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QCA Systems Limited Operation Manual Ridley Terminals Canada Site HMI Station In Central Office Prepared by: Wayne Leung Controls Specialist QCA Systems Limited Version: 0 Date: February 28, 2013

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  • QCA Systems Limited Operation Manual

    Ridley Terminals Canada

    Site HMI Station

    In Central Office

    Prepared by: Wayne Leung

    Controls Specialist QCA Systems Limited

    Version: 0 Date: February 28, 2013

  • TABLE OF CONTENTS

    QCA SYSTEMS LTD.

    Unit 16-7355 72nd Street, Delta, British Columbia, Canada V4G 1L5 Ph: 604.940.0868 Fax: 604.940.0869 Toll Free: 1.877.940.0868

    May 8, 2009 Page 2 of 32

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    1.0 Introduction ................................................................................................................................ 4

    2.0 Title Bar ...................................................................................................................................... 6

    3.0 Overview display ....................................................................................................................... 9

    3.1 Components on Overview ....................................................................................................... 9

    3.2 Color Legend ........................................................................................................................... 10

    3.3 Status of equipment ................................................................................................................. 10

    3.3.1 Status of Conveyors ....................................................................................................... 10

    3.3.2 Feeders........................................................................................................................... 11

    3.3.3 Stacker/Reclaimers ........................................................................................................ 11

    3.3.4 Gates .............................................................................................................................. 11

    3.3.5 Dumper ........................................................................................................................... 12

    3.3.6 Surge Bin ........................................................................................................................ 12

    3.4 Alarm Banner ........................................................................................................................... 13

    3.4.1 Alarm Priority .................................................................................................................. 13

    3.4.2 Event Time...................................................................................................................... 13

    3.4.3 Message ......................................................................................................................... 14

    3.4.4 Alarm Class .................................................................................................................... 14

    3.4.5 Alarm Name .................................................................................................................... 14

    3.5 Navigating to equipment status from Overview ....................................................................... 14

    4.0 Major Equipment Status ........................................................................................................... 15

    4.1 Status of the conveyors ........................................................................................................... 16

    4.1.1 LED ................................................................................................................................. 18

    4.1.2 Retangular light boxes .................................................................................................... 18

    4.2 Chute Gate status .................................................................................................................... 20

    4.2.1 Chute Actuator E3 + for CV313 and CV303 Chute Gate Actuator ................................. 21

    4.3 Chute Vibrators for CV303, CV313 and CV316 ...................................................................... 22

  • TABLE OF CONTENTS

    QCA SYSTEMS LTD.

    Unit 16-7355 72nd Street, Delta, British Columbia, Canada V4G 1L5 Ph: 604.940.0868 Fax: 604.940.0869 Toll Free: 1.877.940.0868

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    4.3.1 Chute Vibrator E3+ for CV303, CV313 and CV316 ....................................................... 23

    4.4 Surge Bin Status ...................................................................................................................... 24

    4.5 Substation 2A Building Status ................................................................................................. 25

    5.0 Route Handling .......................................................................................................................... 26

    5.1 Accessing the Route Selection Table ...................................................................................... 26

    5.2 Route Selection Table ............................................................................................................. 27

    5.3 Route Selection Map ............................................................................................................... 28

    5.4 Route Select and Deselect Confirmation................................................................................. 29

    5.5 Route Request Status Resullt table ......................................................................................... 30

    6.0 PLC Status.................................................................................................................................. 31

    6.1 Major Status display pane ....................................................................................................... 31

    6.2 Date and Time pane ................................................................................................................ 32

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    1.0 Introduction

    The purpose of this document is to provide an understanding and description of the operation of

    the Site HMI Station in regards to plant overview, major equipment status, routes selection and

    deselection, and etc. The HMI station when started up will run automatically and display the first

    overview page with a Title Bar at the top, a major screen display area in the middle and a status

    bar at the bottom.

    Sample display

    Title bar area at the top allowing navigation to major displays such as overview, routing and alarms.

    Main screen area showing the overview, routing and various pop up windows.

    Status bar at the bottom showing status message of the Factory View Software.

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    1.1 Scope of control for Site HMI

    The Central Office has a ControlLogix (CLX) PLC acting as gateway to all future CLXs in various

    Substations. The Central Office CLX now connects to the Central PLC5 PLC and receives

    operational status from existing PLC5s. Through a Site wide fiber network, the Central CLX will

    be connected to Sub2A HMI Station and a PLC Engineering Work Station. The Central CLX will

    not control any equipment but it performs the very important and centralized task of Route

    Selection and Interlock.

    The Site HMI runs the same Factory Talk View Client application as the Sub2A HMI in the Substation 2A. The Site HMI has the following major components:

    - Title Bar

    - Site Overview

    - Major Equipment Status

    - Route Handling

    - PLC Status

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    2.0 Title Bar

    The Title Bar shows up at the top on every display and remains there as it provides the root navigation means to other levels of displays.

    Title Bar

    From the top right corner, the following navigation keys are available:

    - when pressed, all displaying screens will be closed and return to the Overview screen in the major display area with the Title Bar at the top.

    - when pressed, a Navigation Pane (see below) will pop up on the left side of the screen to allow further selections of displays:

    When alarm navigation button is selected a choice will be given as to which alarm page

    Shows the name of the major pages: Overview and Routes

    Computer name and user

    Major navigation keys to different displays

    Time and date display Button to quit the Factory Talk View Client application

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    - when pressed, the following Route Selection display will show up. This display shows an array of route selection buttons enabling the operator to select or deselect the proper route.

    - when pressed, another selection pane (see below) will pop up showing the PLC you can address to.

    Buttons when pressed navigates to different equipment

    Button to close this Navigation Pane

    Buttons when pressed navigates to different PLC

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    - when pressed, the following Alarm History display will show up giving the operator access to the alarm history database. (Not relevant in Site HMI)

    - when pressed, the following Alarm Summary display will show up giving the operator a summary of the alarms. (Not relevant in Site HMI)

    At the top right corner of the Title Bar, a Quit button is located :

    - when pressed, the following confirmation prompt will show up at the middle of the screen which allows the operator to re-think either to quit or not.

    When pressed, the Client application quits.

    When pressed, this quit operation is cancelled.

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    3.0 Overview display

    3.1 Components on Overview

    The Overview screen shows an overview of the status of the site conveyors, the stacker/reclaimers, the gates in different Transfer Towers, the dumpers, the scales at various locations and etc.

    Production data

    Shows a legend of the color used for status of the equipment

    Alarm banner showing the most updated alarms

    Alarm acknowledge and reset button

    Colors of conveyors and gates shows the status of the equipment

    Pressing the name box pops up a status window of equipment

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    3.2 Color Legend

    Status of the conveyors are displayed by different colors and operators may refresh their memory

    from the Color Legend bottom at the top right corner of the Overview display. When pressed the following window will pop up:

    3.3 Status of equipment

    The status of the following equipment will be represented by the color. There are 6 major group of equipment: Conveyors, Feeders, Stacker/Reclaimer, Dumper, Gate and Surge Bin using 3 types of color codes.

    3.3.1 Status of Conveyors

    The conveyors use the following color codes:

    The conveyors include: CV201, CV202, CV203, CV204, CV302, CV303, CV305, CV306, CV316, CV307, CV404, CV407, CV408, CV409.

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    3.3.2 Feeders

    The feeders F402 and F403 share the same color codes with the conveyors.

    3.3.3 Stacker/Reclaimers

    The Stacker/Reclaimer SR300, SR301 and SR310 have the layout and status display and each of them is made up of the following parts:

    3.3.4 Gates

    Conveyor having a gate will have it at the head end where products will fall to the correct downstream belt according to the position of the gate. The gates have a different set of colors to denote their status:

    Bucket wheel shares the same color code as the conveyors

    Stacking arrow in red appears when in stack mode

    Boom conveyor shares the same color code as the conveyors

    Reclaiming arrow in red appears when in reclaiming mode

    Through arrow in red appears when in through mode

    Route selected and running with this SR

    Production data : Tonnes per hour and total tonnes

    Slew Position and Traverse Position

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    The Site HMI show positions of the gates in TT04, TT07, TT08 and TT10.

    3.3.5 Dumper

    The Dumper has the same color scheme as the conveyor to show its status. The Overview shows its status using D190 and D200:

    3.3.6 Surge Bin

    There is one surge bin and the status is shown by the following colors:

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    3.4 Alarm Banner

    The Alarm Banner docks at the bottom left hand corner and it shows the most updated 5 alarms at the top but scoll bar is available to allow the operator to show more alarms in the list.

    The Alarm Banner has the following columns:

    3.4.1 Alarm Priority

    The alarm priority in the alarm banner has this symbol and it denotes the urgency of the event according to the severity levels:

    Severity levels:

    3.4.2 Event Time

    The time at which the alarm condition or sub-condition changed into the currently displayed state. The Event Time shows the date and then the time in precision up to a second.

    200 normal warning

    400 if prolonged condition exists, lead to loss of section of plant

    600 loss of section of plant

    800 loss of plant-wide control

    Scoll bar to view alarm down the list

    5 columns for each alarm message

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    3.4.3 Message

    Message is the descriptive text for the alarm event and the text is configured in the PLC. Changes to this descriptive text must be made in the PLC.

    3.4.4 Alarm Class

    The Alarm Class is a classification string that is associated with an alarm when it is defined during PLC programming. The Alarm Class provide a user defined string that can be used for filtering and sorting alarms.

    3.4.5 Alarm Name

    The Alarm Name is the name of the tag in the PLC for that alarm event.

    3.5 Navigating to equipment status from Overview

    The operator may navigate directly to the status pop up display of an equipment by moving the cursor to over the rectangular name box of an equipment and then click and release. For examples, if one wants to navigate to the status page of CV316, the operator should move the

    cursor over the CV316 rectangular box and click to navigate to the CV316 status page. As the cursor moves over the rectangular box, the name box is highlighted with a thicker border so that the operator knows the cursor is sitting over it.

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    If a name box has more than one piece of equipment like TT07 where there are two gates to select, another pop up selection window will be displayed so that the operator may choose his perference, in this case, either CV303 gate or CV313 gate.

    4.0 Major Equipment Status

    Conveyor status may be accessed by pressing the button on the Title Bar. A small window pops up on the left like the following:

    Conveyor status key when pressed will bring you to another selection window

    Step 1: hit TT07

    Step 2: TT07 Gate Navigation window pops up

    Step 3: Operator selects the gate he wants to view.

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    All conveyors in the coal yard can be selected. Starting from CV201 after the dumper, up to CV409 before the ship loaders. The status of the Surge Bin and the Feeders F402 and F403 may be selected from this pop up window. The gate and vibrators under control by Sub2A PLC may also be selected.

    4.1 Status of the conveyors

    When any button in the above Conveyor Navigation Pane is pressed, a pop up for for that corresponding conveyor or equipment will be displayed as on the following page. The left hand side of the pop up summarize the status of the conveyor including the permissives, routes, any alarm and any warning.

    The status displays for different conveyors vary but similar. The figure on the following page shows the CV202 conveyor status pop up.

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    The Status pop up uses LEDs to summarize conditions, and light boxes to show individual element status.

    Permissives pane

    Pop up title bar with the title name of the pop up and a Close button to quit the pop up

    Route status pane

    Conveyor status pane

    Major Alarm status pane

    Permissive Start status pane

    Other related alarm status pane

    Permissive Restart status pane

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    4.1.1 LED

    LED is used to summarize conditions, very often fault and warning related. There are several types of LED displays:

    / Orange when OFF and Green when ON.

    To indicate condition which is a warning during OFF and OK or Ready when ON.

    / Yellow when OFF and Green when ON

    To indicate condition which is an alarm fault when OFF and OK or Ready when ON

    / Grey when OFF and Green when ON

    To indicate condition which is inactive when OFF and OK or Ready when active

    / Grey when OFF and Yellow when ON

    To indicate condition which when OFF indicates no alarm exists and fault exists when ON

    / Grey when Off and Orange when ON

    To indicate condition which when OFF indicates no warning and warning exists when ON

    4.1.2 Retangular light boxes

    Light box is used to indicate status of fundamental elements in control logic.

    Similarly the light box may change color in the following manner:

    1. Orange / Green

    2. Yellow / Green

    3. Grey / Green

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    4. Grey / Yellow

    5. Grey / Orange

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    4.2 Chute Gate status

    From the Conveyor Navigating pane introduced in Clause 4.0, the operator may choose to select to move to the Chute gate status pop up for either CV303 or CV316 in TT07 by pressing these

    buttons:

    The following pop up will be displayed:

    Push button to navigate to the filtered alarm page for CV303 Chute gate

    Light box indicating Orange at gate Run Off position and Grey when not at Run Off

    Light boxes indicating overtravel Orange when overtravel, and Green for no overtravel

    Light boxes indicating Green at appropriate gate position and Grey when not at position

    Position of the gate in degrees

    Red when the gate moves either forward or reverse direction

    Movement of the gate Green when active and Grey when not active

    Light boxes indicating Green when route is selected and moving direction is confirmed

    Permissive start LED indicating Green for all conditions fulfilled and Grey when not permitted

    Individual permissive Green when fulfilled and Grey for not

    Push button to drill down to the Overload E3 Plus relay

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    4.2.1 Chute Actuator E3 + for CV313 and CV303 Chute Gate Actuator

    When the Actuator E3 button is pressed, the following window will pop up showing the details of the E3+ relay:

    Push button to navigate to the filtered alarm page for CV303 Chute gate actuator

    Pane with light boxes showing overall status of the motor and motor current

    Pane with a Yellow LED showing a trip and light boxes for individual trip condition

    Pane with a Orange LED showing a warning and light boxes for individual warning condition

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    4.3 Chute Vibrators for CV303, CV313 and CV316

    The status of the Chute Vibrators may be reached by the following buttons in the Conveyor Navigation pane described in Clause 4.0:

    The corresponding Vibrator pop up will be shown when one of these button is pressed:

    Push button to navigate to the filtered alarm page for CV303 Chute vibrator

    Pane with a Green LED showing a permit start and light boxes for individual permissive condition

    Pane with bar graph for motor current, and the value equivalent below. The bar turns from Green to Yellow when over 100% load and Red when over 115% load.

    Push button to drill down into the E3+ relay for the vibrator motor

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    4.3.1 Chute Vibrator E3+ for CV303, CV313 and CV316

    Push button to navigate to the filtered alarm page for CV316 Chute vibrator

    Pane with light boxes showing overall status of the motor and motor current.

    Pane with a Yellow LED showing a trip and Green when no trip. And light boxes for individual trip condition.

    Pane with an Orange LED showing a warning and Green when no warning. And light boxes for individual warning condition

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    4.4 Surge Bin Status

    The status of the Surge Bin may be reached by pressing the button in the Conveyor Navigation Pane and the following pop up will be shown:

    Overall status pane showing high and low level alarm of Surge Bin

    Fire alarm pane showing fire alarms related to the Surge Bin

    Other related alarm pane

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    4.5 Substation 2A Building Status

    The Sub2A Station also has fire alarms, HVAC and UPS and the status of these equipment are summarized in a pop up window accessed by pressing the Sub2A Building in the Navigation Pane described in Clause 2.0.

    Please refer to the relevant section in Sub2A HMI Station for details.

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    5.0 Route Handling

    Route selection may be carried out in either the HMI Station in the Central Office or in individual Substation. The idea is to offer the maximum flexibilities to the operation of the plant while maintaining the maximum integrities and safety in route selection. This is done by centralizing the route interlocks in the Central ControlLogix PLC with route selection requests made from every substation. Route selected and running are shown in the route status table so that operator is made well aware of the present route status before he make any route request. When the operator makes a route request, a small map will pop up showing the requested route. Confirmation pop up will be shown once the operator presses either the Select or Deselect button.

    5.1 Accessing the Route Selection Table

    There are two ways to access the Route Selection Table:

    1. Direct from Title Bar

    2.1 From the Navigation Pane

    2.2 Press for Route:

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    5.2 Route Selection Table

    In either case of the above accessing methods, the following table will be shown in the main display area of the HMI:

    The routing table is comprised of two portions: a matrix of the the first 4 columns and 3 rows, and the 5

    th column.

    For the first matrix, the 4 columns denotes the 4 stacker/reclaimers and the rows refer to three operating modes of the SRs.

    The much simpler second matrix is dedicated for selection of the ship loaders S400 and S401.

    For each Route Request Button in the Route Table, the top line describes the route and the bottom line refers to the number of that route.

    The title of the Title Bar will show Route Selection

    The present route status for Substation HMI will be shown by pressing this button

    Route request buttons to make route selection or de-selection request.

    The boundary of the button Green when that route has been selected and running, Grey when inactive

    Route description in wordings

    Route number

    Boundary showing status of Route 5

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    5.3 Route Selection Map

    When a Route Request Button is pressed, a routing map will pop up showing the route details, the route number, route descriptive text, a Select button and a Deselect button:

    Route number and the route in wordings

    Route descriptive text

    Route details diagrammatically highlighted in Green

    Route Select and Deselect buttons

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    5.4 Route Select and Deselect Confirmation

    When either the Route Select button or Route Deselect button is pressed, a confirmation window will pop up adjacent to the buttons:

    When either the YES or the NO button is pressed, the confirmation pop up will disappear and return the operator to the Route Select Map window. Operator may check his request action (either Route Select or Route Deselect) by pressing the Route Status button at the top of the Route Selection Table.

    YES button to confirm selection

    NO button to cancel the select operation and quit the pop up

    YES button to confirm deselection

    NO button to cancel the deselection operation and quit the pop up

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    Unit 16-7355 72nd Street, Delta, British Columbia, Canada V4G 1L5 Ph: 604.940.0868 Fax: 604.940.0869 Toll Free: 1.877.940.0868

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    5.5 Route Request Status Resullt table

    The table shows the result of the operator action when he make the request from the Route Selection Table and make any Route Select or Route De-select action from the confirmation pop ups.

  • QCA SYSTEMS LTD.

    Unit 16-7355 72nd Street, Delta, British Columbia, Canada V4G 1L5 Ph: 604.940.0868 Fax: 604.940.0869 Toll Free: 1.877.940.0868

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    6.0 PLC Status

    The PLC Status may be accessed from the button on the Title Bar and then the desired PLC may be selected from the PLC Navigation pane as described in Clause 2.0 above.

    The following pop up will be displayed by pressing the Central PLC button:

    6.1 Major Status display pane

    The major status display pane shows if the PLC is in RUN mode, the battery status, an overall PLC fault status, PLC DHRIO communication fault and RIO communication fault

    The light boxes display Green when OK and Yellow under fault condition.

    Push button to quit this pop up

    Major status pane

    Date and time pane

    Push button to set new time and date

  • QCA SYSTEMS LTD.

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    6.2 Date and Time pane

    The left hand side of this pane displays the date and time data running in the PLC and the right hand side of this pane allows operator input to change the PLC current date and time. The

    operator enters the correct date and time data and press the button to send the desired data to the PLC.