balerjoe

Guys I know this can be done. What I'm trying to do is tie in the load in & out meters in the plant to a excel spreadsheet. This will give a a accurate count of incoming product and out going. In the plant as the machines do there processes they have meters I want to tie this in as well. This will give me accurate count of product coming off the machine. As well as give me some shrink numbers. Help with scheduling loads as well. Any help in this regard will be appreciated. Thanks

I believe we have professional on hand. Thanks

Whats the latest version out??? 6.2? 7.0

Wondering if any of you fine gentlemen have a HMI platform I could have. I thought maybe a Rsview 32 or wonderware. I am working on a project and don't have a one. I do have Rslogix 5000 & Emulate. I know this a tall order but you never know unless you ask. Thanks Joe

When is come to process controls. How makes the best programmers Mechanical Engineers or Electrical Engineers???? Just want to see what the Pros think.

Part 1 of my exercise is Overview of Project. Ok we are going to build a RO (Reverse Osmosis)Processing Milk Machine. This will be a single pass setup. The hard thing is we will be doing this under a cold process which raises the difficulty level. The objective is to take Raw milk extract water from it so it can be transported in high concentration. Raw milk coming from dairy not processed. When machine runs 80gpm goal with proper ratios. This machine will consist of 24 membrane vessels. Each vessel contains 4 membranes being connected by interconnectors. To maintain a proper setpoint ratio we need at least 400-600 psi. To accomplish this we will need 10hp motors and proper pumps on each vessel. Lets use 3phase 480 with VFD's for all motors. We need throttling valves on the back of each vessel. To ensure milk is kept below 45F the membrane vessels have cold water jackets to maintain temp. These will have to be controlled by valves and cold water press. Lets maintain 41F on temp. Hot water will need to routed to all vessels for the CIP process. Lets shoot for a temp machine max temp of 160 w/meduim pressure steam(160-180psi). We will need a balance tank to ensure no air in the process. Compressed air for all the air actuated valves on the machine. We will need to divert to drain on all poor quality product. Poor quality not having proper protein fat ratios. From a control stand point will need HMI showing all setpoints. where the milk will be stored is another project. So I keep this as simple as I can. Control wise we could anything from plc5 to controlnet. There are so many machines that support this should I spec all of these out as well? Heres my first of many post on this project. Help me out guys am I on the right path. Do I need to do a drawing?

That was the proposal for the simplified unit. Sorry I haven't moved forward on this. I have alot of projects at work I'm working on. When I can I will update this. Thanks Joe

I like to know the answer on this as well. I'm working on a project and this would be nice to do. Thanks Joe

In this project we are going to you a prefilter simply as a media to protect from bigger particles contaminating our membranes. Below is a PDF of what I will be using fh_1843_prefilters.pdf

Thanks everyone for your help. After studying them I fully understand what they do & how to use them.

I'm trying at this point to understand how sequencers work. I have Rslogix5000 & emulator. I've looked at several downloads on here but for some reason it just doesn't click. Since you guys seem to be one of the pro's on here can you expain them to me in laymans terms??? It's driving me crazy not understands them totally. Thanks Joe

ok making more sense. VALUE ARRAY SEQUENCER 0-31 MASK -1 DEST: DESTINATION 0-10 EACH ONE HAVING 32BITS CONTROL: CONTROL LENGTH: 8 POSITION: Now I put into the array what I want to see pass through. (e.g. 0001) In this case with the mask being -1 the one should pass. Now why on my Destination do I get 32 bits for each # in length? Shouldn't it just be 0 or 1??? Showing true or false? Because theres no way my array can match my destination. Destination is like 0-31 for each length or step. While the ARRAY is a single digit. I know this must be getting on you guys nerves but I love to ask questions.

twcontrol - Hey it won't let me open it says my version is too old 12.03.

Ok to make sure I know what going on I have attachment of the sample I made. As the sequencer begins to count in this case to 10. I set array to be true from 0-3. So on my destination I have used 2 of the statements that should be true. Are these statements true all time or are they like a one shot? destination[000].4 should be false all the time. During the count when I monitor destination for one second all is true then off then the ones I picked then various ones. Why???? They way I understood was one the length # matched the destination # the statement would be true. As long as the mask allowed it to pass. ( I hope I'm not confusing everyone). RSLogix_5000_Report_s_.pdf

Heres the final proposal. I'll work on the rest of this when I get alittle time. Sorry for the spelling errors I was in a hurry. PROPOSAL_FOR_A_SINGLE.doc

How about a pilot unit? It can just have 8 membrane vessels, a balance tank,shell & tube exchanger. This sounds a little easier. Lets shoot for this to simplify everything.

The only time that will be happen is when one thing is allowed to happen. If milk gets above 45 degrees F other than that lets assume it will be fine. I forgot to mention this machine will not pasteurise the milk. That will be a seperate process.

Heres my first of many flow charts. flowchart.doc

What needs to take place with the vessels is there will be two vessels per pump/motor. I'll explain more & why this is neccesary later. Thanks for the recommendations I'll do what I can to improve.

Here is a link to a PLC school. I'm wanting to dig a little deeper and get better. Check this link out and tell me if it's worth my time. I accidently post this in the AB thread as well. Sorry! Thanks Joe http://www.plctechnician.com/plc_cont.html

Good point I'll keep the CIP process out of this. Let me work on the P&ID list so I can get the programming end of things. I'll finish the drawing later. But I think from what was explained we have a general idea of how things work.

Heres a more accurate description. Nice format I'll keep this in mind. We will not be looking at steam temps & water. Just water These project could easily turn to be alot more than what I am trying to do. Will see as this moves forward how far I can go with it. I'm keeping that out of the scope of this project. PROPOSAL FOR A SINGLE-PASS REVERSE OSMOSIS (RO) MILK PROCESSING MACHINE Process Overview Milk will be brought from a silo to a balance tank. Then pumped into the machine using a 3 stage centrifical pump 50hp motor. This machine will process raw milk received by truck from the dairy and extract water from it resulting in a finished product which can be transported in high concentration. The machine will produce 80 gpm of concentrated milk product. Process Outline The machine will consist of 48 membrane vessels. Each vessel will contain 4 interconnected membranes. Maintaining a proper setpoint ratio will require a minimum differential pressure of 400-600 psi across each membrane. This pressure will be provided by a 10 hp motor and a centrifical pump for each vessel. A VFD (Variable Frequency Drive) will be used to control the speed of each motor. Throttling valves will be provided on the back of each vessel. There will be 4 stages of vessels with 2 vessels per stage. Each stage having 6 pumps & motors. Milk tempature will maintain 43 degrees F. Not exceeding 45 degrees F and will not drop below 37 degrees F. Each membrane vessel will be equipped with a cold water jacket. These jackets will be controlled by proportional valves which will regulate the flow of cold water. In the colder months milk will run through a shell & tube heat exchanger. This will ensure regardless of the season the machine can run in spec. Provisions for Clean In Place (CIP) Operations Hot water will be routed to all vessels for the CIP (Clean In Place) process. This will be supplied by the balance tank. Proper chemical mixture will be done by hand. The hot water requirements will be 88 gpm with a temperature range of 140 to 160 degrees F. A balance tank will be used to ensure that no air enters the process. System Control This process will be controlled by an Allen-Bradley PLC-5/20E processor. The program will be written using commonly accepted practices of ladder logic programming. Each instruction and rung will be documented with meaningful comments to ensure ease of troubleshooting and maintenance of the system. Operator’s Interface The machine will be provided with an Allen-Bradley PanelView terminal to allow for the equipment operator to monitor and control the system. Output Storage Storage and handling of the finished product is beyond the scope of this proposal. Handling of Poor Quality Product Poor quality product will be defined as product which does not have the proper ratios of protein to fat. Any poor quality product will be diverted to a wastewater drain. Other Required Facility Services The electrical service will be 3-phase 480 VAC. Compressed air will be required for the air actuated valves. Cold water will be a mixture of 70% water 30% gycol.

What do you mean? This is just a SIMPLE overview of a project Ron wanted me to do. All the controls will be discussed later. Thats where you along w/the pros on heres help will come in.

Do I get a degree from this project? J/K I'll see what I can do.

Alright here a little history on me. I work in a dairy plant. In this plant we use Allen Bradley Rslogix500 & 5000. We use Carlson HMI. Everything from devicenet to controlnet. I have read some of the books downloadable here on this site. I have rslogix 5000 & Emulator on my pc. No hmi platform on here yet. I've been playing w/it created a traffic light simulation. I 'm trying now to understand Sequencers. Also trying to pick up PID's well. I got it to work but I still don't understand them well. I can write logic ok but I want to be really good. Here at the plant we have one person who know controls but is not real willing to share. I work w/projects here at the plant. Being able to write my own code would be nice to save a few dollars on smaller projects. Being capable at controls gives me the ability to help w/reducing shrink which is king in this buisness. Understanding how to improve the process increase productivity. These are things that at the end of the day will put more money in my back pocket. I will be working on building new plants in the future. Being on the same level as a intergrator & programmer will be nice. Any help will be much appreciated. Thanks Joe