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This document is an example of the output from a ControlDraw model, in this case the Milkshake plant demo.It has been produced entirely in the ControlDraw Print and Review software.
The model itself contains portions of text from the original EBF working group. The model has now been developedfollowing the developments in ControlDraw and in experience gained with it's deployment on many projects, althoughit is still under development in several respects.
The model is part of a suite of sample models that are anchored in a single reference model. These are not justdemonstrations, they are usable libraries of process automation objects.
The New Milkshake model
IntroductionWhen originally conceived, the intention was to illustrate a realistic process that 'challenged' S88 and then toshow how the standard can be interpreted to meet these challenges. These challenges are identified below.Further on this document describes where the milkshake plant shows examples of them.The ControlDraw model presented here provides workable solutions to a number of these issues. These arenot the only answers, but they are we think they are good ones.They are based on the work done by experts and represent typical good practise.The model also demonstrates many of the advanced features of ControlDraw.
The model is not yet complete
The challenges:The CIP issue
There is a common perception among CIP specialists that CIP does not 'fit' S88. This is illustrated in part bythe CIP process description that was provided by GEA for the originally EBF working Group.It is possible to view CIP processes as Servers to the Process Units, so that when a unit wants to be cleanedit can call on the CIP Common Resource to carry out the clean. However this seems unnatural - the cleanerwhen cleaning must be completely in charge of the equipment. What about a line clean, where is the unit inthat?
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What is a Storage Tank?
Is it a Unit - or a Common Resource?This topic can cause a considerable amount of lively discussion in a group of batch specialists.
It's not a Unit because although Tanks can have a batch in them, they also often have a mix of batches. Ofcourse a proper S88 Unit never has a mix of batches in it, so this type is not a unit under the presentdefinitionArguably if it only stores one batch and does something to look after the batch (even just monitoring it) thensuch a tank could be a unit.
Cont inuo us processing equipm ent with the batch
Often there are parts of a batch process that are really continuous in operation
Handl ing of mater ial rout ing Equ ipment
Often this is a major challenge in plants especially where multiple routes are required.
Bou ndar ies between S88 objects
Often it is not clear where the boundaries, should these be placed, in fact sometimes there seem to bealternative boundaries depending what is happening , eg CIP or production.
Effic ient m odu lar isat ion
How best to split the process into modules and to make the modules re-usable
The Milkshake plantThis section briefly describes some feature of the plant that illustrate the above issues
CIPThis plant includes multiple CIP 'units', numerous line cleans and tank cleans. To further complicate theissue, the CIP 'unit' can run two cleans at once, and shares the Water, Acid and Caustic tanks
Storage Tanks
The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.A similar concept applies to the product tanks except here the rules are that different products shouldobviously not be mixed.
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Cont inuous process ing equipment
The homogenisers are examples of continuous 'units' in the process.
Material rout in g The milkshake plant, like many dairies, breweries and other liquid food processes uses valve manifolds
Dif ficul t Boun dar ies
For example in our milkshake plant units such as the Batch Vessels, have things around them (the inletvalves are a good example) that intuitively seem to belong to the units.However, the 4 port valves can carry both process fluids and cleaning fluids. Whilst they are under thecontrol of a cleaning program it seems equally reasonable that they should belong to the CIP system as to theUnit or line that is being cleaned.
The Milkshake Model Solutions
CIP
In the model, CIP is treated as the master - a Unit whose function is to clean a collection of 'dumb'equipment.
In fact the model contains two CIP units, each sharing the same collecion of
Storage Tanks
The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.A similar concept applies to the product tanks except here the rules are that different products shouldobviously not be mixed.
Cont inuous process ing equipment
The homogenisers are examples of continuous 'units' in the process.
Material rout in g
The milkshake plant, like many dairies, breweries and other liquid food processes uses valve manifolds forCIP and process routing.
Dif ficul t Boun dar ies
In our milkshake model, the Batch Mixing Unit and the silos contain 'shared' equipment modules. Takingthe example of the inlet valves, these are acquirable so that whilst they are taking part in the mixing unit
procedure they are under control of the Mixing Unit, however when running a CIP or a transfer then they arecommanded by the CIP
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However, the 4 port valves can carry both process fluids and cleaning fluids. Whilst they are under thecontrol of a cleaning program it seems equally reasonable that they should belong to the CIP system as to theUnit or line that is being cleaned.
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Table of Contents
Section PageCover 1Table of Contents 5
Project Description 7Project Information 8Project Details 9Diagrams 15
1 - Milkshake Plant Overview 15 2 - Liquids Processing Bldng 16 3 - Milk Silos 17 5 - Product Silos 18
7 - All CIP Recipes 19 8 - Material Reception Recipes 20 9 - Milk shakes 21
10 - un Milk/Product Silo 22 . . . Variant 1 - Product Silo 22
. . . Variant 2 - Milk Silo 23 11 - un Additive Storage Hopper 24
12 - un Batch Mixing 25 13 - un Homogeniser 26 14 - un Packaging Line 27 15 - un Solids Blending 28
16 - un Solids Preparation Line 29 19 - CIP Generation System 30 23 - CIP Unit 31
24 - crFreshWater 32 25 - Homogeniser Outlets manifold 33 26 - Milk Distribution Manifold 34 27 - Milk Supply manifold 35
28 - Product Homogenisation manifold 36 30 - Product to packaging manifold 37
31 - Recycled water 38 32 - Tank, LSL,LSH,Agit, TT 39
. . . Variant 1 - Caustic 1 39 . . . Variant 2 - Caustic 2 40
. . . Variant 3 - Acid 41 33 - Tanker unloading bay 42 34 - em Agitator 43 . . . Variant 1 - Fixed Speed 43 . . . Variant 2 - Variable Speed 44
35 - em CIP Drain 45 36 - em CIP Line Select 46
37 - em CIP Supply 47 38 - em Discharge 48
39 - em Generic Machine Interface 49 40 - em Heat/Cool Jacket 50
41 - em Homogeniser 51 42 - em Homogerniser in 52 43 - em Loss In Weight Feeder 53 44 - em Tanker Reception 54
45 - em Transfer in 56 . . . Variant 2 - Type 2 56 46 - em Transfer out 57
47 - em Water Feed 58
. . . Variant 1 - In-Line 58 48 - rcp Additive Preparation 59
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49 - rcp Batch Mixing 60 . . . Variant 1 - With Homogenising 61 . . . Variant 2 - No Homogenising 62 50 - rcp generic Vessel CIP 63
51 - rcp Receive Addiitive 64
52 - rcp Receive milk 65 53 - up Fill and Pack Procedure 66 57 - op Batch Mix and Homogenise 67
58 - op CIP Supply to Vessel Clean 68 59 - op Homogenising 69 60 - op Line Clean 71
61 - op Silo Deliver 72 62 - op Silo Receive 73 64 - op Unload Tanker 74 65 - op Vessel CIP 75
66 - ph Add Milk 76 67 - ph Add Milk and Solids 77 69 - ph Mix and Heat 78
70 - ph Vessel CIP 79 71 - Mixproof Valve 80 72 - On Off Valve 81 . . . Variant 3 - 2 Limit Switches 82
73 - Fixed Speed Motor 83 74 - Variable Speed motor 84 75 - cm Agitator Control 85 76 - cm CIP Status Control 86
78 - Standard PID Loop 87 79 - Control Valve 88 80 - Analog Input from Transmitter 89 81 - Weight measurement 90
82 - Alarm Switch Input 91
83 - Controller Status 92 84 - Interface 93
85 - CIP Routing diagram 94 86 - CIP Routing diagram snapshot 2 95 87 - Complete CIP Graphic 96 89 - Jacket Heat/Cool Type 1 98
Data Reports: 99 Alarm 99 Motor 108 Control System IOList 109
Equipment Parameter Real 122 Effector Analog 124Page Instance Count 125
Back Sheet 129
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Project Information
Item Value
Project Name:EBF WG3 Milkshake Plant
File: F:\cdArchive\milkshake2.cnd524Client: The World Batch ForumLast Author: Francis LoveringDate Edited: 23/10/2003 16:53:07Date Printed: 23/10/2003Issue 0DVersion: 524Version: Minor Issue - 0D Rev 520 - Issue for interim Web site publishiing ArchivePath: F:\cdArchiveBase Model Version: 149Reviewer View Name: Web Publish in F:\_CDReference\Samples\comments.mdb
Issue History
Date Issue Version Author Details23/10/2003 Minor Issue - 0D 520 Francis Lovering Issue for interim Web site publishiing
09/10/2003 Minor Issue - 0C 409 Francis Lovering
The model has now been developed
following developments inControlDraw and experience gained init's deployment on many projects.
The model contains portions of textfrom the original EBF working group,and is designed to address the issuesraised.
08/08/2003 Minor Issue - 0B 328 Francis Lovering Added CIP state and pulsing to silos13/05/2001 Issue Reset 0 Francis Lovering Cleared Model History
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Milkshake Process descr ipt ion Additive Deliveries
On arrival of a lorry at the Additives reception bay the pallets of additives are unloaded by fork lift truck and
taken to the Additive Warehouse.A procedure is required to register the arrival, which should match an expected delivery as scheduled in theMESAdditive Warehouse
The Additive Warehouse stores palettes of Flavour additives. Each pallet contains a number of sacks oradditives A system to control the location of materials and to ensure that they are used in an appropriateorder, such as first-in first out or according to use by dates will be required. This document does not explorethese areas of functionality.Solids Processing
Flavour additives materials are depalletised then the sacks are slit, the contents extracted and then pneumatically conveyed into the Additive Silo.Additives are then milled, sieved and then weighed into IBC'sThis is driven by the production campaign requirements so that the right additives in the right quantities are processed.Intermediate Product StoreThe Intermediate Product Store provides a buffer which is used to store IBC's which have been prepared inadvance of when they are needed or in case of a hold up in the liquids processing.Milk Reception
On arrival of a tanker at the mile reception bay the tanker is connected up to one of the three possibleunloading points. Milk is then pumped from the tanker into one of the 3 milk silosOn completion of the unloading of the tanker a clean is carried out of the tanker and the pipework whichroutes the milk from the tanker to the silos.The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.Only one tanker is unloaded at one time and generally to only one milk silo.However, operators can in exceptions unload into one silo until it is full and then the nextCIP Chemical Deliveries
On arrival of a lorry at the CIP chemicals reception bay the drums are unloaded by fork lift truck and takento the CIP Chemical Store.A procedure is required to register the arrival, which should match an expected delivery as scheduled in theMESCIP Chemical Store
The CIP Chemical Store stores drums of cleaning chemicals A system to control the location of the drums and to ensure that they are used in an appropriate order, suchas first-in first out or according to use by dates will be required. This document does not explore these areasof functionality.CIP Generation System
The Clean In Place system provides rinse water and also doses the cleaning chemicals into the water tomake cleaning liquidsThe system also takes the returned liquids and can store the final rinse water for use in subsequent firstrinsesLiquids Processing Building
Batch Mixing Processes are carried out to make batches of the various products. Certain products are then
homogenised on their way to the Product Silos.A typical mixing process comprises
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Add Milk Start qtyAdd Milk and AdditiveAdd Final Milk QtyMix
Mix and HeatTransfer Out
Packaging Building
In the packaging building liquid product from one of the product silo's is filled into bottles and then labelledand packed into pallets - further details are given below.The operation of the packaging lines is organised in terms of Work Orders.A Work Order is characterised by:
The number of bottles to be packedThe labelling on the bottle - one work order per label typeThe customer - a single customer per work order
A single work order may be made up from one or more Product SiloBottlesBottles are supplied to the filling line in boxes of pallets. A depalletising machine takes the boxes from each pallet, and the de-boxer takes bottles from the boxes. Bottles are then fed onto an accumulation conveyorwhich feeds into the filling machine.
Customers
Milko Ltd supplies to a large number of customers including the premium Supermarkets, Milko Ltds own brand and some others. Milko also has a strategy to be able to supply new customers in response to order placed over the phone or the Internet when the customers usual supplier is unable to meet the demand or hasa production problem. The pricing of such orders is a strategic decision made by Milko's senior management
- sometimes the cost will be high in order to make sure that the costs of the disruption to the schedule aremore than covered, however sometimes the work is done at cost or even at a loss if the new customer isconsidered strategically important enough.Rework
Just occasionally, and notwithstanding the highly effective scheduling system ,a batch is made which doesnot meet the critical quality standards of Milko Ltd.This can happen when there is an equipment failure - in general equipment failures can be tolerated by putting the process into hold, repairing the failed item, and then re-starting.However, sometimes there are failures which cannot be fixed in time to allow the batch to be completed.In these cases it is highly preferable to be able to re-use the batch if possible. This is far more acceptablethan disposing of the batch down the effluent system, and can be achieved by using small percentages of the
batch in subsequent batches of similar products provided this is done in time.This practise is accepted to a greater or lesser degree by the customers.The pipework in the plant makes it possible to divert a failed batch back into one of the milk silos forsubsequent rework.
A further issue with rework is that when a problem does occur and some rework is needed , it can becomenecessary to change the production schedule to make product which can use up the reclaimed batch. (It mayalso require that the current schedule is altered in order to free space in a Milk Silo to hold the batch. )
Recipes
The plant produces a large number of products, in a variety of packages.
There are three basic types of recipeSplodge Drinks
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These include Banana, Strawberry and other fruit based milkshakesFudge DrinksThese include Chocolate and other cocoa based drinksAlchoshake
These are the hot sellers, Milko Ltds latest introduction of milk shake alcoholic drinks have taken the clubdrinks market by storm since their introduction.
Recipe CharacteristicsEach type of products is made in a different way
Within each general recipe type there are a large number of specific recipes. The Premium Supermarkets,and Milko themselves each have their own recipes but the lower price customers all use exactly the samerecipe.
Rework is handled by a rework substitution algorithm - this is a set of recipe parameter which define how
much of a particular type of rework batch can be added. For example, small parts of banana milkshake can be added to all other product which also contain banana, no rework which contains alcohol can be used inany non-alcoholic products etc.PackagingThe product is packed in a variety of ways. Each customer has their own labels for the bottles or cartonswhich are use. Alcoshake is provided in bottles with child-proof caps. And each customer has their own barcoding standard.Homogenisation
Homogenisation is essentially a mixing process which ensures that the various constituents of a batch aredeeply mixed. The depth of the mix is determined by the physical properties of the batch and the pressureand flow through the homogeniser.
Homogenisation, if required, takes place in the process of transferring a batch from a Batch vessel to theProduct Silos.
The process of starting up a homogeniser is a complicated by the mechanical problems of raising the pressure, which can be very high and the fact that it is possible to physically damage the equipment byrunning it empty. hThe homogeniser supplier provides a control system specifically for this equipment and refuses to guaranteeit if this system is not used. Consequently Milko has bought the homogeniser and it's control system as acomplete package. The vendors system includes a serial interface so that all of the control parameters thatthe vendor considers relevant can be set from a supervising system.
GEA P.T. Automation Ltd.
Milkshake PlantCIP Process Descriptions
2 April, 1997
Table of Contents1. Introduction 3
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2. CIP Station P&ID 3
3. CIP Process Description 33.1. Line CIP 33.2. Tank CIP 43.3. CIP Tank Make-Up 4
4. CIP Recipe 55. The Physical Model 56. CIP Batch and CIP Batch Scheduling 5
7. CIP Batch Reports 6
1. Introduction
The CIP Station for the milk shake plant essentially consists of one Fresh Water Tank, one ReturnWater Tank, one Hot Caustic Tank, one Acid Tank and two feed and return lines.
The CIP station is used to clean the Milk Silos area, the Liquids Processing area and the ProductSilos. These are two types of CIP sequences, line CIP and tank CIP.
2. Download original document
3. CIP Process Description
3.1. L ine CIP
The normal sequence for a line CIP is as follows;
1 Pre-Rinse Return Water Tank to drain at CIP station via selected line2 Push Out Water with Caustic Caustic Tank to drain at CIP station via selected line3 Caustic Wash Caustic Tank to Caustic Tank via selected line4 Push Out Caustic with Water Fresh Water Tank to Caustic Tank via selected line5 Post Caustic Wash Fresh Water Tank to Return Water Tank via selected line6 Push Out Water with Acid Acid Tank to Return Water Tank via selected line7 Acid Wash Acid Tank to Acid Tank via selected line8 Push Out Acid with Water Fresh Water Tank to Acid Tank via selected line9 Final Rinse Fresh Water Tank to drain via selected line
3.2. Tank CIP
The normal sequence for a tank CIP is as follows;
1 Pre-Rinse Return Water Tank to drain at CIP station via selected line2 Empty Tank Empty Tank to drain at CIP station via selected line3 Push Out Water with Caustic Caustic Tank to drain at CIP station via selected line4 Caustic Wash Caustic Tank to Caustic Tank via selected line5 Empty Tank Empty Tank to Caustic Tank via selected line6 Push Out Caustic with Water Fresh Water Tank to Caustic Tank via selected line7 Post Caustic Wash Fresh Water Tank to Return Water Tank via selected line
8 Empty Tank Empty Tank to Return Water Tank via selected line9 Push Out Water with Acid Acid Tank to Return Water Tank via selected line
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10 Acid Wash Acid Tank to Acid Tank via selected line11 Empty Tank Empty Tank to Acid Tank via selected line12 Push Out Acid with Water Fresh Water Tank to Acid Tank via selected line13 Final Rinse Fresh Water Tank to drain via selected line14 Empty Tank Empty Tank to drain via selected line
The line and tank CIP's in the milkshake plant would usually only include the acid wash once aweek or once a fortnight. If the acid wash is not included then steps 7 through 12 are skipped.
The sequence for cleaning the Batch Mixing tanks will probably include some additional steps.During wash steps it would also be necessary to pulse sample valves etc..
Assuming that there are two feed and return lines then two CIP's can operate in parallel. Thismeans that one of the mix tanks could be cleaned at the same time as one of the tanker intakelines and that the liquid from one of the CIP tanks (e.g. acid) could be circulated through the intakeline and the mix tank at that time.
In the post caustic wash fresh water is recovered to the return water tank. This leaves thepossibility for cross contamination.
3.3. CIP Tan k Make-Up
The normal sequence for a CIP Tank Make-Up is as follows;
1 Dump Tank Contents Transfer contents of CIP tank to effluent plant2 Fill Tank with Water Fill Tank to High Level with Fresh Water 3 Dose Chemical Concentrate Empty Tank to drain at CIP station via selected line4 Heat Tank Caustic Tank to drain at CIP station via selected line
Fresh Water Tank requires only step 1.Cold Caustic and Acid Tank only require steps 1 and 2.Hot Caustic Tank requires steps 1, 2 and 3.
4. CIP Recipe
The recipe for a CIP will usually consist only of a set of times for each wash step and a singleon/off bit to decide whether to include an acid wash in the CIP sequence.
It is possible to include additional items such as pre-set values for watch dog timers for push outand emptying steps etc.. to allow the operator to tune the CIP's. It would also be possible to allowthe sequence of steps to be modified as part of the recipe but this is not really necessary.
Therefore a CIP recipe can essentially be reduced to the following
1 With Acid Y/N 1 / 02 Pre-Rinse 10 minutes3 Caustic Wash 20 minutes4 Post Caustic Wash 8 minutes5 Acid Wash 15 minutes6 Final Rinse 15 minutes
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5. The Physical ModelThe CIP station is not a process cell, it is not a unit, the individual CIP vessels are not units either
as they do not perform any batch processing (unless we consider the make-up process).If we look at the CIP station in terms of the CIP feed and return lines rather than in terms of the CIPvessels the CIP station can be viewed in a similar way to any other utility. The CIP feed linessupply the required liquids to the various units and transfer lines in the plant. Therefore the CIPStation is probably best viewed as shared resource even though the procedural control for cleaninga unit is associated with the CIP station rather than the unit in question.
The CIP station will be required to clean not only other units (such as the batch mixing vessels) butalso other vessels which might not even be defined as units. For example the CIP station will beused to clean a milk silo and neither the CIP station nor the
Note : If we assume that the CIP station for the Milkshake Plant was delivered with it's own controlsystem then it would require the above recipe to be downloaded from the MES (or SCADA) itwould carry out the sequencing through prerinse, caustic wash etc..and deliver the cleaning media to the various units.
6. CIP Batch and CIP Batch Scheduling
A CIP sequence is not a Batch as defined in S88.01.
A CIP batch could be included in the batch recipe for each product. In this case the CIP unitprocedure would form part of the procedure for producing "Spladge Drink".
In the Milkshake plant it would be necessary to schedule a CIP of a Batch Mixing Tank beforeproducing any "Splodge Drink" if the previous batch had been an "Alchoshake" batch, however ifthe previous batch had been a "Splodge Drink" batch no CIP would be required.
7. CIP Batch Reports
The milkshake plant owner would obviously require some reporting mechanism for the plant CIP.The CIP reports could be attached to batch report to show for example that a Batch Mixing Vesselhad been cleaned before use.
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Diagram Description 1 - Milkshake Plant Overview
RecipesAdditiveWarehouse
Stores the palettes
of Flavour additivesSolids Processing
Flavour additivesmaterials are depalletised
and weighed into IBC's
IntermediateStore
Milk Silos
3 silos filled duringday, cleaned at night
CIP ChemicalStore
CIP Generation System
3 silos filled during day, cleaned at
night
Liquids
Batch MixingProcesses
FLT2 FLT4
FLT5
PackagingBldng
PackagingStore
FLT3 FLT6
ProductSilos
3 silos
Milk shakes
QuarantineStore
Final ProductStore
Stores the palettes
of final product
Product
Additives
CIPChemicals
Packaging
Milk Tankers
Water Treatment PlantSteam
Resources
CIP Recipes
FLT1
Material Reception
Chemicals
Palettes
Milk
17
6
20
3
18 19
2 4
21
5
9
22
7
8
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Diagram Description 2 - Liquids Processing Bldng
This Process cell is where the batches of product are produced.Each batch mixing unit can be making a different product or being cleaned.PCS Design point
The corresponding graphic in the PCS will be animated with the states of the main areas.Sheet Version: 490 Class: Process Cell Sheet 2 of 89 PageID: 15
BV1
Batch MixingUnit
SH1 SH2
BV2
Batch MixingUnit
CIPSupply
HG2
Homogeniser
HG1
Homogeniser
CIPReturn
cr06
Product Homogenising pipework
cr07
Product Distribution manifold
PS1 PS2 PS3
CIPSupply2
CIP Return2
Controller 2
Product Silos
Additive Storage Hoppers
LocalDisplay
Parent Symbols:1 - Milkshake Plant Overview.... , Liquids
Milk ShakeCovers Banana,Strawberry and otherblends
Cross Reference
TagnameBV1
BV2
HG1
HG2
SH1SH2
Sheet262826282528292528
2966
cr08
Product Silo inlet manifold
12
11 11
12
1313
28
25
83
49
25
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Diagram Description 3 - Milk Silos
The milk silos store fresh milk and unused returned milk.In this model they are grouped into one process cellThis is because the batches in this area are not one to one related to other areas.
PCS Design pointThe corresponding graphic in the PCS will be animated with the states of the main areas.Sheet Version: 513 Class: Process Cell Sheet 3 of 89 PageID: 14
MS1
Milk Silo
MS2
Milk Silo
MS3
Milk Silo
cr04
Milk Supply manifold
cr05
Milk Distribution pipework
Milk Reception 1
Tanker UnloadingBay
Milk Reception 2
Tanker UnloadingBay
Milk Reception 3
Tanker UnloadingBay
CIP
Supply 1
CIP
Return 1
CIPSupply 2
CIP
Return 2
Controller 1
LocalDisplay
rp Receive Milk
Cross Reference
TagnameMS1
MS2
MS3
Sheet262729302627293026272930
10/2
10/210/2
27
26
33
33
33
83
52
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Diagram Description 5 - Product Silos
The product silos store the batches of product.In this model they are grouped into one process cellSheet Version: 474 Class: Process Cell Sheet 5 of 89 PageID: 16
PS1
Product
Silo
PS2
Product
Silo
PS3
Product
Silo
cr08
Product Distribution pipework
cr09
Product to Packaging pipework
Controller 3Local Display
10/1 10/1 10/1
25
30
83
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Diagram Description 7 - All CIP Recipes
This diagram will show all the CIP procedures (to be completed)Sheet Version: 513 Class: Recipe Sheet 7 of 89 PageID: 255
Line CIP Recipes Vessel CIP Recipes
rcCIPLine rcCIP MS1
rcCIP MS2
rcCIP MS3
rcCIP BV1
rcCIP BV2
rcCIP HG1
rcCIP HG2
X SH1
rcCIP SH2
rcCIP PS1
rcCIP PS2
rcCIP PS3
X Solids Prep Line 1
50
50
50
50
50
50
50
50
50
50
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Diagram Description 8 - Material Reception Recipes
This diagram shows the Recipe procedure icons for material receptionSheet Version: 515 Class: Recipe Sheet 8 of 89 PageID: 326
Receive Addiitive
Receive Chemical Drums
Receive Packing Pallets
Receive Milk
51
51
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Diagram Description 9 - Milk shakes
Covers Banana, Strawberry and other blendsSheet Version: 522 Class: Recipe Sheet 9 of 89 PageID: 325
FudgeDrink
Alchoshake
FudgeDrink
Banana Milk shakes
Alchoshake
Strawberry Milk shakes
Banana Additive Preparation
Strawberry Additive Preparation
48
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Diagram 10 - un Milk/Product SiloSheet Version: 513 Class: Unit Sheet 10 of 89 PageID: 18Variant 1 - Product Silo
Silo
LSL
Empty
LSH
LAH
LAL
CIP_V1Vessel CIP
ZSAZSO
Manway Switch
Line
From Line to
Silo Receive
Off Set ReceiveRoute
Set Deliver Route
States
Receive
Deliver
Drain
Silo Deliver
Silo CIP
LTSiloLevel
Variants
VariantMilk Silo
Product Silo
TagnameLTLSL
LALWIA
ExcludedXX
XX
VarTag SubVar
em transfer out
em
FeedLine
From Line to
em Discharge
CIP withReturn
Drain
Milk/Product Silo
Off
Set Deliver Route
Deliver
Set Receive Route
CIP with Return
CIP Drain
Receive
Drain
em Discharge
Off
Off
Transfer
Off
Transfer
Drain
Off
Drain
em Feed
Through
Through
Through
Through
Receive
Receive
Receive
Through
emAgitator
Run
Run
Run
Run
Run
Off
Run
Run
Line to
6
6
6
6
6
6
6
6
em transfer out
Through
Through
Send
Through
Send
Through
Through
Through
CIP Drain
emAgitator
op Receive Product82
82
65
82
62
61
58
80
46
45/2
38
34/1
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Diagram 10 - un Milk/Product SiloSheet Version: 513 Class: Unit Sheet 10 of 89 PageID: 18Variant 2 - Milk Silo
Silo
WIA
LSH
LAH
CIP_V1Vessel CIP
ZSAZSO
Manway Switch
Line
From Line to
Silo Receive
Off Set ReceiveRoute
Set Deliver Route
States
Receive
Deliver
Drain
Silo Deliver
Silo CIP
Variants
VariantMilk Silo
Product Silo
TagnameLTLSL
LALWIA
ExcludedXX
XX
VarTag SubVar
em transfer out
em
FeedLine
From Line to
em Discharge
CIP withReturn
Drain
Milk/Product Silo
Off
Set Deliver Route
Deliver
Set Receive Route
CIP with Return
CIP Drain
Receive
Drain
em Discharge
Off
Off
Transfer
Off
Transfer
Drain
Off
Drain
em Feed
Through
Through
Through
Through
Receive
Receive
Receive
Through
emAgitator
Run
Run
Run
Run
Run
Off
Run
Run
Line to
6
6
6
6
6
6
6
6
em transfer out
Through
Through
Send
Through
Send
Through
Through
Through
CIP Drain
emAgitator
op Receive Product
81
82
65
82
62
61
58
46
45/2
38
34/1
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ControlDraw Ltd Milkshake S88 Model
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Diagram Description 11 - un Additive Storage Hopper
Not yet fully modularisedSheet Version: 511 Class: Unit Sheet 11 of 89 PageID: 23
StorageHopper
LSH
LSLEmpty
RV1
Parent Symbols:
2 - Liquids Processing Bldng.... , SH1, SH2
Idle
Feed
Additive Storage Hopper
Idle
Feed
Receive
RV1
Stop
Run
Stop
LSH
Disabled
Enabled
Enabled
LSL
Disabled
Enabled
Enabled
Receive
82
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Diagram Description 12 - un Batch Mixing
The batch mixing Unit is split into a number of equipment modules, these are:em Temp Control Controls the vessel temperatureem Agitator Runs the Agitator
em Discharge Controls discharge to drain or to downstreamem Feed Controls feeds into the vesselem Transfer Out Controls Transfer out of the vesselNote that em Feed and em Transfer Out are not completely owned by the Unit, they can also be acquired by the CIPrecipes and transfer routes.
Sheet Version: 517 Class: Unit Sheet 12 of 89 PageID: 19
BatchVessel
States
em TempControl
WT1
WQ1
Loss-In-Weight Feeder
LSL
LSH
LAH
LAL
ShutDown
CIP
Receive MilkReceive
Additives andMilk
ReceiveAdditives
Hold
Transfer Out
Batch Mixing Unit
ShutDown
Receive Milk
Hold
Receive Additives
Receive Additives and Milk
Settle
Transfer Out
Heat Up
Cool Down
CIP
Drain
emAgitator
Off
Run
Run
Run
Run
Off
Run
Run
Run
Run
Off
em Temp Control
Idle
REG
REG
REG
REG
REG
REG
MH
MC
Idle
Idle
em Feed
Through
Receive
Through
Through
Receive
Through
Through
Through
Through
Receive
Through
em transfer out
Through
Through
Through
Through
Through
Through
Send
Through
Undefined
Send
Undefined
WQ1
Stop
Stop
Stop
Run
Run
Stop
Stop
Stop
Stop
Stop
Stop
LAL
Disable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Disable
Disable
LAH
Disable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Heat Up Cool Down
Drain
Animated
Diagram
Unit interface CM
em Agitator
em Feed
LineFrom
Line to
LineFrom
Line to
em Transfer Out
em Discharge
Settle
op Batch Mixing
op Homogenising
81
43
40
82
82
84
34/2
45/2
46
38
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Diagram 13 - un Homogeniser Sheet Version: 413 Class: Unit Sheet 13 of 89 PageID: 35
emHomogeniser
Line 1
Line 2
Line 1
forwardLine 2
forward
Through
Run
IL01 Interlock
Review Status:Under Development
em Homogeniser
in
Line 2 Line to
CIP_H1
CIP for Homogeniser
em transfer out
http://www.gchahn.com/media/systematic_aeration_en_0103.pdf Double click to open
Line 2 Line to
60
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Diagram Description 14 - un Packaging Line
The packaging area is a process cell containing two packaging lines.The packaging line is treated as a single nit .Each machine is an Equipment module
Sheet Version: 458 Class: Unit Sheet 14 of 89 PageID: 20
Bottles to line
Accumulation
Conveyor
Packing Conveyor
EM01
FillingMachine
EM02Palletiser
EM03Labeller
EM04
CartonFiller
EM05CartonShrinkWrapper
EM06Palletizer
Packing Procedure
Local
Display Text Display
Efficiency 39%MadeTargetShop Order 12313
Button on graphic to callup Shop Order Controls
Shop
Order
Parent Symbols:4 - Packaging Building.... , Packaging Line 1, Packaging Line 2
Shutdown
Running
39
39
39 39 39 39 39 39
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Diagram Description 15 - un Solids Blending
Not yet fully modularisedSheet Version: 449 Class: Unit Sheet 15 of 89 PageID: 22
Blender
IBC2
Blender Drive
RV1
IBC1
LSLEmpty
LSH
LAH
LAL
IBC3
Prepared IBC of Additives
Blend to IBC
Prepare IBC of mixed
additivesOff
Receive
Deliver
73
73
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Diagram Description 16 - un Solids Preparation Line
NOTE - this is not yet modularised in Equipment modulesSheet Version: 513 Class: Unit Sheet 16 of 89 PageID: 21
Sack Slitting Machine
RV1
Fan
AdditiveSilo
Depalletiser
Conveyor
RV2
Mill
Sieve
MetalDetector
IBC
SolidsBatch
IBC
Reject
IBC
Oversize
LSLEmpty
LSH
Prepare IBC
Prepare IBC of Additives
Parent Symbols:6 - Solids Processing Bldng.... , Solids Prep Line 1, Solids Prep Line 2
Off
Receive
Deliver
Solids Preparation Line
Off
Receive
Deliver
Receive andDeliver
Conveyor
Stop
Run
Stop
Run
Fan
Stop
Run
Stop
Run
MetalDetector
Off
Off
On
On
RV1
Stop
Run
Stop
Run
RV2
Stop
Stop
Run
Run
SackSlitting
Machine
Undefined
Undefined
Undefined
Undefined
LSH
Disabled
Enabled
Enabled
Enabled
LSL
Disabled
Enabled
Enabled
Enabled
Receive andDeliver
73
73
73
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Diagram Description 19 - CIP Generation System
This diagram shows how there are Two CIP units that share the same collection of Water, Acid and Caustic tanks.Note that each CIP unit can supply either of the linesSheet Version: 523 Class: Cell Common Resource Sheet 19 of 89 PageID: 36
tk ColdCaustic
tk Acidtk Hot
Caustic
Water
Controller 6Local Display
tk ReturnWater
tk FreshWater
See also CompleteGraphic
CIP Unit1
CIPSupply/Return
CIP Unit2
CIPSupply/Return
See CIP RoutingDiagram
Line 1Routing
Line 2Routing
A
A
B
B
C
C
D
D
D
E
E
32/3 32/1 32/2
83
3124
87
23
23
85
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Diagram Description 23 - CIP Unit
CIP Supply/ReturnSheet Version: 524 Class: Common Resource Sheet 23 of 89 PageID: 318
tk ColdCaustic
Line CleanVessel Clean
Feed A
tk Acidtk Hot
Caustic
Return A
FT2
tk ReturnWater
tk FreshWater
Equipmentor Line
QT2Conductivity TT02
Shutdown Supply AcidSupply Cold
CausticSupply Hot
Caustic
Rinse toRecycle
Acid RecycleCold Caustic
RecycleHot Caustic
Recycle
CIP Unit
Shutdown
Supply Acid
Acid Recycle
Supply ColdCausticCold CausticRecycleRinse toRecycleHot Caustic
RecycleSupply HotCaustic
KV005
Close
Close
Close
Close
Close
Close
Close
Close
CIP SupplyPump
0
0
0
0
0
0
0
0
tk Acid
0
0
0
0
0
0
0
0
tk ColdCaustic
0
0
0
0
0
0
0
0
tk FreshWater
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
Shutdown
tk HotCaustic
0
0
0
0
0
0
0
0
tk ReturnWater
0
0
0
0
0
0
0
0
Valve inManifold
Valve inManifold
Gravity
em CIPSupply
em CIPDrain
em CIP Line Select
6058
8080
32/132/3 32/23124
80
37
35
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Diagram Description 24 - crFreshWater
Whilst having the class of Equipment Module, it is also an exclusive use Common Resource.Only one control recipe can put the module into the feed state at one time.The module has to be explicitely acquired and given it's route select parameter, then it can feed. Once it is released
another recipe canSheet Version: 458 Class: Common Resource Sheet 24 of 89 PageID: 271
FW1
Fresh
water
V02
V01
V03
Water
LSLEmpty
LSHFull
LSMMinimum
Line 2
Line 1
Supply On
Demand
V01 cmd
V02 cmd
EnableFilling
Set/Reset
V03 cmd
Shutdown
Supply 1
Supply 2
A
A
B
B
B
72/3
72/3
72/3
82
82
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Diagram 25 - Homogeniser Outlets manifoldSheet Version: 523 Class: Common Resource Sheet 25 of 89 PageID: 33
HG2
Homogeniser
HG1
Homogeniser
V01
V02
Supply
HG1.em transfer out
[Sheet 2]
HG2.em transfer out
[Sheet 2]
V02
V01
Return
V04
72/3
72/346 46
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Diagram 26 - Milk Distribution ManifoldSheet Version: 515 Class: Common Resource Sheet 26 of 89 PageID: 30
CIP Supply
MS1
Milk Silo
MS2
Milk Silo
MS3
Milk Silo
BV1BV2
CIPReturn
Animated Diagram
Put in Run Mode thenclick the valves
BV2.emFeed
[Sheet 2]
BV1.emFeed
[Sheet 2]
MS1.em transfer out
[Sheet 3]
MS2.em transfer out
[Sheet 3]
MS3.em transfer out
[Sheet 3]
V04
V03
V02
V01
19
12 12
45/245/246 46 46
72/3
72/3
72/3
72/3
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Diagram 27 - Milk Supply manifoldSheet Version: 522 Class: Common Resource Sheet 27 of 89 PageID: 31
CIP Supply
V05
V09
CIPReturn
MS1
Milk Silo
MS2
Milk Silo
MS3
Milk Silo
FromHomogenisers/Batch
vessels
Milk Tanker
Line Control
Controls the
Setting of routes inthe lines
CIP_Check
Clean Status Monitor
Control Modules
V01
Line 1
Line 2
Animated Diagram
Put in Run Mode thenclick the valves
MS1.emFeed
[Sheet 3]
MS2.em
Feed
[Sheet 3]
MS3.em
Feed
[Sheet 3]
em Tanker Reception 1
Milk Tanker
Milk Tanker
em Tanker Reception 2
em Tanker Reception 3
72/3
72/3
72/3
10
77
76
45/2 45/2 45/2
44
44
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Diagram 28 - Product Homogenisation manifoldSheet Version: 515 Class: Common Resource Sheet 28 of 89 PageID: 32
BV1.em
Transfer Out
[Sheet 2]
BV1 BV2
BV1.em
Transfer Out
[Sheet 2]
CIPSupply
CIP
Return
HG2
Homogeniser
HG1
Homogeniser
HG1.em
Homogeniser in
[Sheet 2]
HG1.em
Homogeniser in
[Sheet 2]
V06
V05
V02
V01
V03
V04
V01
46 46
12 12
19
1313
42 42
72/3
72/3
72/3
72/3
72/3
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Diagram 30 - Product to packaging manifoldSheet Version: 474 Class: Common Resource Sheet 30 of 89 PageID: 34
PS1
ProductSilo
PS2
ProductSilo
PS3
ProductSilo
PS1.em transfer out
[Sheet 5]
CIPSupply
CIPReturn
V04
V03
V02
V01
PS2.em transfer out
[Sheet 5]
PS3.em transfer out
[Sheet 5]
5
19
72/3
72/3 46
72/3
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Diagram 31 - Recycled water Sheet Version: 395 Class: Common Resource Sheet 31 of 89 PageID: 273
RW1
Return
water
V02
V04
V03
V01
LSL
Empty
LSH
LAH01
LAL02
72/3
71
72/3
71
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Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 1 - Caustic 1
em Water Feed
CIP Tank Agitator
LAL
LAH
TT
AG1
Water to Next
P3
Caustic
Supply CM
List of Variants
Acid
em Water Feed
to Next
1-Caustic 1
Caustic
/Var 1
2-Caustic 2
Caustic
/Var 2
{Excluded}
3-Acid
/Var 1
em transfer out
em Feed
82
82
73
73
46
45/2
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Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 2 - Caustic 2
em Water Feed
CIP Tank Agitator
LAL
LAH
TT
AG1
Water
P3
Caustic
Supply CM
List of Variants
Acid
em Water Feed
to Next
1-Caustic 1
Caustic
/Var 1
2-Caustic 2
Caustic
/Var 2
{Excluded}
3-Acid
/Var 1
em transfer out
em Feed
82
82
73
73
46
45/2
47 /2
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Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 3 - Acid
em Water Feed
CIP Tank Agitator
LAL
LAH
TT
AG1
Water to Next
P3
Acid
Supply CM
List of Variants
Acid
em Water Feed
to Next
1-Caustic 1
Caustic
/Var 1
2-Caustic 2
Caustic
/Var 2
{Excluded}
3-Acid
/Var 1
em transfer out
em Feed
82
82
73
73
46
45/2
47 /1
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Diagram 33 - Tanker unloading baySheet Version: 273 Class: Common Resource Sheet 33 of 89 PageID: 27
V12
Milk Supplymanifold
Milk Tanker
Pump
LSLLine Empty
LAL
Parent Symbols:
3 - Milk Silos
.... , Milk Reception 1,
Milk Supply
manifold
Off Set Route Deliver
States
Tanker Deliver Fred
Tanker unloading bay
Deliver
Off
Set Route
LAL
Enabled
Disabled
Enabled
Pump
Run
Stop
Stop
V12
Mix
Thru
Mix
Milk Tanker
10
0
10
73
27
82
72/3
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Diagram 34 - em Agitator Sheet Version: 2 Class: Equipment Module Sheet 34 of 89 PageID: 261Variant 1 - Fixed Speed
LT001
Agitation CM
FM01
Vessel
Off
Run
States
epStart_Level
epStop_Level
epOn_Time
epOff_Time
em Fixed Speed Agitator
Off
Run
Agitation CM
Off
On
FM01
Stop
Start
75
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Diagram 34 - em Agitator Sheet Version: 2 Class: Equipment Module Sheet 34 of 89 PageID: 261Variant 2 - Variable Speed
LT001
VSD AgitationCM
Vessel
Off
Run
States
epStart_Level
epStop_Level
epOn_Time
epOff_Time
VM01
epSpeed
SIA
Select
Remote
em Fixed Speed Agitator
Off
Run
VSD Agitation
CMOff
On
VM01
Stop
Start
75
74
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Diagram Description 35 - em CIP Drain
This incomplete module enables the routing of CIP returns to drainSheet Version: 513 Class: Equipment Module Sheet 35 of 89 PageID: 328
KV005
Drain2
72/3
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Diagram Description 36 - em CIP Line Select
This incomplete module switches a CIP Supply and return between one or other linesSheet Version: 515 Class: Equipment Module Sheet 36 of 89 PageID: 329
XV02
XV01 Line 1Routing
Line 1Routing
A
A
BB
C
C
DD
72/3
72/3
85
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Diagram Description 37 - em CIP Supply
This incomplete module controls the supply of CIP into the CIP linesSheet Version: 513 Class: Equipment Module Sheet 37 of 89 PageID: 327
CIP SupplyPump
Feed A
CV
Condensate
Steam
TT01
TIC01
CIPFeed 1
CIP Line
73
79
80
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Diagram 38 - em DischargeSheet Version: 395 Class: Equipment Module Sheet 38 of 89 PageID: 263
V02
Pump
Drain
V01
Next
Off
Transfer
IL01 Pump cannot run if valve not open
Drain
em Discharge
Off
Transfer
Drain
Pump
Stop
Run
Stop
V5
Closed
Open
Open
V6
Closed
Closed
Open
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Diagram 39 - em Generic Machine InterfaceSheet Version: 514 Class: Equipment Module Sheet 39 of 89 PageID: 234
Starved
Alarm code
Machine Status
Machine Supertag
SCADA Tag Points
Machine States
Machine Alarm 1
Machine Alarm 2
Producing
Waiting.
Stopped
Failed
Machine Alarm 3
Machine Alarm 4
Machine Alarm 5
Machine Alarm 6
Machine Alarm 7
Machine Alarm 8
Machine In Count
Machine Out Count
8 SpecificAlarms
Machine Speed
Alarm Code for allalarms
Machine Status as instates
0 to 4
Counter Reset
Integer Value
Discrete Value
Real Value
Key
Reset from new order
Machine Alarm Group
Machine Mimic
Each machine has a mimicdiagram showing all current
machine data.
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Diagram 40 - em Heat/Cool JacketSheet Version: 517 Class: Equipment Module Sheet 40 of 89 PageID: 86
Batch Vessel
TT1
V12
V10
V09
V11
Coolant Supply
Coolant Return
Steam Supply
Temperature ControlEquip phase
Condensate
Parent Symbols:12 - un Batch Mixing.... , em Temp
Control
SMH
Set MaxHeating
MH
Max Heating
MC
Max Cooling
SMC
Set Max
Cooling
StopIdle
REG
Regulating
SREG
Set
Regulating
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Diagram 41 - em Homogeniser Sheet Version: 413 Class: Equipment Module Sheet 41 of 89 PageID: 313
PT01
PT02
HS03
HS04
XA01
XA02
XA03
XA04
XA05
XA06
PBO01
PBO02
PAHH
PAL
HS02
I/O and AlarmsThis shows small PLC controlling the homogeniser that also reports via alarms and some
process measurments.
PLC
Machine Controller
PLCFailPLC Failure
Includes comms failures
SI
Homogeniser
CWS CWR
PD Pump
Material
Material
73
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Diagram 42 - em Homogerniser inSheet Version: 490 Class: Equipment Module Sheet 42 of 89 PageID: 306
V01
V02
Line 1
Line 2
Line 1forward
Line 2forward
Homogeniser
Route Select
V01 cmdEquals1
V02 cmdEquals2
Off
Homogenise
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Diagram 43 - em Loss In Weight Feeder Sheet Version: 517 Class: Equipment Module Sheet 43 of 89 PageID: 46
Hopper
WT
Screw Feeder
Controller 7
SI
81
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Diagram 44 - em Tanker ReceptionSheet Version: 457 Class: Equipment Module Sheet 44 of 89 PageID: 314
Milk Tanker
PumpLAL
Line Empty
XV10
Material
Material
Idle
Feed
Ready
33
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Diagram Description 45 - em Transfer in
Variant 2 - Type 2
This module can be acquired by the batch manager. This also sends a Route number to the module.The unit then sets the module to the Through or Feed State
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Diagram 45 - em Transfer in
Sheet Version: 458 Class: Equipment Module Sheet 45 of 89 PageID: 264
V03
V04
Line 1
Line 2
Line 1forward
Line 2forward
Unit
Through
Receive
Route Select
V01 cmdEquals1
V02 cmdEquals2
IF Transfer in
V06
CIP V04 cmd
CIP Pulse
A
A
A
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Diagram Description 46 - em Transfer out
This module can also be acquired by the CIP recipes and transfer routes.
Sheet Version: 517 Class: Equipment Module Sheet 46 of 89 PageID: 266
Line 1
Line 2
Line 1forward
Line 2forward
Unit
V08
V07
Through Send
Route SelectFrom Recipe Procedure
V01 cmdEquals1
V02 cmdEquals2
A
A
A
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Diagram Description 47 - em Water Feed
Variant 1 - In-Line
This module fills the vessel with water - when the level drops below the low level switch filling starts and it stops onhigh level.
Note that the value of ep Timer SP in the Low level switch modules should be greater then the time taken to allow thewater to increase the level. Also that ep Fill Time SP should be long enough to allow the level to rise enough, but to below the High level switch,since that would trigger a High level alarm.If a third switch just below the LAH were provided then that could be used instead of the timer.Sheet Version: 510 Class: Equipment Module Sheet 47 of 89 PageID: 324
Water
V05
to Next
List of Variants
to Next
V05
V05
1-In-Line
{Excluded}
2-EndLine{Excluded}
{Excluded}
Idle
Feed
LAH.blnVal
[Sheet 32]
EnableFilling
Set/Reset
V05.AutoCmd
[Sheet 47]
LAL.blnVal
[Sheet 32]
em Water Feed
Idle
Feed
Enable Filling
False
True
Timer
ep Fill TimeSP
A
A
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Diagram Description 48 - rcp Additive Preparation
Makes up a batch in an IBC for use in next cellSheet Version: 509 Class: Recipe Procedure Sheet 48 of 89 PageID: 267
UP 0
UP 1
Release
Release
Acquire
Acquire
To be defined
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Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56
Parent Symbols:
2 - Liquids Processing Bldng
.... , Milk Shake
9 - Milk shakes
.... , Alchoshake/1, Banana
Acquire MixingUnit
op Deliver Milk
Acquire Milk Silo
Release Milk Silo
BV1
Mixing Unit
HG1
Homogeniser
PS1
Milk Silo
Acquire
Homogeniser
Release Mixing
Unit
Release
Homogeniser
op Batch Mixing
OP 2 Homogenising
Acquire Storage
Silo
op Receive
Release Storage
Silo
CIP Not Required CIP Required
Prompt to CIP Unit
61 57
59
62
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Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56Variant 1 - With Homogenising
Parent Symbols:
2 - Liquids Processing Bldng.... , Milk Shake
9 - Milk shakes
.... , Alchoshake/1, Banana
Acquire MixingUnit
op Deliver Milk
Acquire Milk Silo
Release Milk Silo
BV1
Mixing Unit
HG1
Homogeniser
PS1
Milk Silo
AcquireHomogeniser
Release MixingUnit
ReleaseHomogeniser
op Batch Mixing
OP 2 Homogenising
Acquire StorageSilo
op Receive
Release StorageSilo
CIP Not RequiredCIP Required
Prompt to CIP Unit
61 57
59
62
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Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56Variant 2 - No Homogenising
Parent Symbols:
2 - Liquids Processing Bldng.... , Milk Shake
9 - Milk shakes
.... , Alchoshake/1, Banana
Acquire MixingUnit
op Deliver Milk
Acquire Milk Silo
Release Milk Silo
BV1
Mixing Unit
HG1
Homogeniser
PS1
Milk Silo
Release MixingUnit
op Batch Mixing
op Mix and Heat
Acquire StorageSilo
op Receive
Release StorageSilo
CIP Not RequiredCIP Required
Prompt to CIP Unit
61 57
59
62
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Diagram 50 - rcp generic Vessel CIPSheet Version: 515 Class: Recipe Procedure Sheet 50 of 89 PageID: 257
Takes place in theUnit vessel being
cleaned
Takes place in CIP Unit
ph Vessel CIP
Acquire CIP Unit
op CIP Supply toVessel Clean
Release CIP Unit
Note - this is a 'Virtual unit'
Acquire Route Acquire Vessel
Release Route Release Vessel
ph Set Route
7058
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Diagram 51 - rcp Receive AddiitiveSheet Version: 513 Class: Recipe Procedure Sheet 51 of 89 PageID: 243
Truck Deliver
This is purely manual
Warehouse Receive
This is purely manual
PrepareCheck delivery note againstorders, sample, tell ERP etc
Acquire WarehouseSlot
Move Truck
To acquired bay
Acquire deliverybay
Parent Symbols:8 - Material Reception Recipes
.... , Receive Addiitive, Receive Chemical Drums, Receive Packing Pallets
Release WarehouseSlot
Release deliverybay
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Diagram 52 - rcp Receive milkSheet Version: 488 Class: Recipe Procedure Sheet 52 of 89 PageID: 244
Tanker Deliver SynchOut
Silo ReceiveSynchIn
PrepareCheck delivery note against
orders, sample, tell ERP etc
Acquire SiloMove Tanker
To acquired bay
Acquire deliverybay
Parent Symbols:
3 - Milk Silos
.... , rp Receive Milk
8 - Material ReceptionRecipes
.... , Receive Milk
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Diagram 53 - up Fill and Pack ProcedureSheet Version: 513 Class: Unit Procedure Sheet 53 of 89 PageID: 55
Start Cartonfiller
Start box filler
Start Stacker
Start ShrinkWrap
Fill and pack
Stop Carton filler
Stop box filler
Stop Stacker
Stop ShrinkWrap
Start up the line
Run Fill/Pack operation
Shut down the line
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Diagram 57 - op Batch Mix and HomogeniseSheet Version: 369 Class: Operation Sheet 57 of 89 PageID: 310
Add MilkStart Qty
Mix andHeat
Add Milkand Solids
Sample
Add MilkFinal Qty
66
69
67
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Diagram 58 - op CIP Supply to Vessel CleanSheet Version: 457 Class: Operation Sheet 58 of 89 PageID: 68
Pre-RinseSet to hState
'Return Water Tank to drain at CIPstation via selected line
True
Push Out Water with Caustic
Caustic Tank to drain at CIP stationvia selected line
Conductivity
Caustic Wash
Caustic Tank to Caustic Tank viaselected line
Timer1
Push Out Caustic with Water
Fresh Water Tank to Caustic Tank viaselected line
Conductivity
Post Caustic Wash
Fresh Water Tank to Return Water Tank via selected line
Timer2
Push Out Water with Acid
Acid Tank to Return Water Tank viaselected line
Conductivity
Acid Wash
Acid Tank to Acid Tank via selectedline
Timer3
Push Out Acid with Water
Fresh Water Tank to Acid Tank viaselected line
Conductivity
True
Empty Tank
Empty Tank to drain at CIP station viaselected line.
Tank Empty LevelSw
Empty Tank
Empty Tank to drain at CIP station viaselected line.
Tank Empty LevelSw
Empty Tank
Empty Tank to drain at CIP station viaselected line.
Tank Empty LevelSw
Empty Tank
Empty Tank to drain at CIP station viaselected line.
Tank Empty LevelSw
Parent Symbols:10 - un Milk/Product Silo.... , Silo CIP23 - CIP Unit.... , Vessel Clean50 - rcp generic Vessel CIP.... , op CIP Supply to VesselClean
A
A
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Diagram 59 - op HomogenisingSheet Version: 509 Class: Operation Sheet 59 of 89 PageID: 312
Mix andHeat
HomogenisingTransfer Out 69 68
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Diagram Description 60 - op Line Clean
Generic Line Clean
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Diagram 60 - op Line Clean
Sheet Version: 457 Class: Operation Sheet 60 of 89 PageID: 69
Pre-Rinse
Return Water Tank to drain at CIP station viaselected line
True
Push Out Water with Caustic
Caustic Tank to drain at CIP station viaselected line
Conductivity
Caustic Wash
Caustic Tank to Caustic Tank via selected line
Timer1
Push Out Causticwith Water
Fresh Water Tank to Caustic Tank viaselected line
Conductivity
Post Caustic Wash
Fresh Water Tank to Return Water Tank viaselected line
Timer2
Push Out Water with Acid
Acid Tank to Return Water Tank via selectedline
Conductivity
Acid Wash
Acid Tank to Acid Tank via selected line
Timer3
Push Out Acid with Water
Fresh Water Tank to Acid Tank via selectedline
Conductivity
True
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Diagram 62 - op Silo ReceiveSheet Version: 513 Class: Operation Sheet 62 of 89 PageID: 247
T
Route Set
LSH or Source LSL
Route Set
Parent Symbols:
10 - un Milk/Product Silo.... , Silo Receive
To Add - Ready check and
set step and transition for the
interface with the sendingunit
S1
Set to Set Receive
Route
Set State
Set to Receive
Set State
Set to Off
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Diagram 64 - op Unload Tanker Sheet Version: 455 Class: Operation Sheet 64 of 89 PageID: 245
Parent Symbols:33 - Tanker unloading bay
.... , Tanker Deliver 55 - up Receive Milk
.... , Transfer Milk
T
Route Set
LSH or Source LSL
Route Set
S1
Set to Set Route
Set State
Set to Deliver
Set State
Set to Off
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Diagram 65 - op Vessel CIPSheet Version: 397 Class: Operation Sheet 65 of 89 PageID: 259
epVesselEmptyLevel
S04_Clean / Drain
Init
S05_CIP
Set to CIP Vessel
T04_Source ActiveSource "Active" signal Set
Destination (Z unit) "Ready" signal Set
T05_Source Flush Reset
Source "Flush" signal Reset
T09_Source Ready Reset
Source "Ready" signal Reset
End
T02_Source Ready Set
Source "Ready" signal Set
S02_Ready to CIP
Set to Ready to CIP Vessel
S07_CIP Drain
Set to CIP Vessel Drain
T10_States Confirm
EM States confirmed
T03_States ConfirmEM States confirmed
S03_Set ReadyDestination "Ready" signal Set
Source "Ready" signal Set
Parent Symbols:
10 - un Milk/ProductSilo
.... , CIP_V1
S06_CIP Drain
Set to CIP Vessel Drain
T06_Source Flush Set
Source "Flush" signal Set
T08_Source Flush Reset
Source "Flush" signal Reset
T07_Source Flush Set
Source "Flush" signal Set
S08_Reset Ready
Destination "Ready" signal Reset
Source "Ready" signal Reset
T11_True
T01_UnitRun
S01_Initialised Stop 'Storage_Timer'
A
A
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Diagram 66 - ph Add MilkSheet Version: 454 Class: Phase Sheet 66 of 89 PageID: 59
Start
T 01 Start
S01 Stabilise
Set to Settle
T 02 StableWeight stable for xseconds
S02 Store Tare Wt
Store the weight for use in batchcalcs
T 03 TrueDummy
S03 Receive
Set to Receive Milk Add milk a full rate.
T 04 WT > WTSPWeight greater thanTarget Weight
S04 Stabilise
Set to SettleWait for the weight to be steady
T 05 Time + WT.StandsstillWeight stable for x seconds
S05 Store Final Wt
Calculate the weight added.Calculate the Inflight weight.
T 06 TrueDummy
WTSP
Target Weight
WTPV Actual Weight
Parent Instances
Set State MatrixBatch Mixing Unit
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Diagram 67 - ph Add Milk and SolidsSheet Version: 298 Class: Phase Sheet 67 of 89 PageID: 58
Start
T 01 Start
S01 Stabilise
Set to Settle
T 02 Stable
Weight stable for xsecondsS02 Store Tare Wt
Store the weight for use in batch
calcs
T 03 True
Dummy
S03 Receive
Set to Receive Additives and Milk
T 04 WT > WTSP
Weight greater than
Target Weight
S04 Stabilise
Set to Settle
Wait for the weight to be steady
T 05 Time + WT.Standsstill
Weight stable for x seconds
S05 Store Final Wt
Calculate the weight added.
Calculate the Inflight weight.
T 06 True
Dummy
WTSP
Target Weight
WTPV
Actual Weight
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Diagram 69 - ph Mix and HeatSheet Version: 456 Class: Phase Sheet 69 of 89 PageID: 63
T_Start
Mix and heat
Set to Heat Up
Time
Time = Mixtmie
jhhoiooiooi
MixTemp
Target Temperature
Mixtime
Time for mixing
Start
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Diagram Description 70 - ph Vessel CIP
This diagram is the procedure for a vessel that is being cleaned. Note that all vessels must have CIP and Drainstates.Basically the vessel is extremely ignorant of what is happening, the CIP unit is in charge
Sheet Version: 455 Class: Phase Sheet 70 of 89 PageID: 311
T01
S 0Set to Drain
T0
S 0
Set to CIP
T0
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Diagram 71 - Mixproof ValveSheet Version: 0 Class: Valve Sheet 71 of 89 PageID: 242
FailOpenInst: Boolean
TypeInst: Text
MixOpen =
Signed
ThruClose =Clean
Upper
CleanLower
Flip Group handling
Clean Upper when the value from the CIP station = Valve Flip group 1Clean Lower when the value from the CIP station = Valve Flip group 2
Can Not Clean Upper and Lower at the same time. (Upper takes preference)Can Not Clean when in Mix position
States
Stroke Count - Upper
can be ResetStroke Count Lower
can be Reset
AutoCmd Auto CommandFrom control logic
ManualManual Command0 = close, 1 = OpenOperator set Valve Driver
Standard Auto/Manual.
Travel is timed in eachdirection. Timeout causesFail to Open or Fail to Close Alarm.The same Travel Time valueis used in the case of 2 limitswitches
Sov
DIClosed
Interlock ConditionSet false by interlock logic if required todeenergize output
OVRCOverride Open - set true to ignore limit switch
efSov
ZSCClosed Limit Switch
TMRMaximum Travel Time
Stroke Count
can be ResetHold
From Unit Hold
Hold Action
Determines whether to open, close, becontrolled or stay put if in Hold. Default toClose (for Fail closed valves) Valve status Log
can be Enabled / Disabled
Auto / Manual Auto/Manual0 = manual, 1 = Auto
Status Open / Close
FTOFail to Open Alarm
FTCFail to Close Alarm
Mixproof Valve
Thru
Mix
Clean Lower
Clean Upper
Sov
Off
On
Off
Off
SovL
Off
Off
On
Off
SovU
Off
Off
Off
On
DOSovUpper
SovU
DOSovLower
SovL
OVRO
Override Open - set true to ignore limit switch
DIOpen
ZSOOpen Limit Switch
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Diagram 72 - On Off ValveSheet Version: 144 Class: Valve Sheet 72 of 89 PageID: 231
A/M Auto/Manual
0 = manual, 1 = AutoSet by Unit Manual
AutoCmd Auto Command
From control logic
MANManual Command
0 = close, 1 = OpenOperator set
Valve Driver
Standard Auto/Manual.
Travel is timed in eachdirection. Timeout
causes Fail to Open orFail to Close Alarm.
Individual times for eachdirection must beprovided.
FTOFail to Open Alarm
FTCFail to Close Alarm
TMRCMaximum Close Travel
Time
DOSovDIClosed
DIOpen
InterlockCondition
OVROOverride Open = If setto 1 the Open limit
switch is ignored
OVRCOverride Closed - If set
to 1 the Open limitswitch is ignored
Valve status
Sov
ZSOOpen limit switch
ZSCClosed Limit Switch
TMROMaximum Open Travel
Time
Stroke Count
List of Variants
DIClosedDIOpen
FTCFTO
OVRCOVROTMRC
TMROZSCZSO
1-Open LS{Excluded}
{Excluded}
{Excluded}OVR{Excluded}
TMR{Excluded}
2-Closed LS
{Excluded}
{Excluded}
OVR{Excluded}TMR
{Excluded}
{Excluded}
3-2 Limit Switches
Signed
FailOpen
Inst: Boolean
TypeInst: Text
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Diagram 72 - On Off ValveSheet Version: 144 Class: Valve Sheet 72 of 89 PageID: 231Variant 3 - 2 Limit Switches
A/M Auto/Manual0 = manual, 1 = AutoSet by Unit Manual
AutoCmd Auto CommandFrom control logic
MANManual Command
0 = close, 1 = OpenOperator set
Valve Driver
Standard Auto/Manual.
Travel is timed in each
direction. Timeoutcauses Fail to Open orFail to Close Alarm.
Individual times for eachdirection must be
provided.
FTO
Fail to Open Alarm
FTC
Fail to Close Alarm
TMRCMaximum Close TravelTime
DOSovDIClosed
DIOpen
InterlockCondition
OVROOverride Open = If set
to 1 the Open limitswitch is ignored
OVRCOverride Closed - If setto 1 the Open limitswitch is ignored
Valve status
Sov
ZSO
Open limit switch
ZSCClosed Limit Switch
TMROMaximum Open Travel
Time
Stroke Count
List of Variants DIClosed
DIOpenFTC
FTOOVRCOVRO
TMRCTMROZSC
ZSO
1-Open LS{Excluded}
{Excluded}
{Excluded}OVR
{Excluded}TMR{Excluded}
2-Closed LS
{Excluded}
{Excluded}OVR{Excluded}
TMR{Excluded}
{Excluded}
3-2 Limit Switches