LUT Manual - Section II - 40101-00002-03 NEWLOGO · This!document!contains!information!considered!proprietary!and!confidential!to!Tecnar!Automation!Ltd.! 40101:00002:03!:!Rev.A! Revisiondate!:2013:01:30!

This document contains information considered proprietary and confidential to Tecnar Automation Ltd. 40101-‐00002-‐03 -‐ Rev.A Revision date : 2013-‐01-‐30 Page 1 of 54

LUT GAUGE

Section II - OPERATION AND SOFTWARE


TABLE OF CONTENT – Section II II.1 LUT GAUGE OPERATION ........................................................................................................................................ 5

II.1.1 BASIC OPERATION GUIDELINE ........................................................................................................................................... 5 II.1.2 PIPE PRESET DATA .......................................................................................................................................................... 5 II.1.3 FULL START-‐UP PROCEDURE ............................................................................................................................................. 6 II.1.4 MAINTENANCE START-‐UP PROCEDURE ................................................................................................................................ 8 II.1.5 AUTOMATIC MEASURING SEQUENCE .................................................................................................................................. 8 II.1.6 MAINTENANCE SHUTDOWN PROCEDURE ........................................................................................................................... 10 II.1.7 FULL SHUTDOWN PROCEDURE ........................................................................................................................................ 11

II.2 LUT GAUGE SOFTWARE ....................................................................................................................................... 13

II.2.1 INTRODUCTION ............................................................................................................................................................ 13 II.2.2 COMPUTER HARDWARE DESCRIPTION ............................................................................................................................... 13

II.2.2.1 Control Unit ..................................................................................................................................................... 13 II.2.2.2 Detection Unit ................................................................................................................................................. 13 II.2.2.3 Remote Control Unit or Viewer ....................................................................................................................... 14 II.2.2.4 Network ........................................................................................................................................................... 14

II.2.3 DATA LOGGING ............................................................................................................................................................ 14 II.2.4 UPPER SCREEN COMMON PART ........................................................................................................................................ 15

II.2.4.1 Caption bar (A1) .............................................................................................................................................. 15 II.2.4.2 Control & Status bar (A2) ................................................................................................................................ 15

II.2.5 [SYSTEM OVERVIEW] TAB .............................................................................................................................................. 17 II.2.5.1 [System Active State] panel (B1) ..................................................................................................................... 17 II.2.5.2 [System Mode] panel (B2) ............................................................................................................................... 17 II.2.5.3 [Pipe Preset Source] panel (B3) ....................................................................................................................... 18 II.2.5.4 [Network Connections] panel (B4) .................................................................................................................. 18 II.2.5.5 [System Messages] panel (B5) ........................................................................................................................ 18 II.2.5.6 [Sub-‐systems] panel (B6) ................................................................................................................................. 19 II.2.5.7 [Probe 1] panel (B7) ........................................................................................................................................ 21

II.2.6 [DATA DISPLAY] TAB ..................................................................................................................................................... 23 II.2.6.1 [Pipe Information] panel (C1) .......................................................................................................................... 23 II.2.6.2 [Statistics] panel (C2) ...................................................................................................................................... 24 II.2.6.3 [Display Layout] panel (C5) ............................................................................................................................. 25

II.2.7 [PRESETS] TAB ............................................................................................................................................................. 28 II.2.7.1 [Active Preset] panel (D1) ................................................................................................................................ 29 II.2.7.2 [Operators Presets] list (D2) ............................................................................................................................ 29

II.2.8 [MAINTENANCE] TAB (CONTROL UNIT ONLY) ..................................................................................................................... 30 II.2.8.1 [Data Recording] panel (E1) ............................................................................................................................ 31 II.2.8.2 [Laser Auto-‐Stop] panel (E2) ........................................................................................................................... 31 II.2.8.3 [Probe Activation] panel (E3) .......................................................................................................................... 32 II.2.8.4 [Scanner Maintenance] panel (E4) .................................................................................................................. 32 II.2.8.5 [Probe Maintenance] panel (E5) ..................................................................................................................... 32


II.2.9 [SUB-‐SYSTEMS] TAB (CONTROL UNIT ONLY) ...................................................................................................................... 34 II.2.9.1 [E-‐Stops] panel (F1) ......................................................................................................................................... 34 II.2.9.2 [Interlocks] panel (F2) ..................................................................................................................................... 35 II.2.9.3 [Blower Monitoring] panel (F3) ....................................................................................................................... 35 II.2.9.4 [Plant PLC Signals] panel (F4) .......................................................................................................................... 35 II.2.9.5 [Length-‐Meter Temperature] panel (F5) ......................................................................................................... 35 II.2.9.6 [System Monitor] panel (F6) ............................................................................................................................ 35 II.2.9.7 [Scanner] panel (F7) ........................................................................................................................................ 35 II.2.9.8 [Devices Status Overview] panel (F8) .............................................................................................................. 35 II.2.9.9 [Detailed Devices Status] panel (F9) ................................................................................................................ 36

II.2.10 [PROBE “N”] TAB (CONTROL UNIT ONLY) ..................................................................................................................... 37 II.2.10.1 [Probe Status] panel (G1) ................................................................................................................................ 37 II.2.10.2 [Probe Active state] panel (G2) ....................................................................................................................... 38 II.2.10.3 [Probe Messages] panel (G3) .......................................................................................................................... 38 II.2.10.4 [Chiller Monitor] panel (G4) ............................................................................................................................ 38 II.2.10.5 [G-‐Lasers] panel (G5) ....................................................................................................................................... 38 II.2.10.6 [G-‐lasers Usage] panel (G6) ............................................................................................................................ 38 II.2.10.7 [Probe Temperature] panel (G7) ..................................................................................................................... 38 II.2.10.8 [Laser Power] panel (G8) ................................................................................................................................. 38 II.2.10.9 [Detection Unit Interlocks] panel (G9) ............................................................................................................. 38 II.2.10.10 [Devices Status Overview] panel (G10) ....................................................................................................... 39 II.2.10.11 [Detailed Devices Status] panel (G11) ......................................................................................................... 39

II.2.11 [NETWORK] TAB (CONTROL UNIT ONLY) ....................................................................................................................... 40 II.2.11.1 [Last Preset] panel (H1) ................................................................................................................................... 40 II.2.11.2 [Plant Preset Connection] panel (H2) .............................................................................................................. 40 II.2.11.3 [Data Logging Connection] panel (H3) ............................................................................................................ 41 II.2.11.4 [Remote & Viewer] panel (H4) ........................................................................................................................ 41

II.2.12 [CRITICAL ERROR] DIALOG ......................................................................................................................................... 41

APPENDIX 1: STATE MESSAGE FOR THE LUT GAUGE ........................................................................................................ 43

APPENDIX 2: STATE MESSAGE FOR THE LUT PROBE ......................................................................................................... 45

APPENDIX 3: ERRORS AND MESSAGES ............................................................................................................................. 46

APPENDIX 4: PIPE LOGGING DATA FILE ............................................................................................................................ 52

APPENDIX 5: DATA LOGGING DATA FILE .......................................................................................................................... 53


TABLE OF FIGURES – SECTION II Figure II. 1-2: Local command panel ......................................................................................................................... 6

Figure II. 1-3: Remote command panel ..................................................................................................................... 7

Figure II. 1-4: Timing from PLC. ............................................................................................................................ 10

Figure II. 1-5: Close System option menu ............................................................................................................... 12

Figure II. 1-6: System shutdown warning dialog box .............................................................................................. 12

Figure II. 2-1: LUT main screen top part ................................................................................................................. 15

Figure II. 2-2: [System Overview] tab ..................................................................................................................... 17

Figure II. 2-3: [Message Details] dialog .................................................................................................................. 19

Figure II. 2-4: [Sub-systems] panel .......................................................................................................................... 21

Figure II. 2-5: [Probe 1] panel .................................................................................................................................. 22

Figure II. 2-6: [Data Display] tab ............................................................................................................................. 23

Figure II. 2-7: [Presets] tab ...................................................................................................................................... 28

Figure II. 2-8: [Maintenance] tab ............................................................................................................................. 31

Figure II. 2-9: [Sub-systems] tab .............................................................................................................................. 34

Figure II. 2-10: [Probe] tab ...................................................................................................................................... 37

Figure II. 2-11: [Network] tab .................................................................................................................................. 40

Figure II. 2-12: [Critical Error] dialog ..................................................................................................................... 41


Introduction

The present document gives a complete description of the operation and software of the LUT gauge, a laser-‐ultrasonic wall thickness gauge for on-‐line measurement of hot pipe/tube from Tecnar Automation Ltée (TECNAR).

II.1 LUT gauge Operation The following section gives a step-‐by-‐step description of the routine procedures for the use of the LUT gauge.

II.1.1 Basic Operation Guideline Always read an entire procedure section before doing any operation on the system. The LUT gauge is a complex system that needs to be operated following this manual.

Always stop the LUT gauge with the active command panel before setting a security key or an e-‐stop on the system except in an emergency situation. The system is designed to be stopped by the LUT OS software in a controlled manner.

WARNING

Using a security key or an e-stop to stop the LUT gauge during its operation can cause permanent damage to the system.

II.1.2 Pipe Preset Data LUT gauge needs preset data to effectuate effective measurements. Those preset data can be sent by two (2) different ways to the system:

1. Plant preset computer: The preset data is sent in an automatic fashion by a plant computer through an Ethernet network.

2. Operator: The preset data is entered by the operator on the Remote Control computer or directly on the control unit.

When a preset in sent to the LUT system, it remains valid until a new preset is received. The LUT system will maintain a measured pipe count and give an incremental number to each pipe measured in a batch. This number will be reset with a new preset data.


II.1.3 Full Start-up Procedure The LUT gauge is a fully automated gauging system. The following described the start-‐up procedure and automated actions of the LUT gauge from a « cold » condition, i.e., when all of the devices have been powered down (for example, for a mill shutdown period).

1. Activate (ON) the main breaker in the control room of the LUT gauge on the electrical distribution unit.

2. Activate (ON) the air supply unit (blower) breaker in the control room of the LUT gauge on the electrical distribution unit.

WARNING

If the blower is not ON while the LUT is measuring, the window can be damage because of dirt accumulation. The LASER can burn the dirt on the window and dramatically affect system performance.

3. Activate (ON) the cooling unit (chiller) breaker in the control room of the LUT gauge on the

electrical distribution unit. Verify that the chiller is active (powered up). If not, verify that the main switch is activate (ON) directly on the chiller unit. If the chiller is not powered up press the start button until the chiller starts. The chiller should always be activated (ON).

4. Activate (ON) the 220Vac bus in the control room of the LUT gauge inside the electrical panel. Activate (ON) the G-laser unit fan breaker, the G-laser unit breaker, the detection laser unit breaker, the detection unit breaker, the control unit breaker, the LUT inspection probe breaker, the length measuring unit breaker and the 110Vac bus breaker. Validate that all breaker in the 220Vac bus are activated (ON).

5. Enable power to the LUT gauge by turning the power key located on the LUT control unit. 6. When the LUT control unit is turned ON, the LUT OS is automatically executed after the booting

sequence of the operating system. The system should display “Connecting Devices” until all the LUT sub-systems are connected and detection unit computer is booted and connected. The [RED STATUS LIGHT] and the [WHITE SYSTEM STATUS LIGHT] will be OFF until all devices are connected.

7. Turn the [Safety switch LUT] key on the local command panel to the « unlock » position.

Figure II. 1-1: Local command panel

8. Turn the [Laser key] of the local command panel to the « unlock » position.


9. Repeat step 8 to 9 on the remote command panel.

Figure II. 1-2: Remote command panel

10. After 1-2 minutes, the pulpit screen and the system should display “System ready to be started” in the system active state window. The [RED STATUS LIGHT] and the [WHITE SYSTEM STATUS LIGHT] will be FLASHING.

11. If the [RED STATUS LIGHT] is still FLASHING, verify that all [Emergency stop] buttons are released. The emergency stop buttons are at the following location: • On the local command panel;

• On the remote command panel (pulpit);

• On the LUT control unit in the LUT equipment room;

• On the LUT detection laser;

• The 3 E-‐stop PLC inputs

• The 3 E-‐stop BNC inputs behind the control unit

12. If the [WHITE SYSTEM STATUS LIGHT] is FLASHING, verify that all safety interlocks are

appropriately set. The safety interlock are located: • On the moving device jib crane

• On the local command panel;

• On the remote command panel (pulpit);

• The 3 interlock PLC inputs

• The 2 interlock inputs behind the control unit

13. On the Local command panel, select which command panel will have control of the LUT gauge by using the 2-positions [Control] button. The yellow [Control light] is ON only for the active panel. When the [Control] button is turn to the [Local] position, the command panel in the electrical room is active while if the button is turned to the [Remote] position, the remote command panel at the production line (pulpit) is active. The [Command] button is only present on the local command panel in the electrical room. Notice that the active command panel, main or remote, can be changed with the LUT gauge in operation.


14. Turn the [Start/Stop] button of the active command panel to the « start » position and release the button. This action enables the powering of the length-meter, generation lasers and the detection laser. The LASER beacon light will turn RED. The screen of the LUT command unit will display “Waiting for System Ready”. The [SYSTEM READY LIGHT] on the command panels will be FLASHING until the system is ready to measure.

15. After the warm-up period, the system will display “System Ready”. The LUT gauge is ready for data acquisition, waiting in “Idle mode”. The [SYSTEM READY LIGHT] on the command panels will be ON.

II.1.4 Maintenance Start-up Procedure When plant operation has been stopped for maintenance, this is the procedure to restart the LUT gauge.

1. Select the “Automatic” mode on the control unit computer.

2. Turn the [Laser key] on the active command panel to the [Unlock] position, and the [WHITE SYSTEM STATUS LIGHT] will be turn ON.

3. Insert and turn the [Safety Switch LUT] key to the [Unlock] position on both command panels. The system will display “System stopped”. The [RED STATUS LIGHT] on the command panels will be ON.

4. Turn the [Start/Stop] button of the active command panel to the “Start” position and release the button. The action enables of the length-meter, generation lasers and the detections laser. The LASER beacon light will turn RED. The system will display “Waiting for system ready”. The [SYSTEM READY LIGHT] on the command panels will be FLASHING until the system is ready to measure.

5. After the warm-up period, the system will display “System Ready”. The LUT gauge is ready for data acquisition, waiting in “idle mode”. The [SYSTEM READY LIGHT] on the command panels will be ON.

II.1.5 Automatic Measuring Sequence With the LUT gauge in “idle mode”, as described in the previous section, the gauge is an automated mode. The LUT gauge will start acquiring data without any operator intervention. The following describes the data acquisition sequence in “automatic mode”. At the beginning, it is assumed that the LUT gauge is in “idle mode”.

1. The mill sends an analog signal (PLC-Input 9) “Activate laser” command to the LUT command unit. The command should be sent at least thirty (30) seconds before the arrival of the pipe/tube at the measuring location of the LUT probe. This delay ensures that the LUT gauge is ready to measure BEFORE the arrival of the pipe/tube. The command should be sent for every pipe/tube to allow the LUT gauge to be in “active mode”. This way we prevent missing the measurement of a pipe/tube in the case where the LUT has automatically been place in «idle mode» because of lack of pipe/tube to inspect (see below). The system will display “Arming Lasers” and the [LASERS ARMED LIGHT] will be FLASHING.

2. After about 25 seconds, the lasers will be armed. The system will display “Lasers Armed” and the [LASERS ARMED LIGHT] will be ON.


3. Depending of the “Pipe Preset Source” selected, the LUT gauge will need one of the following action:

a. Plant Mode: The plant computer has to send one (1) preset data at least 5-10 seconds before the first pipe in batch.

b. Operator Mode: The operator has to manually enter the preset data at least 5-10 seconds before the first pipe in batch.

4. Optionally, the plant computer can send a “Pipe Info” message which contains pipe specific string identifier and number, 5-10 seconds before the target pipe.

5. An analog (PLC-Input 10) signal sends a “Pipe coming” signal to the LUT command unit. The signal is sent to indicate that a pipe/tube is present at the LUT probe location. The PLC signal must be held HIGH during the entire measuring of the pipe/tube by the LUT probe. The signal is needed for laser activation/deactivation. The signal should be raised at least two (2) seconds before the pipe/tube arrives at the LUT probe location. The delay is needed for proper activation of the generation and detection lasers. The delay should be as constant as possible. If the signal is sent a long time before the pipe actually arrives to the measure point, it is possible to add a time delay before the firing of the lasers. The delay is fixed during commissioning.

6. The LUT gauge automatically acquires the laser-ultrasonic signal and pipe temperature, length.

7. The “Pipe coming” signal drops to LOW when the pipe/tube leaves the LUT probe location. The signal should be kept HIGH for the full duration of the pipe/tube measurement under the LUT probe. The LUT gauge will stop acquiring data as soon as the signal drops to LOW. However, it is possible to add a time delay before the stop of data acquisition and lowering of the PLC signal. The delay is fixed during commissioning.

8. At the end of a processing sequence, the LUT gauge processes, stores in a single file, and sends the data of this pipe/tube through the network.

9. The sequence is repeated for the next pipe/tube.

10. If the LUT gauge has not received a “Pipe coming” command after a given time (set at commissioning, typically five (5) minutes), the LUT gauge is automatically placed back in “idle mode”. The action is done to extend the life of the flashlamps used in the LUT gauge.


Figure II. 1-3: Timing from PLC.

T0: Pipe under LUT position

T1: 2-‐5seconds before the pipe reach the LUT position

T2: 30 seconds to 2 minutes before the pipe reach the LUT position

T3: Should be kept HIGH for the full duration of the pipe/tube traveling under the LUT probe measure point.

T4: 1-‐5 seconds kept high to be read by LUT software.

11. When production is stopped (for maintenance or repair of the production), the LUT gauge should be deactivate following the following section.

II.1.6 Maintenance Shutdown Procedure When plant operation is stopped for maintenance, it is recommended to shutdown the LUT gauge using the following procedure.

1. Turn and hold for one (1) second the [System start/stop] switch to the STOP position on the active control panel. (The yellow [Control light] is ON only for the active panel).

2. The system will then perform a controlled shutdown procedure. WARNING


Pressing an Emergency stop buttons or turning any of the safety keys to shutdown the LUT gauge will instantly cut the power to the components. It should never be used to perform a controlled shutdown.

3. If the lasers are armed, the system will display “Stopping Lasers” and the [LASERS ARMED

LIGHT] will be FLASHING until the lasers are stopped. 4. If the lasers were armed, the system will display briefly “System Ready” and the [LASERS ARMED

LIGHT] will be OFF. 5. The system will display “Stopping System”, indicating that the system is communicating the

shutdown command to all of the hardware components of the LUT gauge. The [SYSTEM READY LIGHT] on the command panels will be FLASHING until the system is completely stopped.

6. When the system is stopped, it will display “System stopped” and the [SYSTEM READY LIGHT] on the command panels will be OFF.

7. Turn the [Safety Switch LUT] to the [Lock] position on the active command panel and remove the key if needed to prevent anyone from restarting the system. Turn the [Laser key] on the active command panel to the « lock » position. The laser beacon light will turn GREEN and the [RED STATUS LIGHT] and the [WHITE SYSTEM STATUS LIGHT] will be FLASHING.

8. Select the “Maintenance” mode on the control unit computer.

II.1.7 Full Shutdown Procedure When plant operation is stopped for a period of time, it is recommended to shutdown the LUT gauge using the following procedure.

9. Turn and hold for one (1) second the [System start/stop] switch to the STOP position on the active control panel. (The yellow [Control light] is ON only for the active panel).

10. The system will then perform a controlled shutdown procedure.

WARNING

Pressing an Emergency stop buttons or turning any of the safety keys to shutdown the LUT gauge will instantly cut the power to the components. It should never be used to perform a controlled shutdown.

11. If the lasers are armed, the system will display “Stopping Lasers” and the [LASERS ARMED

LIGHT] will be FLASHING until the lasers are stopped. 12. If the lasers were armed, the system will display briefly “System Ready” and the [LASERS ARMED

LIGHT] will be OFF. 13. The system will display “Stopping System”, indicating that the system is communicating the

shutdown command to all of the hardware components of the LUT gauge. The [SYSTEM READY LIGHT] on the command panels will be FLASHING until the system is completely stopped.

14. When the system is stopped, it will display “System stopped” and the [SYSTEM READY LIGHT] on the command panels will be OFF.

15. Turn the [Safety Switch LUT] to the [Lock] position on the active command panel and remove the key if needed to prevent anyone from restarting the system. Turn the [Laser key] on the active


command panel to the « lock » position. The laser beacon light will turn GREEN and the [RED STATUS LIGHT] and the [WHITE SYSTEM STATUS LIGHT] will be FLASHING.

16. On the LUT control unit, press the “X” icon in the top right corner of the LUT engine software. Select “Power Down All LUT Hardware”.

Figure II. 1-4: Close System option menu

17. Click YES to the following prompt warning message.

Figure II. 1-5: System shutdown warning dialog box

18. Wait until the Control Unit computer is shutdown. 19. Turn the power key located on the LUT control unit to the OFF position. 20. Deactivate (OFF) the 220Vac bus in the control room of the LUT gauge inside the electrical panel.

Deactivate (OFF) the G-laser unit fan breaker, the G-laser unit breaker, the detection laser unit breaker, the detection unit breaker, the control unit breaker, the LUT inspection probe breaker, the length measuring unit breaker and the 110Vac bus breaker

21. Deactivate (OFF) the cooling unit (chiller) breaker in the control room of the LUT gauge. 22. Deactivate (OFF) the air supply unit (blower) breaker in the control room of the LUT gauge. 23. Deactivate (OFF) the main breaker on the electrical distribution unit in the control room of the LUT

gauge.


II.2 LUT gauge Software

II.2.1 Introduction The LUT gauge software, LUT OS, is installed in the control unit (LUT Control unit) and Detection unit (LUT Detection unit). LUT OS has been designed to run on a XP® operating system. The function of the LUT OS is to provide full automated control and data acquisition of the LUT gauge. All the programs are set to start automatically when the computers start.

The LUT OS is composed of several independent software modules. For the operator, there are two (3) different interfaces:

1. LUT Control Engine: This is the main software component of the LUT OS and is located on the LUT control unit. Its function is to control the system operation, maintenance, handle the “Remote Control” and do the link between the LUT gauge and the plant network computers (preset and data logging computers).

2. LUT Remote Control: Software for the operator to get the system status overview, system messages, data display and preset control.

3. LUT Remote Viewer: Software for the operator to get the system status overview, system messages, data display. The user can only visualize the data with this software.

All programs share the same interface except for the four (4) last tab screens that are only available on the control unit.

During normal operation of the LUT gauge, the “LUT Control Engine”, “LUT Remote control” and “LUT Remote viewer” display the current status, messages and data of the gauge. The following sections describe the different screens of the LUT Control Engine.

II.2.2 Computer Hardware Description The following sections describe the different parts of the LUT OS computer hardware.

II.2.2.1 Control Unit The main components of the LUT software are installed on the control unit of the LUT gauge. The software is installed in the folder C:\LUTOS\. The folder is the main directory of the LUT software on the control unit computer. The location and name of this folder should never be changed as this could disable the LUT gauge operation. The control engine of the LUT control unit computer controls the Detection unit control engine.

II.2.2.2 Detection Unit Each LUT inspection probe has its own control/process computer. This computer is located inside the Detection unit. The detection unit computer controls the data acquisition, the detection laser unit, the generation laser


unit, TWM, and the LUT inspection probe. The software is installed in the folder C:\LUTOS\. The location and name of this folder should never be changed as this could disable the LUT gauge operation.

II.2.2.3 Remote Control Unit or Viewer The optional “Remote Control” module of LUT OS is installed in the folder C:\LUTOS\ of the remote control computer, located in the operator pulpit room. The location and name of this folder should never be changed as this could disable the LUT gauge operation.

II.2.2.4 Network The LUT OS makes extensive use of the network for data transfer and control. The LUT gauge has its own internal computer network. The default workgroup is [LUTGROUP]. The LUT network used the range of addresses from 192.168.1.1 to 192.168.4.255 with subnet mask 255.255.0.0.

Operator should refrain from using these addresses as this could interfere with LUT gauge operation.

The LUT system comes with additional network adapters that are configured at commissioning to connect to the plant network system for data transfer and for remote diagnostic via Internet.

II.2.3 Data logging The LUT system records automatically all the data taken by the system. The default location for the data is on the control unit computer:

“D:\LUTData\”

There are five (5) default sub-‐folders inside:

1. [DataLogging]: This folder contains one (1) subfolder for each day. See “Appendix 5: Data logging data file” for file format details.

2. [PipeLogging]: This folder holds a log file of all the data taken in one day. This file can be used to compute data trends. One (1) file is created for each day of operation. A history of thirty (30) days is set by default. This can be changed at commissioning. See “Appendix 4: Pipe logging data file” for file format details.

3. [SavedData]: This folder contains the saved data recorded by the operator during system operation. One (1) folder is created for each pipe recorded. The data is reserved for use by TECNAR personal.

4. [TempData]: Temporary data file used by the LUT system. This folder should not be accessed.

5. [ThicknessReport]: This folder contains the reports of the thickness test effectuated in maintenance mode in PDF format.

Folder shares can be configured at commissioning time for remote data access.


II.2.4 Upper screen common part

Figure II. 2-1: LUT main screen top part

II.2.4.1 Caption bar (A1) The caption bar displays the name and version of the software, the version and the current date and hour.

II.2.4.2 Control & Status bar (A2) This part of the screen is always visible and displays the status of the LUT (with LEDs) and two control buttons.

Leds:

• [Started]: System is started(i.e. Start key has been turn on)

• [Ready]: System is ready (“idle mode”). The lasers can be turned on.

• [E-‐Stop]: An E-‐stop is set somewhere on the system. The LUT can’t start until all the E-stops are pulled off.

• [Interlocks]: An interlock is on somewhere on the system. The system can’t operate until this led is turn off.

A2

A1


• [Lasers Armed]: Lasers are armed and LUT is ready to measure a pipe.

• [Measuring]: System is measuring (i.e. Laser are currently firing)

Buttons:

• [Stop System]: Stop system immediately in a controlled way bypassing the Start/Stop button on the active command panel.

• [Arm lasers]: Arm Laser button is only active when the system is ready. It can be used to arm the lasers bypassing/replacing the PLC signal (Activate Laser) of the plant. When the lasers are armed, the caption of the button becomes “Stop Lasers”. At this moment, the button can be used to stop the lasers in a controlled way.

These sections of the software are always visible independently of which tab is displayed. It shows important information for the operator.


II.2.5 [System Overview] Tab The [System Overview] tab displays a quick overview of all important system information and messages. It also enables the operator to change some operation mode of the system.

Figure II. 2-2: [System Overview] tab

II.2.5.1 [System Active State] panel (B1) The [System Active State] panel (B1) displays the current state of operation of the LUT gauge. The state message indicates the current action being performed by the LUT gauge. See Appendix 1 for a complete list and description of the states.

II.2.5.2 [System Mode] panel (B2) The [System Mode] panel (B2) displays the current mode of the system. There are two (2) different operation modes.

B2

B1 B3

B4

B5

B6 B7


1. Automatic Mode: This is the normal system operation mode. In that mode, the LUT operates automatically. However, some operator intervention may be necessary depending of the preset source. Refer to the [Pipe Preset Source] panel description below for a complete description of each different preset source.

2. Maintenance Mode: This mode is used for maintenance of the system. This mode enables the [Maintenance] button on the [Options Panel]. Refer to the description of this panel below for a complete description of the maintenance mode.

II.2.5.3 [Pipe Preset Source] panel (B3) The [Pipe Preset Source] panel (B3) is used to source of the pipe preset information. This information is used to configure the LUT software for measurement. Two (2) sources are possible:

1. Plant: The plant computer has to send a preset data at least 5-10 seconds before each the first pipe. The preset is valid until a new preset is received.

2. Operator: Enable the [Presets] tab. The operator has to manually enter the next pipe preset. The preset is valid until a new preset is received.

When a mode is selected, the other modes are disabled.

II.2.5.4 [Network Connections] panel (B4) The [Network Connections] panel (B4) shows the actual status of the network connections to the LUT gauge engine. There are three (3) different LEDs:

Remote Controller: Means that the remote software is connected to the LUT Control Engine.

Plant Computer: Means that the plant computer is connected to the LUT Control Engine

II.2.5.5 [System Messages] panel (B5) The [System Messages] panel (B5) is a text window cumulating the last one hundred (100) (can be changed at commissioning time) system messages and error of the LUT gauge. The messages can be informative status messages or error messages. See the “Appendix 1 LUT Errors and Messages”.

The error messages are displayed the following colors:

1. Red: Error messages

2. Black: Warning messages

3. Blue: Normal messages

In normal mode the [Messages Details] dialog is showed on the right part of the [System Messages] panel. This dialog is used to get more information on the current message or error. It also allows the operator to enter some notes on that particular message or error. There are seven (7) different fields on the screen:

1. [Timestamp]: Gives the date and time of the error


2. [Type]: Gives the type of message (error, etc)

3. [Code]: Gives the numeric code value of the message

4. [Message Text]: Gives the text version of the message

5. [Extra Information]: Gives any extra details on the current message.

6. [Description]: Gives additional description of the message

7. [User notes]: Field where the operator can enter additional notes or comments about a particular message.

When the operator enters new information in the [User Notes] field, the [Save Changes] button becomes enabled and permits the operator to save the new changes. If the [Close] button is used, any change will be discarded.

Figure II. 2-3: [Message Details] dialog

II.2.5.6 [Sub-systems] panel (B6) The [Sub-‐systems] panel (B6) gives a quick overview of all the LUT sub-‐systems that are not included in the probe:

• [Status] group:


ο [Ready] led: Indicates if all sub-‐systems are ready to operate. Light green means that the sub-‐systems are ready. Dark green means that the sub-‐systems are not ready.

ο [Error] led: Indicates if there is any error with the sub-‐systems. Light red means that there is at least one (1) error on one or more of the sub-‐systems. Dark red means that the sub-‐systems are working well or that the status is not read yet.

ο [Interlocks] led: Indicates if there is any interlock on the system, not related with the probe sub-‐systems. Light red means that there is at least one (1) interlock on the system. Dark red means that there is no interlock or that the status of the interlocks is not read yet.

• [Blower] group:

ο [Fault] led: Indicates if there is any error with the blower. Light red means that there is an error and that the filter needs to be change. Dark red means blower status is normal.

• [Scanner] group (optional):

ο [Position] field: Indicates the current position of the positioning device in degrees if available.

ο [Error] led: Indicates if there is any error with the positioning device. Light red means that there is an error. Dark red means the positioning device status is normal or that the status is not read yet.

ο [Reset Error] button: When the [Error] led turns light red, this button becomes enabled. Pressing this button will reset the current error.

• [Length-‐meter Temperature] group:

ο [Fault] led: Indicates the length-‐meter box temperature status. Light red means that the length-‐meter box temperature is too high. Dark red means that the length-‐meter box temperature is normal.

• [Sub-‐Systems Details…] button: Open directly the [Sub-‐Systems] tab for more details on the sub-‐systems.


Figure II. 2-4: [Sub-systems] panel

II.2.5.7 [Probe 1] panel (B7) The [Probe 1] panel (B7) shows a quick overview of the probe status.

• [Enabled] group

o [Probe]: Display the enabled state of the probe. A green check means that the probe is enabled. A red cross means that the probe is disabled.

o [Laser 1]: Display the enabled state of the generation laser 1. A green check means that the generation laser 1 is enabled. A red cross means that the generation laser 1 is disabled.

o [Laser 2]: Display the enabled state of the generation laser 2. A green check means that the generation laser 2 is enabled. A red cross means that the generation laser 2 is disabled.

• [Laser Status] group

o [Armed] Led: Indicates the “Armed” status of the probe lasers. Light red means lasers are armed. Dark red means lasers are not armed.

o [Firing] Led: Indicates the “Firing” status of the probe lasers. Light red means lasers are firing. Dark red means lasers are not firing.

o [Error] Led: Indicates an error status. Light red means lasers are in error. Dark red means lasers status is normal.

o [Reset Error] button: When the [Error] led turns light red, this button becomes enabled. Pressing this button will reset the current error.

• [Status] group:

o [Connected] Led: Indicates the probe network connection status. Light green means that the probe “Detection Engine” is remotely connected. Dark green means that the probe “Detection Engine” is not connected.

o [Ready] Led: Indicates if all the probe sub-systems are ready to operate. Light green means that the probe is ready. Dark green means that the probe is not ready.


o [Error] Led: Indicates if there is any error with the probe sub-systems. Light red means that there is at least one (1) error on one or more of the probe’s sub-systems. Dark red means that the probe sub-systems are working well or that the status is not read yet.

o [Interlocks] Led: Indicates if there is any interlock related with the probe sub-systems. Light red means that there is at least one (1) interlock on one or more of the probe’s sub-systems. Dark red means that there is no interlock or that the status of the interlocks is not read yet.

o [Temperature] Led: Indicates the probe temperature status. Light red means that the probe temperature is too high. Dark red means that the probe temperature is normal.

o [Cooling Unit] Led: Indicates the cooling unit status. Light red means that the cooling unit water temperature is too high or that the water flow is too low. Dark red means that the probe cooling group is working normally.

• [Probe Details] button: Open directly the [Probe] tab for more details on the probe status and its sub-system.

Figure II. 2-5: [Probe 1] panel


II.2.6 [Data Display] Tab The [Data Display] tab displays the last measured pipe data. The operator can control the data display using the different controls on the screen.

Figure II. 2-6: [Data Display] tab

II.2.6.1 [Pipe Information] panel (C1) The [Pipe Information] panel (C1) displays the pipe information that is either entered by the operator or sent by the plant preset computer. There are six (6) different fields:

1. [Lot]

2. [Piece No]

3. [Alloy Code]

C1

C2

C3


4. [Nominal Thickness]

5. [Nominal Diameter]

6. [Nominal Length]

7. [Nominal Temperature]

8. [position for measurement] (optional)

II.2.6.2 [Statistics] panel (C2) The [Statistics] panel (C2) displays the minimum, maximum and average values of different configurable measurements of the displayed pipe:

Here are a list of the options and measurement:

Display Deviation Column

Display Batch Column

Display Temperature Statistics

Display Top Temperature Statistics (beginning of the pipe)

Display Middle Temperature Statistics

Display Bottom Temperature Statistics (end of the pipe)

Display Cold Thickness Statistics

Display Top Cold Thickness Statistics

Display Middle Cold Thickness Statistics

Display Bottom Cold Thickness Statistics

Display Eccentricity Statistics

Display Top Eccentricity Statistics

Display Middle Eccentricity Statistics

Display Bottom Eccentricity Statistics


Display Collected Light Statistics

Display Top Collected Light Statistics

Display Middle Collected Light Statistics

Display Bottom Collected Light Statistics

1. [Speed]: Speed (in meter/second) measured by the length-meter.

2. [Temperature]: Temperature (in degrees Celsius) measured by the pyrometer.

3. [Cold Thickness]: Wall thickness (in millimeter) determined by ultrasound signal and temperature.

4. [Eccentricity] (Optional): Pipe eccentricity in %. This option can be activated at commissioning time.

On the right hand side of the panel, the operator has access to two (2) additional statistics of the current pipe and of the current batch:

1. [Pipe Length]: Length (in meters) measured by the length-meter.

2. [Performance]: Performance of the displayed measurement. The performance led can takes three (3) different colors:

a. Green: The ultrasonic measurement was well-done.

b. Yellow: The ultrasonic measurement was valid, but with lower quality.

c. Red: The ultrasonic measurement was not valid.

The performance evaluation is done with several criteria on the data acquisition results.

II.2.6.3 [Display Layout] panel (C5) This panel enables the operator to view the display layout. The [Display] panel (C5) shows the measurements of the LUT gauge according to the display options. It is a real time viewer of the last tube measurement.

The cold thickness profile can be set to display the nominal, minimum and maximum wall thickness lines depending of the preset value. This can be set at commissioning time.

Two different profiles can be shown on the display. You can also enable the option to view the 1-‐5 last profiles. Here are the profile that you can get on the display:

1. Display Mean Thickness Profile

2. Display of the profile

3. Display Eccentricity Profile (site specific)

4. Display Temperature profile


To change the profile that are displayed on the screen you have to click on the text on the right or the left of the display screen.


II.2.6.3.1 [Data Display Selection] panel (C5) Three (3) units for the X axis are available:

1. Seconds

2. Points

3. Meters

The default options are:

1. Layout: Probe 1 & 2

2. Left Y Axis: Thickness

3. Right Y Axis: Temperature

The default display options can be configured at commissioning time.

II.2.6.3.2 [Display] panel (C5) Zoom option

To execute a zoom action:

• Left-‐click and hold the mouse button directly on the axis you want to zoom. Be sure that the mouse pointer is outside the grid where the profiled are displayed. In other words click on where the number of the axis are.

• Holding the mouse button, move the mouse for a certain distance on the axis you want to zoom. The distance that the mouse will have been moved will set the factor of the zoom action. The longer the distance is, the higher the zoom/scroll factor will be. For the X zoom action, a left to right displacement will do a positive zoom action. A right to left displacement will do a negative zoom action. For the Y zoom action, a down to up displacement will do a positive zoom action. An up to down displacement will do a negative zoom/scroll action.

• Release the mouse button to apply the new zoom factor.

• Double click to reset the display

To execute a scroll action:

• Left-‐click and hold the mouse button directly on the profile display in the grid that you want to scroll. Be sure that the mouse pointer is inside the grid and on the profile displayed.

• If you left click between 2 profiles you will scroll both profile.

• Holding the mouse button, move the mouse for a certain distance on the axis you want to scroll. The distance that the mouse will have been moved will set the factor of the scroll action. The longer the distance is, the higher the scroll factor will be. For the X scroll action, a left to right displacement will do a positive scroll action. A right to left displacement will do a negative scroll action. For the Y scroll action,


a down to up displacement will do a positive zoom/scroll action. An up to down displacement will do a negative scroll action.

• Release the mouse button to apply the new scroll factor.

• Double click to reset the display

II.2.7 [Presets] Tab The [Preset] tab is used to see the active preset and preset mode and to manage preset list for the “operator” preset mode. The system operator can prepare and manage preset data and activate them when needed.

Figure II. 2-7: [Presets] tab

D1

D2

D3

D5 D4


II.2.7.1 [Active Preset] panel (D1) The [Active Preset] panel displays the active preset currently in used for measurement. It is possible to manually edit at all time.The activation time and the source are also shown.

The second section show the plan preset received from the process computer. It cannot be edited.

II.2.7.2 [Operators Presets] list (D2) The [Available Presets] lists the available presets that can be activated. There are eleven (11) different fields needed for a preset:

1. Information: Information string about the preset up to 20 characters. This field can be used if additional information is needed.

2. Lot: Lot number in integer format. The valid range is from 0 to 4294967295.

3. Piece: Start number in integer format for the first pipe in a batch. The valid range is from 0 to 4294967295. This number will be automatically incremented after each measurement.

4. Alloy: Material composition code. This number is used to get the correct speed of sound calibration for a particular alloy. The codes representing each alloy composition have to be set in the system at commissioning time.

5. Thickness: Nominal wall thickness of the pipe. Used to adjust the system data processing to get optimal results.

6. Diameter: Nominal diameter of the pipe. Used to set to measuring distance of the system.

7. Length: Nominal length of the pipe. This value is used in case of failure of the integrated length-‐meter.

8. Speed: Nominal speed of the pipe.

9. Temperature: Nominal temperature of the material. This number is used to calculate the speed of sound in the material.

10. Mode (optional): Fix or scan mode for use with a positioning device.

11. Angle (optional): Angle of measurement for use with a positioning device.

12. Lower thickness: Lower thickness tolerance from the nominal thickness. This tolerance will be displayed in the Data display.

13. Upper thickness: Upper thickness tolerance from the nominal thickness. This tolerance will be displayed in the Data display.

14. Lower Diameter: Lower Diameter tolerance from the nominal diameter.

15. Upper Diameter: Upper Diameter tolerance from the nominal diameter.

16. Ovality tolerance: Ovality limits of the pipes produced.

17. Line position: From 1 to 3. Use in the case the production line (bottom line) is moving depending on the OD produced.


The list is displayed with different font:

• Active preset is shown in bold

• Selected preset is shown in blue.

• Selected cell that can be edited is shown in light blue.

The operator can effectuate the following operations on the preset list:

• Activate a preset: The [Activate] button (D3) is used to activate the selected preset. When a preset is activated, it will be used for the next measurement. A preset can be activated at anytime.

A preset can only be activated when the system is set to the “Operator” mode

• Add a preset: Use the [New] button (D4) to add a preset at the end of the list. The added preset will be copied from the previous preset in list.

• Edit a preset: Click in the desired cell or use the keyboard arrows to bring the cell selection. The active preset (shown in light green) cannot be edited.

• Delete a preset: [Delete] button (D5): Delete the selected preset (row shown in blue). The active preset cannot be deleted.

II.2.8 [Maintenance] Tab (Control Unit only) The [Maintenance] tab is used to handle system maintenance. It is only available in the “Control Unit” program. The operator can set different options of the system and execute some operations needed with the system maintenance.


Figure II. 2-8: [Maintenance] tab

II.2.8.1 [Data Recording] panel (E1) The [Data Recording] panel (E1), with the [Record] button can be used to record up to 5consecutive pipes. The desired pipe number must be entered in the field beside the button. This record option is used to record the entire raw data signal for diagnostic or calibration purposes. The button becomes [Stop Recording] when the recording option is activated. The button can be pressed to stop the recording.

II.2.8.2 [Laser Auto-Stop] panel (E2) The [Laser Auto-Stop] panel (E2) is used to change the maximum laser idle time. This delay is used to unarmed (stop flashing) the lasers when no pipes are coming under the LUT gauge probe. This parameter is useful to extend the flashlamps lifetime. The maximum pipe wait time parameter is used to stop firing the lasers in the case where no pipe is detected by the LUT gauge probe after the PLC signal (pipe coming) has been activated.

E1

E2

E3

E4

E5

E7

E8

E6

E9


II.2.8.3 [Probe Activation] panel (E3) The [Probe Activation] panel (E3) is used to activate or deactivate the LUT gauge when more than one (1) gauge is present on the system. The probes that are not checked will not be in used during the LUT operation. At least one (1) probe must be active at any time.

II.2.8.4 [Scanner Maintenance] panel (E4) This panel is enabled only when the system is in maintenance mode.

The system must be started and the scanner must ready to operate to enable the controls.

Use only when the optional positioning device is installed. The [Actual Position] displays the current angular position in degrees of the positioning device.

To move the positioning device, the operator can press one of the three buttons to activate the movement.

WARNING

Always verify that the operation area is clear of any personal before enabling the positioning device. Not doing so could result in severe injury or death. Also always verify that no obstacle stands in the area of the positioning device. Any obstacle in the path could damage severely the positioning device.

II.2.8.5 [Probe Maintenance] panel (E5) The [Probe Maintenance] panel (E5) is used for all the required operation with probe maintenance. It is enabled only when the system is set to maintenance mode. The system must be in "System Ready" state to enable the controls.

II.2.8.5.1 [Probe Selection] list (E6)

The [Probe Selection] list (E6) is used to select which LUT gauge probe to use for maintenance when more than one (1) gauge is present on the system.

II.2.8.5.2 [Thickness Test] (E7)

The [Thickness Test] panel (E7) gives the operator the option to take a test measurement with the LUT gauge probe without the use of the PLC signals and the pipe detection system. The operator has to enter the material setup before executing the test:

• [Test Material] selection: Shows all available material which parameters are already set in the system. Select the “Custom” material to enter manually the parameters.

• [Custom Test Setup] section:

o Speed of sound: Speed of sound in the test material in m/s.

o Nominal thickness: Nominal thickness of the sample in mm.

• [Start Test] button: Used to start the test. After the test is started, this button becomes the [Stop Test] button that can be used to stop the test immediately.


• After the completion of the test a PDF file is generated. The file can be found at this location: D:\LUTDATA\thicknessreport.

II.2.8.5.3 [Laser maintenance] panel (E8)

The [Laser Maintenance] panel (E8) is used for maintenance operation on the lasers. Only one (1) laser can be use at the time. There are 2 different controls on this panel:

• [Laser Selection] list: This section is used to select the active laser on which the operations will be done. There are 3 different choices in this list:

o [Detection Lasers]: Select to operate the command on the detection laser.

o [Generation Laser 1]: Select to operate the command on the generation laser 1.

o [Generation Laser 2]: Select to operate the command on the generation laser 2.

• [Laser flash count]

o [Current flash count]: Displays the current flash count of the selected laser.

o [Reset Flash Count]: This button must be used when the selected laser flashlamps have been changed. It will reset the flashcount to 0 and assure the correct counting of the flashcount to evaluate the flashlamps life.

II.2.8.5.4 [Cold pipe thickness test] panel (E9)

The [Cold pipe thickness test] panel (E9) is used to perform a cold test on a pipe online moving exactly as a hot one.

Please contact TECNAR if you want to perform this test.


II.2.9 [Sub-Systems] Tab (Control Unit only) The [Sub-‐Systems] tab displays the detailed status of all the sub-‐systems hardware of the LUT system. It is only available in the “Control Unit” program.

Figure II. 2-9: [Sub-systems] tab

The [Sub-‐Systems] tab is a detailed view of all the LUT sub-‐systems.

II.2.9.1 [E-Stops] panel (F1) The [E-‐Stops] panel (F1) displays all the E-‐Stops state of the LUT gauge. Light red means that e-‐stop is active and dark red that the e-‐stop is not active or that its status is unknown. An E-‐stop will physically cut the power of the lasers, the length measuring unit and the positioning device (option).

F1

F2

F3

F4

F5

F7

F7

F8

F6


II.2.9.2 [Interlocks] panel (F2) The [Interlocks] panel (F2) displays all the interlocks of the LUT gauge not related with the detection unit. Light red means that the interlock is active and dark red that the interlock is not active or that its status is unknown.

II.2.9.3 [Blower Monitoring] panel (F3) The [Blower Monitoring] panel (F3) shows the monitoring of the blower’s air intake. The [Blower Fault] led indicates the blower monitor status. Light red means that the monitor has detected a fault and dark red that the status is normal or unknown.

II.2.9.4 [Plant PLC Signals] panel (F4) The [Plant PLC Signals] panel (F4) displays the PLC signals from the factory. The inputs 1 to 3 are E-‐stop signals. Inputs 4 to 6 are interlock signals. Inputs 7 and 8 are used with a motorized positioning device. The inputs 9 and 10 are used in automatic mode for “Laser On” and “Pipe Coming” signals. Light green means that PLC is activated. Dark green means that the PLC is not activated or that its status is unknown.

II.2.9.5 [Length-Meter Temperature] panel (F5) The [Length-‐Meter Temperature] panel (F5) displays the temperature inside the length-‐meter container unit. The led indicates if the temperature exceeds the maximum limit (customizable at commissioning). Light red means that there is an error and dark red that the state is normal or unknown.

II.2.9.6 [System Monitor] panel (F6) The [System Monitor] panel (F6) displays the water temperature and flow of the cooling unit and the temperature inside the generation unit cabinet. The led indicates if the temperature exceeds the maximum limit (customizable at commissioning). Light red means that there is an error and dark red that the state is normal or unknown.

II.2.9.7 [Scanner] panel (F7) The [Scanner] panel (F7) displays the scanner position in degrees in the case that the LUT gauge is mounted on a scanning unit. The [Error] led indicates if there is an error with the scanner. Light red means that an error is signaled and dark red that there is no error. When an error happens, the [Reset Error] button becomes active. It can be use to reset the scanner controller to try to clear the error.

II.2.9.8 [Devices Status Overview] panel (F8) The [Devices Status Overview] panel (F8) displays a short version of the [Detailed Devices Status] panel. The operator can see in a glimpse of an eye when all the peripheral devices are ready or if an error has occurred. When the [Details] button is pressed, the appropriate sub-‐tab window in the [Detailed Devices Status] panel is brought to the front screen.


II.2.9.9 [Detailed Devices Status] panel (F9) The [Detailed Devices Status] panel (F9) displays the detailed status of the different peripheral sub-‐systems of the LUT gauge. The sub-‐system includes:

• The length-‐meter (option),

• The length-‐meter temperature (option),

• the I/O board control,

• the scanner (option),

• the length-‐meter positioning slide (option),

• the system monitor (option)

• the Profibus communication system (option).

• Other tab are available depending of the option of the LUT system.

On each sub-‐tab of the [Detailed Devices Status] panel, the operator can see the software server connection, the status of the peripheral device and error text bar to display the possible errors. The operator can click on the [History] button to see the list of errors that occurred with that device.


II.2.10 [Probe “N”] Tab (Control Unit only) The [Probe “N”] tab displays the detailed status of one (1) probe hardware of the LUT system. If the system has many probes, it will have up to four (4) of this tab. It is only available in the “Control Unit” program.

Figure II. 2-10: [Probe] tab

II.2.10.1 [Probe Status] panel (G1) The [Probe Status] panel (G1) displays a summary of the probe status. There are four (4) different fields:

1. [Enabled] image: Indicates the “Enabled” state of the probe. A green check sign means that the probe is enabled and a red X that it is disabled.

2. [Connected] led: Indicates the connection status with the probe “Detection Engine”. Light green means that the probe is connected. Dark green means that the system is unable to connect to the probe.

3. [Powered] led: Indicates the system “Started” state. Light green means that the system is started and dark green that the system is stopped.

4. [Interlock] led: Indicates if there is any interlock local to the probe. Dark red means that there is no Interlock.

G1

G2

G3

G10

G4

G5

G6

G7

G8

G9

G11


II.2.10.2 [Probe Active state] panel (G2) The [Probe Active state] panel (G2) displays the state of the probe “Detection Engine” software. The state indicates the current action being performed by the probe. The following table describes the different states.

II.2.10.3 [Probe Messages] panel (G3) The [Probe Messages] panel (G3) is a text window cumulating all the system messages of the “LUT Detection Engine”. The messages can be normal status messages or error messages. Please refer to the “Appendix 1: Errors and Messages” for the complete list.

II.2.10.4 [Chiller Monitor] panel (G4) The [Chiller Monitor] panel (G4) displays the actual temperature and flow of the chiller and two (2) alarm leds linked with that information. Light red means that there is an error and dark red that the state is normal or unknown.

II.2.10.5 [G-Lasers] panel (G5) The [G-‐Lasers] panel (G5) displays the error condition of the generation lasers. The [Error Condition] led indicates the error status of the G-‐Lasers. Light red means that there is an error and dark red that the state is normal or unknown. The operator can reset the error by clicking the [Reset] button.

II.2.10.6 [G-lasers Usage] panel (G6) The [G-‐lasers Usage] panel (G6) permits the operator to choose which generation laser will be used for measurement. Usually, this option is used if one laser is not operating properly or if the system is in a maintenance state outside the LUT probe. In this case the LUT gauge will measure at half rate instead of full rate.

II.2.10.7 [Probe Temperature] panel (G7) The [Probe Temperature] panel (G7) displays the temperature inside the probe. The [Alarm] led indicates if the probe temperature exceeds the maximum limit (customizable at commissioning). Light red means there is an error and dark red that the state is normal or unknown.

II.2.10.8 [Laser Power] panel (G8) The [Laser Power] panel (G8) displays the laser power status. Dark green means the power state is unknown, light that the power is normal and light red that the power is low.

II.2.10.9 [Detection Unit Interlocks] panel (G9) The [Detection Unit Interlocks] panel (G9) displays the interlock status of all the panels of the detection unit. Light red means that there is an interlock detected and dark red that the interlock state is normal or unknown.


II.2.10.10 [Devices Status Overview] panel (G10) The [Devices Status Overview] panel (G10) displays a short version of the [Detailed Devices Status] (G11) panel. The operator can see in a glimpse of an eye when all the probe sub-‐systems are ready or if an error has occurred. When the [Details] button is pressed, the appropriate sub-‐tab window in the [Detailed Devices Status] panel is brought to the front screen.

II.2.10.11 [Detailed Devices Status] panel (G11) The [Detailed Devices Status] panel (G11) displays the detailed status of all the probe sub-‐systems. The sub-‐systems are both generation lasers, the detection laser unit, the ultrasound analyzer & pyrometer, the range-‐meter, the power logger, the probe temperature, the (TWM) demodulation unit, the IO controller and the focusing slide (option). On each sub-‐tab of the panel, the operator can see the software server connection, the status of the peripheral device and error text bar to display the possible errors. The operator can click on the [History] button to see the list of errors that occurred with that particular device.


II.2.11 [Network] Tab (Control Unit only) The [Network] panel displays the LUT system network status for plant connection. It is only available in the “Control Unit” program.

Figure II. 2-11: [Network] tab

II.2.11.1 [Last Preset] panel (H1) The [Last Preset] panel (H1) indicates the last pipe parameters and its time received from the plant preset computer.

II.2.11.2 [Plant Preset Connection] panel (H2)

• [Network Connection]: Indicates the status of the server and client part of the “Process Computer” communication. Light green indicates an active connection.

• [Statistics] section: Indicates statistics with the “Process Computer” connection.

• [Reset Statistics] button: Reset the data of the [Statistics] section.

H1

H2

H3

H4


II.2.11.3 [Data Logging Connection] panel (H3) • [Network Connection]: Indicates the status of the server and client part of the “Data Logging Computer”

communication. Light green indicates an active connection.

• [Statistics] section: Indicates statistics with the “Data Logging Computer” connection.

• [Reset Statistics] button: Reset the data of the [Statistics] section.

II.2.11.4 [Remote & Viewer] panel (H4)

• [Remote Connection] led: Light green indicates that the “LUT Remote Control” software is connected to the “LUT Control Engine”.

• [Viewer Connection Count]: Indicates how many “LUT Viewer“ are connected to the “LUT Control Engine”

• [Statistics] section: Indicates how many times the “LUT Remote Control” has connected to the “LUT Control Engine”.

• [Reset Statistics] button: Resets the data of the [Statistics] section.

II.2.12 [Critical Error] Dialog

Figure II. 2-12: [Critical Error] dialog

The [Critical Error] dialog will be displayed if a critical error happens on the system. There are six (6) different critical errors:

1. Stop Lasers Fire Timeout: An error happens while trying to start the lasers.


2. Stop Lasers Timeout: An error happens while trying to stop the lasers.

3. Slide movement Timeout: An error happens while trying to position the length-‐meter positioning slide.

4. Scanner movement Timeout: An error happens while trying to move the scanner unit.

5. Init data file timeout: An error happens while trying to initialize the result data files.

6. Close data file timeout: An error happens while trying to close the result data files.

Any of these errors will bring the [Critical Error] dialog. This dialog enables the operation to do two (2) different operations:

1. [Reset Error] button: Reset the error. The system will try to continue its normal operation.

2. [Reboot System] button: If the [Reset Error] button and the system cannot operate correctly, this button can be used to reboot all the LUT hardware including the control computer and probe control computer(s).


Appendix 1: State message for the LUT gauge

System State Description

Connecting Devices LUT gauge OS is attempting to connect every LUT gauge software modules and detection unit computer. There is at least one software module for each hardware component of the LUT gauge. LUT gauge OS will stay in this state until all modules are connected and operating properly.

Initializing I/O LUT gauge OS is doing input and output initialization sequence.

System Stopped LUT gauge OS is properly connected to all modules. The LUT gauge is ready to be activated (ON) and is currently in a “stop” mode.

Waiting for System Ready The LUT gauge OS has been started. LUT OS is waiting for verification of all safety interlocks and power-up of the length-meter, detection laser unit, the generation laser unit and the positioning device (optional).

Waiting Error The LUT gauge OS is scanning the system to determine the source of system errors.

Homing Scanner The LUT gauge OS is homing the positioning scanner.

System Ready The LUT gauge OS is ready for laser arming. The system’s E-stop and interlocks are all positives. The gauge is waiting for the instruction to arm the lasers.

Arming Laser The LUT gauge OS is sending the command to arm the detection laser and generation lasers to all probes. LUT OS is waiting for confirmation of the status of the lasers.

Lasers Armed The detection and generation lasers are ready to fire. The gauge is in a “laser safe” condition and laser firing is possible. The lasers are NOT firing in this state.

Positioning System The LUT gauge OS is sending a command to position the LUT probe at the focus position depending on OD value. In the case where there is a motorized positioning device, the LUT gauge OS is sending a command to place the LUT probe to its measuring position (optional).

Pipe Coming The LUT gauge OS has received « pipe coming » signal from the


plant PLC. Data acquisition is initiated in all sub-systems and probe(s) control computer.

Waiting for Pipe The LUT gauge OS is waiting for a new pipe to measure.

Measuring Pipe The LUT gauge OS has detected the presence of a pipe/tube under the LUT probe measure point and start acquiring data.

Pipe Ending The « pipe coming » signal has dropped to LOW. LUT gauge OS waits until the internal pipe detection system has detected that the pipe has left the LUT measure point.

Stopping fire and measure The LUT gauge is stopping lasers firing after the pipe has left the LUT measure point.

Processing data The LUT gauge OS has completed data acquisition for a pipe. The data is being processed, displayed, saved and transferred through the network Once those operations are done, the LUT gauge OS places the gauge in the [Lasers Armed] state.

Stopping Lasers An orderly shutdown of the LUT gauge lasers is underway.

Stopping System An orderly shutdown of the LUT gauge is underway. All electrical power will be automatically cut to the components in a few moments.

Fatal Error The LUT Control Engine was unable to start correctly. Error has to be corrected and the LUT control Engine has to be restarted.


Appendix 2: State message for the LUT probe

System State Description

Connecting Devices LUT Detection Engine is attempting to connect every LUT probe sub-systems software modules. There is at least one software module for each hardware component of the LUT probe. LUT Detection Engine will stay in this state until all modules are connected and operating properly.

Probe Stopped LUT probe is ready to be activated (ON) and is currently in a “stop” mode.

Waiting for Probe Ready LUT probe has been started. The probe is waiting for all its sub-systems to become ready.

Probe Ready LUT probe is ready for laser arming. The probe is waiting for the instruction to arm the lasers.

Arming Laser The detection and generation lasers are being armed.

Lasers Armed The detection and generation lasers are armed.

Preparing Probe LUT probe is settings its measure position (optional).

Prepare Data Logging LUT probe is initializing data acquisition in all sub-systems

Ready to Fire LUT probe is ready to fire

Fire Laser LUT probe is actually firing its lasers

Stopping Fire LUT probe is stopping the lasers from firing

Stopping Data Logging LUT probe is stopping data logging operation

Stopping Lasers An orderly shutdown of the LUT probe lasers is underway.

Starting G-Laser Water Flow LUT probe is starting the water flow of one of its generation laser

Cycling G-Laser Water LUT probe cycling the water of one of its generation laser

Stopping G-Laser Water Flow LUT probe is stopping the water flow of one of its generation laser


Appendix 3: Errors and Messages Message

Code Message

Type Message Text Description

0 No Message or Error

No Error

1 System Message

System Stopped LUT gauge is stopped

2 System Message

System Ready to Be Started LUT system is ready to be started, all E-stop are OK and safety keys turned ON

3 System Message

Critical Error Prevents System Start

A Critical error occurs on the system: the system cannot be started until the error is cleared

4 System Message

Blower Failure Prevents System Start

The filter of the blower is blocked, clean the filter or change it to start the LUT gauge

5 System Message

E-Stop or Safety Switch Prevents System Start

An E-stop or a safety switch (key) is activated, Please correct the error to start the LUT gauge

6 System Message

Lasers Stopped on Batch End LUT gauge has stopped the lasers after receiving a "End Batch signal"

7 System Message

System Set to "Automatic" Mode

LUT gauge has been set to "Automatic Mode"

8 System Message

System Set to "Maintenance" Mode

LUT gauge has been set to "Maintenance Mode"

9 System Message

All Device Servers Connected All the LUT software server modules (sub-systems) are connected to the LUT Engine

10 System Message

System Started LUT gauge is started: all sub-systems and lasers are powered

11 System Message

Starting Manual Measurement LUT gauge is starting its measurement in manual mode (laser firing)

12 System Message

Manual Measurement Finished LUT gauge has finished its measurement in manual mode


13 System Message

System Initialization Done LUT "Control Engine" has started correctly: all parameters and required file are loaded correctly

14 System Message

Waiting for all Systems to be Connected...

LUT "Control Engine" is waiting for all the software server modules to be connected

15 System Message

System Ready LUT is powered and ready to be used. Lasers can be activated.

1001 System Error

Connection Failed One or more connection with a software server module has failed

1002 System Error

E-Stop Caused System Stop An E-stop was activated and has shutdown the system

1003 System Error

Interlock Caused System "Not Ready"

An interlock was activated and caused the LUT system to be "Not Ready"

1004 System Error

Device "Not Ready" A Software server module is not ready

1005 System Error

Unable to Change System Mode

LUT gauge was unable to change its current mode

1006 System Error

Maintenance is Required for this Operation

LUT gauge has to be in "Maintenance Mode" to perform the requested action

1007 System Error

Invalid Probe Number The selected probe number is invalid

1008 System Error

Lasers must be Stopped for this Operation

LUT gauge cannot performs the selected action while the lasers are firing

1009 System Error

Unable to Change Laser(s) Settings

LUT gauge was unable to change the laser(s) settings

1010 System Error

Invalid Laser(s) Setting The chosen setting(s) for the laser are invalid

1011 System Error

Scanner "Not Ready" for this Operation

The LUT gauge scanner cannot perform the requested operation

1012 System Error

No Pipe Detected after Pipe Signal

LUT gauge has received the "pipe is coming signal" but did not detect the pipe under the measuring position

1014 System Error

Unable to Move Scanner LUT gauge was unable to move the scanner


1015 System Error

Maximum Scanner Error reached

LUT gauge has detected an position error with the motor controller

1016 System Error

Error Moving Scanner An error happen while LUT tried to move the scanner

1017 System Error

Laser Idle Time Expired No PLC signal came from the factory after the maximum idle time period: LUT gauge has stopped the lasers

1018 System Error

Scanner not Installed The scanner option is not installed on the system. The operation cannot be completed

1019 System Error

Bad Probe Configuration Setting

An invalid probe configuration was set

1020 System Error

File Copy Error LUT gauge has got an error while trying to copy a data file

1021 System Error

Blower Fault: Please Check Blower Operation Before Restarting System

Blower Fault: The Blower filter needs to be checked

1022 System Error

Invalid Raw File Recording Setting

LUT gauge has detected an error with the RAW data acquisition settings

1023 System Error

Probe 1 Detection Engine Error

LUT "Control Engine" has detected an error with the probe 1 "Detection Engine"

1024 System Error



1025 System Error



1026 System Error



1027 System Error

Detection Engine not Connected

A probe "Detection Engine" is not connected to the LUT "Control Engine"

1028 System Error

Error Closing Data Files An error happen while closing the data files

1029 System Error

Error Intializating Data Files An error happen while intializating the data files

1030 System Error

Error while Stopping Laser Fire

An error happen while stopping the lasers fire


1031 System Error

Error while Stopping Lasers An error happen while stopping the lasers

1033 System Error

Stop Lasers Timeout Error A timeout error happen while stopping the lasers

1034 System Error

Stop Scanner Error An error happen while stopping the scanner

1035 System Error

Scanner Movement Error An error happen while moving the scanner

1036 System Error

Scanner Move Timeout Error A timeout error happen while starting the scanner movement

1037 System Error

Scanner Needs to be Reseted: Press "Reset" Button

An error happened during the scanner operation. The scanner needs to be reseted with the "Reset" Button

1038 System Error

Length-Meter Slide Move Timeout Error

Length-Meter Slide Move Timeout Error

1039 System Error

Unable to Move Scanner: Please Verify Scanner Contactor and Reset Error

Unable to Move Scanner: Please Verify Scanner Contactor for AC power and Reset scanner driver Error

1040 System Error

E-Stop Prevents Scanner Movement

The LUT scanner cannot move because an E-stop is activated

1041 System Error

This Operation Requires the System to be in "Ready" State

The system has to be in "Ready State" to perform the requested operation

1042 System Error

Maximum Measuring Time Expired

The maximum measure time has been reached with the current pipe: the measurement has been interrupted

1043 System Error

Arm Laser Timeout Error The maximum arm laser delay has been reached. Lasers errors should be checked

1044 System Error

Timeout During Probe Setup A timeout occurred on a multi-probe system while setting the active probe(s)

1045 System Error

Detection Laser Power Low: Flashlamp need to be Changed

The laser power output of the detection laser is too low. The flashlamp needs to be change or there is a problem with the laser

1046 System Error

Generation Laser 1 Power Low: Flashlamps need to be Changed

The laser power output of the generation laser 1 is too low. The flashlamp needs to be change or there is a problem with the laser

1047 System Generation Laser 2 Power The laser power output of the generation laser 2 is too


Error Low: Flashlamps need to be Changed

low. The flashlamp needs to be change or there is a problem with the laser

1048 System Error

Chiller Temperature Too High: Verify Chiller Operation

The water temperature of the chiller is too high. Check the LED and display status on the front of the chiller unit

1049 System Error

Chiller Water Flow Too Low: Verify Chiller Operation.

The flow of the chiller is too low. Check the LED and display status on the front of the chiller unit

1050 System Error

Generation Laser(s) Error: Verify Error Number, When Error Condition is Fixed, Use the G-Lasers "Reset Error" Button

An unexpected error occurred on a generation laser. The laser condition has to be checker and the error has to be connected. When error condition is fixed, the screen "Reset Error" button can be used to cleared the error

1051 System Error

Program Configuration File Error (*.ini)

LUT "Control Engine" has encountered an error into its configuration file ( *.ini)

1052 System Error

Device Software Not Found Cannot find the server software program file. Refer to the additional information in the "System Messages" panel

1053 System Error

Error Executing Device Software

An error occurred while starting a software server program. Refer to the additional information in the system message panel

1054 System Error

System Initialization Failed: Problem must be fixed and Program Must be Restarted

System Initialization Failed: Problem must be fixed and program must be restarted. Refer to the additional information in the "System Messages" panel

1055 System Error

Device Disconnected: Unable to Complete Operation

The device has been disconnected from the LUT "Control Engine" software: the requested operation has failed

1056 System Error

Generation Laser is Disabled The generation laser is disable and cannot be operate

1057 System Error

Probe is Disabled The probe is disabled and cannot be operate

1058 System Error

Error Setting Probe Setup An error occurred while setting the active probe configuration

1059 System Error

Measurement Failed LUT gauge measurement has failed. Refer to the additional information in the "System Messages" panel

1060 System Error

Measurement Completed with Warning(s)

LUT gauge has completed the last measurement with a warning message. Refer to the additional information in the "System Messages" panel


1061 System Error

Database Access Failed The Access to the message database has failed

1062 System Error

Alloy Code Conversion File Error

There was a problem with the Alloy code conversion file

1063 System Error

Alloy Code Not Found in Alloy Database File

The Alloy code was not found in database file

2000 Local Message

Connected to LUT Control Computer

The remote controller or viewer program has been connected to the "Control Engine" software

2001 Local Message

Disconnected from LUT Control Computer

The remote controller or viewer program was disconnected from the "Control Engine" software

3001 Local Error

Program Initialization Problem The remote controller or viewer program has detected an error during the initialization of the software


Appendix 4: Pipe logging data file The pipe logging file contains the measurement data for one (1) day of operation. One (1) line is added for each new measurement. The file can become large if the production is very large for a day.

The file is written in the following format:

• Two (2) lines of heading:

1. “Tecnar LUT Measurement Log File version x.x.x” : Display the version of the file to identify the format in case of change.

2. “Result From Computer: LUT-‐CTRL-‐NNNN”: Gives the name of the computer where the file was created.

• One (1) line for the columns title: “Date Time PipeInformation Lot Piece Alloy OD Nom.WT Nom.Length Nom.Speed Nom.Temp Mode Angle VeloTemp WaterFlow WaterTemp MeasureStatus TotalShots AvgGPR Length VeloStatus ScanStatus LapStatus DataValid GPR Status Shots ProcessType Avg USStatus RgmStatus PwrLogStatus AvgTemp AvgPyroCh0 AvgPyroCh1 PyroGain AvgUs Power Pump Light AvgWT AvgDistance AvgRgmChan0 AvgRgmChan1 Eccentricity DLVolts DLFC GL1Volt GL1FC GL1Energy GL1HeadTemp GL1WaterTemp GL2Volt GL2FC GL2Energy GL2HeadTemp GL2WaterTemp ProbeTemp”

• The following lines are the results of the measurement. Here is an example: “2009-05-14 10:13:31 0041-001 70649100 1 103 0.1112 0.00360 16.14 1.90 850 FALSE 0 33.9 7.4 20.0 0 1110 83.6 16.10 0 12 12 TRUE 84 0 1110 1 1 0 0 0 721 0.17 0.19 7 0.04000 75 26 46 3.50 12.3 46 40 4.55 896 224750987 765 64083220 -1.0 0 30 750 44614555 0.0 0 33 27.9”


Appendix 5: Data logging data file The data logging file contains a complete measurement result for a pipe. One (1) file is created for each measurement.

The file is written in the following format:

-- Tecnar LUT Result File Version x.x.x -- -- System Settings -- Pipe Info 70626856 Lot No 405 Piece No 0.00390 Nominal Thickness 131 Alloy Code 0.1118 Diameter 850 Nominal Temperature 16.210 Nominal Length 1.900 Nominal Speed NO Scan Mode 0 Measure Angle 0 LUT Mode 0.000000 Laser Fire Delay YES Velocimeter Installed NO Scanner Installed 1 Number Of Probe -- Measurement Result -- 0 Processing Status 1003 Total Shots 97.1 Average GPR 0 Velocimeter Measure Status 12 Scanner Measure Status 12 LAP Measure Status -- Probe 1 Measurement Result -- YES Probe 1 Active YES Probe 1 Data Valid 0 Ultrasound & Pyrometer File Status 0 Ultrasound & Pyrometer Process Status 0 RangeMeter File Status 0 PowerLogger File Status 0 Eccentricity Process Status 0.010 Base Trigger Rate 1 Averaging Length 1 Echo Number 0.55 Minimum Correlation 0.00600 Lasers Beam Distance 7 Pyrometer Gain 717 Average Temperature 0.16 Average Signal Pyrometer Channel 1 0.15 Average Signal Pyrometer Channel 2 0.03 Average Signal Ultrasound 47.1 GPR 1003 Number of Shot -- Measurement Result Data – Shot Position Angle Temperature-1 Thickness-1 HotThickness-1 Distance-1 Light-1 Eccentricity-1 MeanThickness-1


0 0.0000 0 852 0.00000 0.00000 0.0 130.0 -1.00 0.00000 1 0.0220 0 862 0.00000 0.00000 0.0 141.0 -1.00 0.00000 2 0.0430 0 873 0.00310 0.00310 0.0 141.0 -1.00 0.00000

Documents

LUT Manual - Section II - 40101-00002-03 NEWLOGO · This!document!contains!information!considered!proprietary!and!confidential!to!Tecnar!Automation!Ltd.! 40101:00002:03!:!Rev.A! Revisiondate!:2013:01:30!