitable for oil and air For water at max 60 C NBR is suitable for oil water and air IC PD 200 D8 02 52086672 11 71 Data sheet Solenoid valves type EV220B 15 EV220B 50 Function Coil voltage disconnected closed I Coil I NC brass DZR brass and When the voltage is disconnected the valve plate 2 nd mg stainless steel 3 is pressed down against the pilot orifice 4 by 4 Pilotorifice the armature spring 2 The pressure across the skar diaphragm 5 is built up via the equalizing orifice 2 7 The Hagen dioses the mall cris 0 A Due as soon as the pressure across the diaphragm is equivalent to the inlet pressure The valve will be closed for as long as the voltage to the coil is 2 disconnected 3 Coil voltage connected open When voltage is applied to the coil 1 the pilot a ss orifice 4 is opened As the pilot orifice is larger 7 RY than the equalizing orifice 7 the pressure across the diaphragm 5 drops and therefore it is lifted clear of the main orifice 6 The valve is now open for unimpeded flo
53. iagram ligne 8 Figure 2 3 Bypass active uuu ea ed 8 Figure 24 Bypass inactive u usa n EI Aa 8 Figure 2 5 Filtration circuit diagram Sasse ae 9 Figure 2 6 Filter cleaning bypass diagram eese esee eene eene 11 Figure 2 7 Industrial on off switch in ladder language 14 Figure 2 8 PLC internet connection diagram eese esee eene 14 Figure 2 9 Remote Operator Merce kn a keine 15 Figure 2 10 Sick MHF15 level sensor 14 ini prete a 17 Figure 2 11 IFM PM2653 pressure sensor 15 18 Figure 2 12 PM2653 connection diagram 30 18 Figure 2 13 Longrun LRF 2000M flow meter 17 19 Figure 2 14 Longrun ultrasonic transducers 18 19 Figure 2 15 Ultrasonic transducer V mounting method 17 20 Figure 2 16 Danfoss EV220B solenoid valve 20 22 Figure 2 17 Electrical enclosure diagram eee edu dirae ee eeu dada panni cua 24 Figure 2 18 Internal structure of activated carbon 26 24 Figure 3 1 Prototype I connection diagram 28 Figure 3
54. ich pops upon tapping the password field there displayed After the user gains access to the system and is done with it he may lock the PLC by navigating back to the login screen The system will also revert automatically to the login screen if no touchpad activity is present in 60 seconds 3 2 3 Phase 1 Waiting tank The waiting tank functionality is fully implemented Upon request and as long as the tank is not already full the inlet valve will open allowing water to flow in Once the level reaches the top sensor a timer runs for 60s at which end the inlet closes This is used for ensuring the sensor is fully submerged once the water is still for water turbulences will create waves on the surface which will prematurely activate the sensor 30 Thus after the sensor detects water uninterruptedly for 60s the inlet valve closes and a dedicated timer runs which marks the time the tank has been full This timer will be user configurable in the future permitting geoSilica to adjust the time the water should rest before being processed When the timer reaches zero a marker is set indicating the water has waited for a long enough period waiting ready bit With this bit set the concentration process may begin The waiting ready bit is reset once the lower sensor stops detecting water For an easy understanding of this process Figure 3 6 shows the logic flow diagram upon which it was designed Open inlet pa Lue Close inlet Start t
55. ill depend on the pressure conditions Closing times can be changed by replacement of the equalizing orifice Installation Optional but vertical solenoid system is recommended Max test pressure 25 bar Max 50 cSt Valve body Brass W no 2 0402 Armature Stainless steel W no 1 4105 AISI 430 FR Armature tube Armature stop Stainless steel Stainless steel W no 1 4306 AISI 304 L W no 1 4105 AISI 430 FR Materials R Springs Stainless steel W no 1 4310 AISI 301 O rings Valve plate EPDM FKM or NBR EPDM FKM or NBR Diaphragm EPDM FKM or NBR 62 IC PD 200 D8 02 520B6672 Data sheet Solenoid valves type EV220B 15 EV220B 50 Brass valve body NC Media temperature min to max C EPDM 032U7115 NBR 10 90 03207170 FAME 15 4 03 10 0 1009 03207116 EPDM 20 8 03 16 30 120 032U7120 NERI 20 75 03 16 10 90 03207171 FKM 03207121 EPDM 03207125 NBR 10 90 03207172 FK 25 n 03 10 0 1009 03207126 EPDM 32 18 03 16 30 1209 032U7132 NBR 32 18 Ge 10 90 032U7173 FKM 32 18 03 10 0 1009 03207133 EPDM 40 24 03 16 30 1208 03207140 NBR 40 24 03 16 10 90 03207174 FAME 40 24 03 10 0 1009 0327141 EPDM 50 40 03 16 30 120 032U7150 NBR 50
56. imer INC Figure 3 6 Waiting tank process logic diagram This process has been created in duplicate meaning that two waiting tanks may be used in the production Although the rest of the program takes into consideration only the first tank a second tank can thus be effortlessly added what allows for a larger production and or reduced waiting time between batches 29 3 2 4 Phase 2 Concentration The concentration process is still in development The interface has been designed as seen in a previous subchapter and the logic is in development The PID and autotune functions for the pump are fully researched and implementing them should not present an issue The reading of the analog pressure sensors is programmed and linearization of the values implemented The linearized values are displayed in the real time gauges on the display The sensors have not been yet tested but their functionality and connection method are fully researched 3l The reading from the flow sensor is not yet developed It has been determined that the readings should be transferred through the serial communications port as explained in the following subchapter Figure 3 7 presents the flow diagram upon which this part of the system is being designed Turn on PID YF autotune amp open tub valve Turn on PID pump YE Turn on in 4 recirculation pump Figure 3 7 Concentration process logic diagram The alert system s logic is also left
57. is available within this line of valves it was later observed that this valve was built of standard copper thus Figure 2 16 Danfoss being non ideal and possibly prohibited for potable water EN220B OA valve i systems applications The price of the valve supplied by Danfoss is 8 757 ISK VAT and although this valve is likely to be unsuitable for the project it gives a reference point on valve prices To actuate the valve a solenoid coil is required Prices for this coils oscillate around 5 000 ISK VAT with little cost variations between models Because of the ambiguity of the matter the health department Heilbrig iseftirlit Sudurnesja was reached to assist on the sourcing of information regarding the approval of the DZR brass on potable water systems There it was confirmed that the celandic Food and Veterinary Authority was responsible for regulating such systems and the names of the individuals responsible of these operations were acquired It was though impossible to contact them at the time because of a workforce strike which still stands at the time of writing this report The health department recommended to attempt reaching the Danfoss central office in Denmark for the Danish are experts on these kinds of regulations After several phone calls and emails the same EV220B type of valve was recommended by their technical sales support department without giving any specifications on the material It was then observed that the di
58. l rights reserved 13 IC PD 200 D8 02 520B6672 6 Danfoss A S DCS IMCGP RJA 2015 03 73 74 Appendix E RM CL55BD user guide RMC L55BD RMC L55BD Description model Two terminals for 24 V supply connection A Power ON LED Three input selector switches depending on model An output selector switch depending on model A sealable protective cover A screw terminal block for inputs A screw terminal block for outputs gh U k N Zelio Analog converters have the following on their front panel depending on the Appropriate Selection terminals blocks Input type selection 9 Current Voltage Um Ll oa _ 10V Not used 0 10V 10V Vi IPG iem 4 20mA 0 20 mA Not used izpe 4 20mA 0 20mA Output type selection 10V 0 10V 0 10V e V att Vo OPG I 0 20mA H 4 20mA 4 20mA 75 76 Appendix F Zelio program Ga S m B18 3 D 3 Qo m a B35 5 m ii m M 2 lt Dia g x m ir 8 t Fe ei z m A 8 g t 5 H is amp 8 EE g t e m 2 2 5 8 3 nis sU pa nl S Iu AR E z s 233 sS e 2 wi 77 78 lagram d ion V350 connecti Appendix G dund
59. lfide corrosion as stated in chapter 2 6 Although the basic design has been created the choice of enclosure filter format and filtering material remains undone Pricing for the different components is yet unknown and more research is needed into the required air flow rate necessary filtering material volume surface of contact and longevity of the air filter This part of the project needs to be completed preferably before installing the system in Hellisheidi as to avoid damage to the electrical components which compose the system 35 Itis emphasized that the cost of research and development of the filtrated electrical enclosure is fully justified by the fact that without it the system would have a greatly reduced lifespan resulting into higher long term costs 36 4 Cost estimate This chapter summarizes the cost involved on the development of the different sections of the project The prices for the various components cost estimates for the parts with unclear prices and estimated development times with the relating hourly rates are added together giving a notion of the overall project cost at the different stages The tables in the following subchapters present this information Prices marked est are estimates considered 4 1 Waiting tank The waiting tank logic is fully developed in the prototype built during the project presented in this thesis therefore the only cost involved with this part of development is the ins
60. m This solution is meant for human consumption as a nutritional supplement This base system is fully operated by hand with some analog sensors for the user to monitor the status of the system At the time of starting this project the system was in development stage and several factors needed to be determined Thus development of the automation system had to be in constant adaption to its evolvement Therefore the thesis statement is To design and prototype an automation system for geoSilica s production line complying with all the system requirements while keeping the cost to a minimum As it now stands the system is composed of two distinct sections Waiting tank The geothermal water is collected into an array of interconnected tanks effectively creating a large storage unit where the silica particles are given time to increase in size The tanks must be filled and left to rest for a given period of time before initiating concentration Filtering unit Once the silica particles have increased in size the water is pumped into a recirculation system Figure 1 1 where a filter is present which allows water arsenic and other solutes to flow out of the system while the silica stays trapped into the recirculation system After all the water from the tanks has been pumped through the remaining fluid is rinsed with fresh water to purify the silica solution Waste Liquid Filtered Pressure Gauge Pressure Gauge Air Drain Valv
61. n process The implementation of the pump is not accounted for since it is not decided whether it will be controlled through an analog output or relay Regardless one port of each remains available on the PLC for whichever case To fully develop the design presented in this thesis including filter cleaning bypass and evacuation system an additional set of relays is necessary Two expansion modules are available solely for this purpose e IO ROS This module adds eight relays to the V350 PLC Its price is 13 004 ISK VAT e IO ROI6 This module adds 16 relays to the V350 PLC Its price is 17 578 ISK VAT To implement the filter bypass six additional electronic valves are to be controlled Therefore the O RO8 expansion module is diagnosed to be sufficient to complete the system s functionality As mentioned in chapter 2 3 an expansion adapter is required to connect any expansion modules to the PLC The EX A2X expansion adapter is chosen for this purpose which allows up to 8 expansion modules to be connected to the PLC 5 Its price is 8 737 ISK VAT which added to the price of the O RO8 totals in a sum of 21 741 ISK VAT 3 3 1 Serial communications flow sensor As explained in chapter 2 4 3 the LRF 2000M supports serial communications through the RS 485 connector The design shown in Appendix G takes advantage of this communications port to retrieve the current flow of the system as well as read and reset the meter s totaliz
62. o estimate the time remaining to completion 3 1 Prototype 1 flow monitoring Early into the project s development geoSilica decided that the measurement of water flow through the recirculation system was of interest Given the early stages of development at the time no control system had been decided upon thus a solution had to be implemented in a way that it would be reusable later on in the project It was also decided that flow rate could be used for a simple system diagnostics platform where an abnormally low or high flow would indicate a potential failure filter cleaning required air bubbles in the piping etc Budget was a recurring issue as well therefore the solution should be low cost without incurring a big impact in performance and reliability Thus the project was centered for a time period into finding and implementing this quick fix 3 1 1 Flow meter The flow meter presented in chapter two was chosen at this point because of its low cost contact less measuring method and versatility In accordance with geoSilica s interests a suitable pipe section was chosen for flow measuring The configuration steps for the meter were followed which required determining certain values as stated in chapter 2 4 3 Once configured the distance between transducers was noted and these placed accordingly The output method used was the analog output which can be effortlessly ported to any given controller An ideal range of 400
63. ol any pump by the use of a relay or analog output the cost of such device is considered to be outside of the scope of this project any suitable pump can be controlled with no modifications to the system here presented The cost of development is substantial given the complexity of the system and the frail nature of the filter Nevertheless most of the alerts involving pressure ranges should be programmed in the concentration phase which are reusable on this one Therefore an estimated development time of one month is assigned to this phase The cost involved can be seen in Table 4 6 Table 4 6 Filter cleaning bypass workforce cost estimate Reason Hourly cost ISK Hours Total ISK Workforce 5 000 165 825 000 A summary of the cost of components can be seen in Table 4 7 Many of these are rough estimates which need to be further researched 39 Table 4 7 Filter cleaning bypass component cost estimate Component Unit price Quantity Total price Description ISK no VAT ISK no VAT EX A2X 8 737 1 8 737 Local expansion adapter 10 RO8 13 004 1 13 004 8 relay expansion module PM2653 88 489 1 88 489 Pressure sensor Sensor adapter 15 903 1 15 903 Pressure sensor adapt CYJV2 3 000 est 1 3 000 Pressure sensor wire EV220B 20 000 est 3 60 000 2 2 valve 3 way valve 40 000 est 3 120 000 Rough estimated cost Solenoid coil 5 000 est 6 30 000 To actuate valve Total 339 133 4 5 Batch mode The batch mode do
64. olded cable 2 m PUR halogen free Cable M12 4 pin straight connector female with molded cable 5 m PVC Cable M12 4 pin straight connector female with molded cable 5 m PUR halogen free Cable M12 4 pin straight connector female with molded cable 10 m PVC Cable M12 4 pin straight connector female with molded cable 10 m PUR halogen free Cable M12 4 pin straight connector female with molded cable 15 m PVC Cable M12 4 pin angled connector female with molded cable 2 m PVC Cable M12 4 pin angled connector female with molded cable 2 m PUR halogen free Cable M12 4 pin angled connector female with molded cable 5 m PVC Cable M12 4 pin angled connector female with molded cable 5 m PUR halogen free Cable M12 4 pin angled connector female with molded cable 5 m PUR halogen free irradiated Cable M12 4 pin angled connector female with molded cable 10 m PVC Cable M12 4 pin angled connector female with molded cable 10 m PUR halogen free D0L 1204 W02M DOL 1204 W10M Appendix C PM2653 datasheet efectorsoo PM2653 PM 025 REA01 E ZVG US P Pressure sensors 1 tightening torque 20 Nm K CE us EC 1935 2004 EHEDG Certified EDA LISTED Product characteristics Electronic pressure sensor Made in Germany Connector no dead space Zero and span adjustable Programmable via EPS interface Sealing cone G1 male Process connection Sealing cone G1 male Analogue output Measuring rang
65. or seeing the potential in me when I was still looking for my path You recruited me to take this course what turned out to be one of the best decisions in my life Thanks to all the staff in Keilir Institute of Technology You make this faculty a friendly yet professional one The warmth of this place restored my faith in education Last but not least thanks to my advisor Burkni as well as Fida Davi and the rest of the staff in geoSilica You gave me the opportunity to work with you on this project which turned out to be not only perfect for me but also a tool for introspection which helped me realize where my potential lays xix 1 Introduction Automation is the application of automatic equipment in a process or system By means of automation manufacturing and other industrial processes are nowadays able to function at unprecedented speeds thanks to the high speed and accuracy of modern electronic devices One hundred years ago an industrial process would require constant supervision and several human workers In the modern world machines take the biggest part in the procedure by replacing most or all of the positions where a routine takes place such as assembly or process management This shift in methodology implies a lower demand of unskilled hand of work to perform and monitor the process while generates a higher demand for control systems specialists who create and implement automatic means of production Such systems are m
66. ostly composed of three main groups of components which the specialist must be able to configure and puzzle together into a design that carries the job s required These are e Control unit The brains ofthe system it receives the information from the sensors and controls the actuators as well as hosts the UI This device needs to be programmed to implement the logic required to complete the process Examples of such control systems are PLCs microcontrollers and any kind of computer which supports I Os e Sensors These collect data from the system and transfer it to the control unit In many cases they need to be programmed for a specific purpose such as output signal type operational range etc and always need to be chosen to be compatible with the control unit Examples of inputs are limit switches pressure meters and temperature meters e Actuators The devices which move or control a mechanism or system typically powered by an electrical source The actuators are the automated analogy of human hands physically adjusting the variables to be controlled Common examples are solenoid and motorized valves motors and pneumatic jacks 1 1 The system to automatize In this project a base system designed by geoSilica a local start up company is to be automatized This system processes waste water from a geothermal power plant separated geothermal brine to generate a highly concentrated solution of silica in a purified water mediu
67. perated 2 2 way solenoid valves Type EV220B 15 EV220B 50 EV220B 15 EV220B 50 is a universal indirect servo operated 2 2 way solenoid valve program Valve body in brass dezincification resistant brass and stainless steel ensures that a broad variety of application can be covered Built in pilot filter as standard adjustable closing time and enclosures up to IP67 ensures optimal performance even under critical working conditions Features and versions For water steam oil compressed air and gases EV220B NC and NO brass version for neutral Flow range for water 1 3 160 m h liquids and gasses Differential pressure 0 3 16 bar EV220BD NC DZR version for neutral and Media temperature from 30 140 C slightly aggressive liquids and gases Ambient temperature Up to 80 C Coil enclosure Up to IP67 EV220BSS NC Stainless steel version for neutral and aggressive liquids and gases Also available with NPT thread Thread connections From G Y G2 DN 15 50 Viscosity Up to 50 cSt Water hammer damped Built in filter for protection of pilot system Adjustable closing time available IC PD 200 D8 02 520B6672 1 61 Data sheet Technical data brass valve body Main type NC and NO Solenoid valves type EV220B 15 EV220B 50 EV220B 32B EV220B 40B EV220B 50B Time to open ms Time to close ms The times are indicative and apply to water The exact times w
68. ral of these such as the recirculation pump and drainage pump are easily controlled by a relay which activates the motor at the pre programmed power Since it is possible to calibrate acceleration and deceleration on the controllers and these pumps are meant to be active for long periods at a time there is no risk of over stressing the motors which would result in shortened lifetime 24 Other pumps namely the inlet pump between the waiting tank and the filtering system need to have a variable flow rate as to maintain the system at a steady pressure level To do so it is necessary to use some kind of regulatory signal as the constant switching of a relay would be inefficient and stressing for the motor Two methods for signaling the frequency changes to the motor controller are available to choose from serial communication and analog signal Serial communication Modbus CANbus etc is a highly efficient protocol allowing for bi directional data transfer between several controllers on one single data line In addition to handle the frequency variations it also permits to adjust parameters and read operational data yet these features are not required for the project at hand Also implementing serial communications can be an arduous task which in this case can be avoided It also requires the controller to include a suitable port Analog signaling to the motor controller requires an analog output port on the PLC The V350 model early p
69. ral ready to use models which are bundled by the Icelandic distributor Mounting method and measuring range varies between models yet in this case the clamp on Figure 2 14 Longrun small size LFR 2000MNB1 model with a measuring range of ultrasonic transducers 18 15mm to 100mm was chosen 18 Figure 2 14 These transducers need to be clamped around the outside of the pipe section where the flow rate is of interest A few configurations may be used being the most common the reflective mode or V method Figure 2 15 19 A Upstream Transducer A Downstream Transducer Transducers Spacing Figure 2 15 Ultrasonic transducer V mounting method 17 For a good sound transmission through the pipe a special grease is recommended to be applied between the pipe and the transducers which fills the gaps in between and prevents the sound wave to be diffused through the air The Molykote 111 Compound produced by DOW Corning was recommended by the distributor for this purpose To achieve an accurate flow measurement the following parameters need to be configured 17 e Pipe outer diameter e Pipe wall thickness Pipe materials for those pre configured in the controller or sound speed for the pipe material Pipe liner material if any its sound speed and thickness Liquid type for those pre configured in the controller or its sound speed Transducer type used Transducer mounting method such as V method After
70. reatest TEMPCO of the span lt 0 2 Reaction times Response time analogue output ms 3 Ambient temperature C 25 80 Storage temperature C 40 100 Protection IP 67 EMC EN 61000 4 2 ESD 4 kV CD 8 kV AD EN 61000 4 3 HF radiated 10 V m EN 61000 4 4 Burst 2 kV EN 61000 4 6 HF conducted 10 V Shock resistance DIN IEC 68 2 27 50 g 11 ms Vibration resistance DIN IEC 68 2 6 20 g 10 2000 Hz MTTF Years 271 Process connection Sealing cone G1 male Materials wetted parts ceramics 99 9 AI2 O3 PTFE stainless steel 316L 1 4435 surface characteristics Ra lt 0 4 Rz 4 Housing materials stainless steel 316L 1 4404 PEI FPM Viton Min pressure cycles 100 million Weight kg 0 528 Connection M12 connector Gold plated contacts Wiring 5 oo efeckorsoo PM2653 PM 025 REAO1 E ZVG US P YA pu y L 2 s 1 Sy L Pressure sensors 2 1 f Remarks linearity incl hysteresis and repeatability limit value setting to DIN 16086 with temperature fluctuations 10 K in 96 of the span per year The 3 A qualification is only valid if adapters with 3 A qualification are used for installation Pack quantity piece 1 ifm electronic gmbh Friedrichstra e 1 45128 Essen We reserve the right to make technical alterations without prior notice GB PM2653 26 03 2009 39 60 Appendix D EV220B valve datasheet MAKING MODERN LIVING POSSIBLE Data sheet Servo o
71. resented includes two of these while the Samba would require an additional expansion module Implementing such control method is abysmally simpler than the serial bus approach Therefore it is chosen for this project to utilize an analog signal to control the motor controller s frequency in those places where this is needed By this method any pump connected to a controller supporting analog input may be used With minimal configurations on the controller s interface the control system would be able to handle it regardless of brand and model This output is handled by a PID controller which adjusts the speed as required to maintain the ideal pressure in the system A PID autotune function block is available in Visilogic which performs a PID calibration routine This routine is carried out as follows 25 e The system is allowed to run at full power fluid pumped in until the setpoint pressure mark is surpassed e The system is stopped until the control variable pressure drops under the setpoint e The previous two steps are now repeated three times while the systems response is monitored e The data collected automatically generates the configuration variables required for the PID controller which may be run at this point 23 This method is ideal for this project the autotune feature can be used every time the system begins the concentration process thus calibrating the PID and filling the system with the same procedure 2 6
72. rt with a proprietary CANbus protocol UniCAN allowing the I O module to be up to 1000 m away from the PLC 6 The latter is about three times more expensive and also renders the serial port useless for any other purposes 6 Remote expansions require more programming time for a separate program needs to be uploaded to it as well as the communications protocol configured on both the PLC and expansion unit 7 Since there is no need to implement remote sensors actuators a remote adaptor is not needed unless the Samba model is chosen for the project which does not support the local expansion When comparing the total price of both PLC models together with their supported expansion adaptors Table 2 6 it comes to light that the price difference is not that great Given the additional complications and work required to make the remote expansion functional it is suggested to invest in the V350 The additional supported features will also be of interest for future development of the project such as SD card data logging web server and the already mentioned analog outputs Table 2 6 Price comparison of PLCs with expansions SAMBA SM J R20 VISION V350 35 RA22 BASE PRICE 29 900 ISK VAT 79 765 ISK VAT EXPANSION MODULE PRICE 28 511ISK VAT 8 737 ISK VAT TOTAL PLC EXPANSION 58 411ISK VAT 88 502 ISK VAT EXPANSION CONFIGURATION Complicated P amp P 13 Therefore it is concluded that the V350 PLC is more adequate for this
73. s This chapter presents the different sensors selected for the system These are chosen based on suitability price and reliability The Unitronics PLCs support both PNP and NPN digital inputs with the user able to configure the ports by use of on board jumpers It must be pointed out that no individual input can be configured it is all PNP or all NPN Also when using NPN the analog inputs cannot be used as such if present on the module Therefore all digital sensors used in this project are chosen to be PNP which is the most common choice in the industry 10 2 4 1 Fluid level To determine the state of the waiting tank as well as fluid presence in the recirculation system a method of detecting water presence is required 15 Several options are available where the detection method greatly varies The different types of sensor considered for this project are 16 e Capacitive Generally used as proximity detectors capacitive sensors can detect objects located behind a non conducting layer by monitoring changes on a generated electric field 11 These sensors can thus detect the level from the outside of the container avoiding contact with the processed material e Floater Level sensors based on floaters can work based on several different principles such as magnetic field detection mechanical switch activation and resistive variances 12 Contact with the fluid requires the sensor to be built of food processing approv
74. st free and permitted this project to carry on with minimum expenses 3 2 1 Navigation panels The UI is displayed on the PLC s HMI The different screens have been designed along the programming of the different parts of the system The main screen offers the user to log in via a password field gives a brief message of the current status of the system and displays the current time Figure 3 2 While the HMI is displaying any other screen a 60s countdown triggers the return to this screen This timer is reset every time the display is touched Sica Insert Password System Status Figure 3 2 HMI main screen Figure 3 3 HMI waiting tank screen Once the correct password is entered the waiting tank display is presented Figure 3 3 There the current level of the tank is shown and it is possible to activate the filling process A timer can be seen which indicates how long the tank has been full The arrows on the top corners permit returning to the main screen or advancing to the next one The next panel is the concentration and purification display Figure 3 4 There a graphical representation of the recirculation system is found A bar indicator beneath the inlet pump shows the current power level sent to the pump controller The two valves in the inlets and the recirculation pump change colors depending on their state on off The two gauges give real time feedback on the pressure sensors Lastly the LED
75. st point in the system allowing air to efficiently escape as it floats upwards This drain is floater based functioning without the need of an electric source The inlets for the concentration and purification processes are controlled by normally closed solenoid valves which are opened as required The cold water inlet is regulated with a diaphragm valve ensuring the inlet pressure does not surpass the maximum allowed by the system This diaphragm is adjusted by hand and should not require much attention once it is set An outlet valve is also present which opens when the system is to be emptied by the drainage pump The level switch present in the inlet outlet of the tank allows to determine when the tank has been fully emptied These parts are optional as the system can be emptied manually once the process is done The three three way valves seen in the circuit are used to switch between concentration purification and filter cleaning loops In Figure 2 5 these are in their normal position non powered where the circuit is configured for concentration purification The two pressure sensors found in the original system are replaced by analog transducers which send the current pressure to the control unit The correct use of this data is critical for the filter to function properly it determines the amount of fluid required at the inlets while processing as well as it monitors the state of the filter for possible issues such as filter obstr
76. steinsvetni Accessed 29 April 2015 B V Salas M S Wiener R Z Koytchev G L Badilla R R Irigoyen M C Beltr n N R Nedev M C Alvarez N R Gonzalez and J M B Rull Copper Corrosion by Atmospheric Pollutants in the Electronics Industry International Scholarly Research Notices vol 2013 no n a pp 1 7 2013 Koch Membrane Systems Inc Romicon TM 3 Hollow Fiber Cartridges Koch Chemical Technology Group LLC Wilmington Massachusetts 2014 Unitronics EX A2X I O expansion module adapter December 2009 Online Available http www unitronics com Downloads Support IO 20and 20COM 20Modules I O 20Expansions EX A2X_SPEC_12 09 pdf Accessed 30 April 2015 Unitronics EX RC1 remote I O adapter May 2008 Online Available http www unitronics com Downloads Support IO 20and 20COM 20Modules I O 20Expansions EX RC1_SPEC_05 08 pdf Accessed 30 April 2015 UnitronicsWebinars PLC Training Remote I Os via EX RC1 UniLogic for UniStream by Unitronics September 2013 Online Available https www youtube com watch v APnEBvSghks Accessed 04 May 2015 GSM Arena EDGE Enhanced Data for Global Evolution n a Online Available http www gsmarena com glossary php3 term edge Accessed 04 May 2015 Phonearena Which carrier offers the fastest mobile data and coverage 4G 3G speed comparison n a Online Available http www phonearena com news Which carrier offers the fas
77. style bar Figure 3 4 HMI concentration screen above the system presents the real time flow rate on the outlet E Filter Pressure Figure 3 5 HMI trend When pressing the gauges and or the LED bar it is possible to access the relevant trends Figure 3 5 which show a history of the different measurements over a period of time From that panel the configuration menu for these sensors will be accessible to adjust the desired pressure levels and flow limits 3 2 2 Internet connectivity To connect the PLC to the internet a V 00 17 ET2 Ethernet module is required Its price is 11 813 ISK VAT and it is easily installed Its functionality has been tested by configuring the PLC under a household s internet connection and accessing it from a remote location By using the Remote Operator software the PLC responds with an almost unnoticeable lag 29 Remote programming through Visilogic has also been tested with flawless results This gives the possibility of updating the software in the future without requiring to access the Hellisheidi power plant To adapt the PLC to any other network the internal IP of the PLC needs to be configured as required by the router and the port must be forwarded to it This can be done easily once a modem is purchased for this project Several phone companies in Iceland offer wireless internet modems and data plans and it is left to geoSilica to find the most suitable one given that any wo
78. tallation itself Table 4 1 presents the prices of the components required for this section of the project Table 4 1 Waiting tank component cost estimate Component Unit price Quantity Total price Description ISK no VAT ISK no VAT V350 35 RA22 79 765 1 79 765 PLC PSU available at geoSilica MHF15 27 787 2 55 574 Level sensors 21NG1HSM M12x1 4 pin 2 260 3 4 520 Level sensor cable connector EV220B 20 000 est 1 20 000 2 2 valve Solenoid coil 5 000 est 1 5 000 To actuate valve Total 164 859 4 2 Concentration and purification The concentration phase is in early stages of development while the purification phase is not programmed at all although both share much of the same code Being one of the most complex stages to program and requiring extensive testing it is estimated that two months of full time work will be necessary to complete this part of the project Table 4 2 presents an estimated workforce cost 37 Table 4 2 Concentration and purification workforce cost estimate Reason Hourly cost ISK Hours Total ISK Workforce 5 000 330 1 650 000 Table 4 3 sums up the component s prices The components already available at geoSilica recirculation pump three phase relay motor controller are not taken into consideration Table 4 3 Concentration and purification component cost estimate Component Unit price Quantity Total price Description ISK no VAT ISK no VAT LRF 2000M 86 421
79. test mobile data and coverage 4G 3G speed comparison_id53828 Accessed 04 May 2015 Various NPN vs PNP inputs control com 19 September 2001 Online Available http control com thread 1000870647 Accessed 09 May 2015 W Kwasny and A Blazejewski Mechatronics Module 5 Mechatronic Components Wroclaw Wroclaw University of Technology 2007 47 12 13 14 15 16 17 18 19 20 21 22 23 48 Deeter Electronics Inc Float Switches amp Liquid Level Sensors The Deeter group 2015 Online Available http www deeterelectronicsinc com products float switch liquid level sensors overview Accessed 05 May 2015 Sick AG Level sensors Sick AG 2015 Online Available http www sick com group EN home products product_portfolio instrumentation P ages level_sensors aspx Accessed 05 May 2015 Sick AG MHF15 Sick AG 2015 Online Available http www sick com instruments EN home products level_sensors Pages MHF15 a spx Accessed 15 May 2015 IFM Electronic Ltd PM2653 pressure sensors IFM Electronic Ltd 2015 Online Available http www ifm com products uk ds PM2653 htm Accessed 12 May 2015 Unitronics Vision OPLC technical specifications July 2013 Online Available http www unitronics com Downloads Support Technical 20Library Vision 20H ardware Vision3509620Specifications V350 35 RA22 J TECH SPEC 07 13 pdf Accessed 12 May
80. though low maintenance are overly expensive Also two units are needed on the tank e Floater based sensors may require too high maintenance due to silica scaling e Both guided radar and hydrostatic are too costly given the level of maintenance required Three types remain to choose from e Ultrasonic could be a great choice as long as budget is not an issue e Both photoelectric and vibration sensors present a cheap solution even though two units are required to monitor the tank Since budget is of concern in this project only photoelectric and vibration sensors remain as an option Because of its price and availability a diffuse photoelectric sensor was selected for this project The model chosen is MHF15 21NG1HSM by Sick AG Figure 2 10 a compact optical level switch built on a stainless steel housing with a polysulfone apex 14 This low cost sensor gives a signal through its PNP output when liquid is detected more information in Appendix B Figure 2 10 Sick Given its operational method and design it is both suitable for MHFIS level sensor 14 the waiting tank requiring two units and the recirculation system for the evacuation phase Maintenance wise it is expected to observe a slow buildup of scaling on the apex therefore the sensors should be removed regularly for cleaning It is recommended to monitor the state of the sensors monthly to eventually determine the ideal maintenance schedule 17 Its pri
81. to program The different pressure levels around the filter the pressure difference between the filter s outlets and the possible issues regarding flow rates have to be monitored and accounted for The different actions which should outcome from these issue diagnostics need to be programmed as well such as system hold filter cleaning and e mail notifications Altogether the remaining development of this phase is likely to be one of the larger tasks left to program It is also a crucial part of the system which requires attention to details and constant testing to ensure it functions according to the necessities 3 3 Remaining Development As seen in chapter 2 the Samba PLC has been diagnosed to be not appropriate for this project The Vision series V300 35 RA22 has been chosen as the most adequate and cost effective solution thus a new prototype needs to be built based on this platform All the development made on the Samba can be effortlessly imported into a V350 project for both PLCs are fully compatible within Visilogic Therefore development of this final prototype may continue from the current point it is in 32 A full connection diagram for this new prototype can be found in Appendix G which shows how the main phases of the system waiting tank concentration and purification can be developed without the need of an expansion module The diagram takes into account the level switch and solenoid valve required for the evacuatio
82. totalizer up to 64 sets per day and 32 sets per month Fully programmable batch controller Data logger 32 records of power on power off data Given all these features which can only be accessed by the PLC through a serial connection it is determined that the time required to set up such communication system is feasible for this project and highly recommended over the analog output option 2 5 Actuators A set of actuators is required to control the system By means of relays analog signals and or serial bus protocols the PLC changes the state of these devices what in turn handles the transition between phases adjusts flow ratios etc 2 5 1 Electronic valves Several solenoid valves are required to control the flow in the system as seen in chapter 2 2 Some are simple two way valves which act like an open close gate while others are more complex three way valves that control the direction in which the liquid flows Regardless of the specific type all of these are in contact with the final product at some stage of processing Therefore the build and construction materials must be approved for food processing systems The Icelandic Food and Veterinary Authority Matv lastofnun was contacted to enquire about this issue for it is the institution responsible of food regulations in Iceland After a long conversation it seemed as if they did not have access to this information and they failed to refer the researcher to a better sour
83. u4SO OH 6H20 and others which have completely different properties from copper and causes general deterioration and eventually malfunctioning of electrical devices 3 Due to this all electronic components must be insulated and the electronics box which hosts the controllers should have an air filtration system to avoid sulfide entering the enclosure Internet access The offices of geoSilica are located about 100 km away from Hellishei i where the filtering takes place It is thus required to be able to control and monitor the processing remotely avoiding the constant travelling between locations Security Given that the system will be connected to the internet a solid security system must be implemented to avoid unwanted access 2 1 1 The filter The filter utilized by geoSilica for concentrating the fluid is a specialized one which has very specific operational instructions Regarding the control system the operating limits 4 are of outmost interest as listed below e Operating pressure 2 8 bar maximum pressure or 6 9 bar if permeate side is pressurized e Permeate pressure 1 4 bar maximum pressure at all times including backflush e Differential pressure 2 1 bar maximum differential pressure across both ends of the filter These limits must be constantly monitored by the system to ensure no damage is done to the filter 2 2 System planning The control system is built around the filtration unit already constructed
84. uction Lastly a flow sensor monitors the filter s waste outlet This measurement in combination with the pressure sensors helps determining the state of the filter The amount of fluid exiting the system is also monitored on the purification process which helps deciding when the concentrated product has been fully flushed of arsenic This sensor can be configured to communicate either through Modbus or sending an analog signal see chapter 2 4 3 Table 2 3 summarizes the required I Os on the PLC for this part of the process Table 2 3 Filtration circuit I Os 1 0 Amount Description Digital input 1 Level switch optional Analog input 3 Pressure amp flow optional Relay output 5 Solenoid valves recirculation pump amp drain pump optional The three way solenoid valves are open for this circuit on their normal position therefore no relays are needed to power them at this point The relays powering these to switch positions are accounted for in the next subchapter 2 2 3 Filter cleaning bypass The filter bypass Figure 2 6 allows for the cleaning of the filter without the need of removing it from the system It also permits to pause the production process to perform a cleaning routine without interfering in the final product s quality 10 MOT 5 gt IKK gt K Hinlet Cold s S 1bar Figure 2 6 Filter cleaning bypass diagram Once the recirculation circuit is switched over the cleaning circuit b
85. uld work with the system The only requirement is to ensure the modem has a static IP what might present an additional cost in some cases Two companies Nova and Vodafone were approached to enquire about the availability of these services and service costs Both offer very similar modems with Nova being a slightly more economic purchase Vodafone did not offer any data plans under 5GB of download what seems excessive given the connection speed in the Hellishei i area and the minimalistic data transfers of Remote Operator Additionally Nova offered the static IP service at no cost while Vodafone had a subscription fee for such service The author thus recommends to contract Nova s services for the system at hand although ultimately it is geoSilica s choice to make as previously stated Security The system needs to be protected from unwanted remote access To accomplish this several security measurements are put into practice For the user to connect to the remote station both the static IP address of the system and the PLC name case sensitive must be known being the later chosen by the administrator and hardcoded into the program These are then input into Remote Operator for establishing a connection Once connected to the PLC the user is presented with the login screen where the current system status is displayed To be able to access any other screen the correct password needs to be typed by clicking on a virtual keypad wh
86. unt of complications all aspects must be delineated and established In the following subchapters the system requirements are listed the overall design is presented and the individual components selected 2 1 System requirements After several meetings and interviews with geoSilica s staff numerous points were noted which list the requisites of the automation system The design will take into consideration all of these points Food processing approved Since the final product is meant for human consumption any parts of the system in contact with the fluid must be food approved Research on requirements needs to be conducted pinpointing materials and other aspects relevant to this point High efficiency and reliability The system must perform all tasks required with minimal supervision Therefore it must require low maintenance have the ability to self diagnose issues and be able to alert the administrators when a problem is encountered Low cost With geoSilica being a start up company funding for the development of this project is limited Special effort must be placed on achieving optimal functionality with the lowest possible cost Shielded from Sulphur corrosion The production plant is to be located on the premises of Hellisheidavirkjun a geothermal power plant where the level of hydrogen sulfide gas H2S is very high 2 Sulfide reacts with copper forming thin layers of metallic sulphides such as geerite CusSs posnjakite C
87. vibrate at its resonant frequency Once it is covered in liquid the vibration frequency change is detected by the sensor 13 While some of these sensors are able to detect the exact level of the fluid ideal for the waiting tank such feature implies the transmission of data as an analog signal Analog inputs on a PLC are more expensive than digital ones and generally few are present by default requiring an expensive expansion module On the other hand fluid level switches only detect the presence of the liquid at a given point and thus require two units to determine both full and empty states Yet these are often cheaper and output the signal into digital inputs on the PLC which are cheaper and abundant Contact with the fluid is also relevant for it dictates the use of food grade materials and hygienic designs which increases the price of the unit Level of maintenance is also afflicted as silica sediment might obstruct the sensor Therefore an adequate choice of sensor s presents a conundrum which can only be solved by comparing the options side to side as seen on Table 2 7 In this table only food grade sensors are considered when in contact with the fluid Table 2 7 Level sensor types comparison SENSOR UNIT COST PRECISE LEVEL MAINTENANCE CAPACITIVE FLOATER GUIDED RADAR HYDROSTATIC PHOTOELECTRIC ULTRASONIC VIBRATION By analyzing this data it is possible to eliminate certain options e Capacitive sensors al
88. w and will be open for as long as the minimum differential pressure across the valve is maintained and for as long as there is voltage to the coil Function Coil voltage disconnected open 1 Coil NO brass DZR brass and When the voltage to the coil 2 is disconnected s Dept stainless steel the pilot orifice 4 is open As the pilot orifice is 4 Pilotorifice larger than the equalizing orifice 7 the pressure 5 Diaphragm across the diaphragm 5 drops and therefore it is A prd UM P lifted clear of the main orifice 6 The valve will be open for as long as the minimum differential pressure across the valve is maintained and for as long as the voltage to the coil is disconnected Coil voltage connected closed When voltage is applied to the coil the valve plate 3 is pressed down against the pilot orifice 4 The pressure across the diaphragm 5 is built up via the equalizing orifice 7 The diaphragm closes the main orifice 6 as soon as the pressure across the diaphragm is equivalent to the inlet pressure The valve will be closed for as long as there is voltage to the coil SAR NN 4 72 IC PD 200 D8 02 52086672
89. y activation of the three way valves cleaning fluid as chosen by the operators is pumped into the system through the filter s output backflow by changing the state of the three way valve present at the waste outlet The pressure sensor present there is used to ensure the backflow pressure does not exceed the permissible limits As pressure builds up the recirculation pump is activated and the fluid is pressurized in the system When the solvent is well saturated the waste outlet opens and fresh water is used to rinse the circuit This process may be repeated as many times as needed until the pressure and flow sensors determine the filter to be clean Once the filter is fully cleaned and rinsed the valves switch back to the main loop and production may continue The container for the cleaning fluid is not yet designed and the fluid itself has not been decided upon It might be necessary to add a sensor to determine the level of fluid in that tank This is left to decide in the future when the details of the cleaning solution are solidified The cleaning solution pump can be pre configured to work on an ideal rate as chosen by geoSilica s staff This pump may be activated with a relay filling the system and stopping until the fluid has been flushed out The pressure sensors help determining when enough fluid has been pumped in It is also possible to control the pump with an analog output and if desired attach a PID controller to it

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