ETP DCS

Familiarisation

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Introduction

The AD Plant is controlled by ABB’s 800xa DCS, this DCS system is the same used on all three paper
machines and in the not too distant future the Primary and remainder of the secondary plant. The
ETP DCS system uses the Beta system which it shares with E-Line and also PM6, however E-Line and
PM6 operators cannot access the ETP Control system and vice versa.

The AD Plant Control system is made up of two ABB AC800M PM861A Controllers which are
configured as redundant controllers. There are 3 profibus networks which are also configured for
redundancy and a back-up PP885 HMI which can be used to control critical parts of the process if the
control network or one of the two DCS operator workplaces failed.

There are two operator work places, one located in the ETP control room and another in the AD
Plant operator room, both of these workplaces show the same information and can be used to
control the AD Plant in exactly the same way.

The DCS training is to give an appreciation of the system and its functions, normal operating
procedures must be followed at all times, if you are unsure seek advice before making any decisions.

Accessing the Workplace

To access the workplace you must first log in using the following;
Username – etpoperator
Password – operator
Once you have logged on, the operator workplace will be automatically loaded and the ETP Startup
Menu will be displayed.

All active alarms can be viewed Main Menu Button – Access to the Alarm Band – The most recent alarms
by pressing one of this buttons. main menu, here you can navigate are shown here. Double click each one
to the various graphic displays. to open the object faceplate.

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Navigation

Once you have accessed the main menu there are a number of different ways to navigate around
the various graphic displays. Below is the main menu page, it has been split into a different process
areas for ease of use. To navigate to different graphic displays simply click on the appropriate
button.

Drop Down Menu- this shows

you a list of recently viewed
displays, you can click on one Graphic Display Buttons –
of these to navigate back to clicking on the appropriate
that display. button will take you to the
required display. For example
Graphic Display Aspects – click – “Conditioning Tanks AD
here will show you a list of all Reactors” will take you to an
available displays, click on one overview page displaying
of these to navigate to them. these.

Forward and back buttons –

use these to navigate to
previously opened displays.

Graphical Elements

When viewing the different graphic displays, you will see a number of graphical elements every
piece of equipment around the AD plant will have its own graphical element. The graphical elements
are interactive and change state depending on its current working position. Clicking on the graphical
element will make a faceplate appear, this is where you can control each piece of equipment. A
number of graphical elements have been highlighted on the screen shot below.

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Hand Valves

Closed Hand Valve

Open Hand Valve

Auto Valves

Auto Valve Closed in Manual Mode

Auto Valve Open In Auto Mode

Auto Valve in Fault

Control Valves

Control Valve Closed

Control Valve Open

Motors

Motor Available but not Running in Manual Mode

Motor Interlocked in Manual Mode

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 Motor Running in Auto Mode

Motor in fault in Auto Mode

PID Control Loops

A PID control loops is a way of controlling an output such as a motors speed or valve position to
achieve a setpoint, that setpoint may be entered by an operator or be set remotley by the DCS. The
required setpoint is monitored by a measurement device such as a flow meter and then the output
is adjusted to achieve this. Below is an example of a PID Loop, the measurement device is an oxygen
analyser, the output is the speed of two motors.

A PID control loop running in auto mode but in alarm.

A PID control loop running in auto

mode.

Analog Inputs

An analog Input is a measuement feedback from a field

intstument such as a pressure transmitter, they can be displayed as a
numerical graphic displaying the feedback as a number or as a
measurment bar when the feedback is from a level transmitter.

Analog input in alarm

Analog input OK

Analog input Failed

Analog input force value

Analog input displayed as a bar rather than a number, green bar is within limits, red bar in alarm.

Digital Inputs

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A Digital Input is feedback from a device such as a pressure switch or proximity switch.

Digital Input in Alarm

Digital Input OK – Filled Green is ON, Not filled is OFF

Digital Input Forced – Filled Yellow is Forced ON, not filled is Forced OFF

Faceplates

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Each Graphical Element has a faceplate, the faceplate is used to control the piece of equipment the
grahical element represents. All of the faceplates look very similar but have different functions
depending on the device its controlling. Below is an example of a faceplate that is used to control a
motor driven be a variable speed drive.

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 Trends

A Trend is a historical record of information it can include setpoints, measurment feedbacks or

results of calculations. As a standard all analog inputs are recorded every 10s with and saved for 14
days. A trend can be a very useful tool to monitor and diagnose any issues with the process. A trend
for individual analog inputs can be accessed via the faceplate or there are a number of prebuilt
trends whcich can be found by navigateing to the trend menu.

Various
Prebuilt

Clicking on one of the buttons will open the corrosponding trend display.

Navigation, zoom and Current Value of Time and value that is

trend length tools. measured value and being measured by the
the high and low range ruler.
of the Y axis.
Tag number and
description of devices Minimum, Maxiumum
displayed on the trend. and average value of all
the trend data on the
display.

Alarms

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Alarms are generated when a variable has exceeded its high or low limits; or when a digital input has
changed state. Alarms are used so faults can be identified before objects become interlocked, stop
working and affect the process. Alarms are visible in the alarm band, alarm list or are indicated by a
change in colour im the DCS graphics

Alarms can be identified in a number of ways included;

 An object that has changed colour from green to red.

 An alarm has been generated on the alarm bar or alarm list.
 For critical alarms a text message may be sent to your mobile phone.

An alarm must be acknowledged before the object will turn from red to green.

In order to acknowledge an alarm you must click on an object to reveal its faceplate. And click on the
alarm triangle in the top right corner.

The alarm triangles are different depending on the alarm status.

Object is in Alarm

Object is in alarm but has been acknowledged.

Object has been in alarm but the alarm condition is no longer active

Object alarm has been acknowledged and is no longer active.

AD Plant Specific Control

Calibration Mode

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Calibration mode is enabled by pressing the On button within the calibration box, when the
calibration mode is on the last value is retained, this retained value is used for all of the alarm limits,
this means that any interlocks or alarms will not be active during this time. After a period of 15
minutes an alarm will be generated to tell you that the calibration mode is still active.

Calibration Mode On

Calibration Mode On and in Alarm.

Master/Slave Level Selection

There are two level transmitters on the conditioning tanks and also on the gas buffer, one of these
level transmitters is selected as the master and the other the slave. The interlocks work from the
master transmitter. The master and the slave level are compared and in the event of a measurement
deviation of more than 10% on the conditioning tanks or 5% on the gas buffer a deviation alarm will
be generated. In this event the operator shall visually check the transmitters and decide which ion is
reading correctly and then select it as the master on the DCS graphics.

Conditioning Tank 2 – Level transmitter A selected as the master

and not in Alarm.

Reactor Feed Pump Selection

There are three reactor feed pumps;

 M4606 – Reactor 1 Feed Pump

 M4607 – Standby Reactor Feed Pump
 M4608 – Reactor 2 Feed Pump

In fully automatic running conditions M4606/M4607 shall get be controlled in flow control, the set
point for the flow is based on the level in the conditioning tanks. If one of the feed pumps cannot
maintain its flow set point then the standby pump will start and assist to achieve the required flow.
As well as working as an assist pump, the standby pump will also start in the event of a failure of the
one of the other reactor feed pumps.

The Feed pump that requires assistance should be selected on the DCS Graphics. Depending on the
selection, AD1 or AD2, the standby pump will work as the standby/assist pump for the respective
feed pump.

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 Reactor 2 feed pump running with the Standby pump
chosen to assist it. As shown by the yellow indication on the push button.

Biomass Transfer

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 Dependant on the level of the Biomass in the AD reactors you may need to transfer biomass in or
out of the reactor. In order to start Extracting (Biomass to Biomass Buffer) or Feeding (Biomass to AD
Reactor) you must carry out the following on the DCS Graphics;

1. Select Mode – Extraction or Refeed, the selected mode is indicated in yellow.

2. Select Reactor – 1 or 2, the selected reactor is indicated in green.
3. Start the Sequence – use the Start Push button
4. The sequence will stop automatically or when the Stop push button is activated.
5. Once the Extraction or Refeed sequence has been carried out then the lines should be
flushed, this is the done by selected the required reactor and then pushing the start button.

Mode Selection

AD Selection

Start/Stop Feed or Extraction

Start/Stop Flushing Sequence

Sequence

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