QCA Systems Limited Operation Manual Ridley Terminals Canada In Central Office Prepared by: Wayne Leung Controls Specialist QCA Systems Limited Version: 0 Date: February 28, 2013
TABLE OF CONTENTS 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 May 8, 2009 Page 2 of 32
TABLE OF CONTENTS 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 May 8, 2009 Page 3 of 32
1.0 Introduction The purpose of this document is to provide an understanding and description of the operation of the 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. May 8, 2009 Page 4 of 32
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 May 8, 2009 Page 5 of 32
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 When Major navigation alarm navigation keys to button different is displays 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 Time and date display Button to quit the Factory Talk View Client application 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: May 8, 2009 Page 6 of 32
Buttons when pressed navigates to different equipment Button to close this Navigation Pane - 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 PLC May 8, 2009 Page 7 of 32
- 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. May 8, 2009 Page 8 of 32
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 Pressing the name box pops up a status window of equipment Alarm banner showing the most updated alarms Alarm acknowledge and reset button Colors of conveyors and gates shows the status of the equipment May 8, 2009 Page 9 of 32
3.2 Color Legend Status of the conveyors are displayed by different colors and operators may refresh their memory from the Color Legend bottom display. When pressed the following window will pop up: at the top right corner of the Overview 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. May 8, 2009 Page 10 of 32
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: Stacking arrow in red appears when in stack Bucket wheel shares mode the same color code as the conveyors Boom conveyor shares the same color code as the conveyors Route selected and running with this SR Reclaiming arrow in red appears when in reclaiming mode Through arrow in red appears when in through mode Production data : Tonnes per hour and total tonnes Slew Position and Traverse Position 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: May 8, 2009 Page 11 of 32
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: May 8, 2009 Page 12 of 32
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. 5 columns for each alarm message Scoll bar to view alarm down the list The Alarm Banner has the following columns: 3.4.1 Alarm Priority The alarm priority in the alarm banner has this symbol according to the severity levels: and it denotes the urgency of the event Severity levels: 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 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. May 8, 2009 Page 13 of 32
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. May 8, 2009 Page 14 of 32
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. Step 2: TT07 Gate Navigation window pops up Step 1: hit TT07 Step 3: Operator selects the gate he wants to view. 4.0 Major Equipment Status Conveyor status may be accessed by pressing the small window pops up on the left like the following: button on the Title Bar. A Conveyor status key when pressed will bring you to another selection window May 8, 2009 Page 15 of 32
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. May 8, 2009 Page 16 of 32
Pop up title bar with the title name of the pop up and a Close button to quit the pop up Route status pane Permissives pane Conveyor status pane Major Alarm status pane Other related alarm status pane Permissive status pane Start Permissive status pane Restart The Status pop up uses LEDs to summarize conditions, and light boxes to show individual element status. May 8, 2009 Page 17 of 32
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 May 8, 2009 Page 18 of 32
4. Grey / Yellow 5. Grey / Orange May 8, 2009 Page 19 of 32
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: Push button to navigate to the filtered alarm page for CV303 Chute gate The following pop up will be displayed: Red when the gate moves either forward or reverse direction Light boxes indicating overtravel Orange when overtravel, and Green for no overtravel Light box indicating Orange at gate Run Off position and Grey when not at Run Off Movement of the gate Green when active and Grey when not active Light boxes indicating Green at appropriate gate position and Grey when not at position Permissive start LED indicating Green for all conditions fulfilled and Grey when not permitted Position of the gate in degrees Individual permissive Green when fulfilled and Grey for not Push button to drill down to the Overload E3 Plus relay Light boxes indicating Green when route is selected and moving direction is confirmed May 8, 2009 Page 20 of 32
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 May 8, 2009 Page 21 of 32
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 May 8, 2009 Page 22 of 32
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 May 8, 2009 Page 23 of 32
4.4 Surge Bin Status The status of the Surge Bin may be reached by pressing the the Conveyor Navigation Pane and the following pop up will be shown: button in 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 May 8, 2009 Page 24 of 32
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. May 8, 2009 Page 25 of 32
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: May 8, 2009 Page 26 of 32
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 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 deselection request. The boundary of the button Green when that route has been selected and running, Grey when inactive 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. Route description in wordings Route number Boundary showing status of Route 5 May 8, 2009 Page 27 of 32
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 details diagrammatically highlighted in Green Route Select and Deselect buttons Route descriptive text May 8, 2009 Page 28 of 32
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: 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 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. May 8, 2009 Page 29 of 32
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. May 8, 2009 Page 30 of 32
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: Push button to quit this pop up Major status pane Date and time pane Push button to set new time and date 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. May 8, 2009 Page 31 of 32
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 the desired data to the PLC. button to send May 8, 2009 Page 32 of 32