0 CJVP OperationManual

Operations
Manual
0213-10390387-5004
! WARNING!
Read and follow all safety precautions before working on this
equipment.
Read all safety precautions throughout this manual and on safety signs
attached to this equipment. Failure to follow all safety precautions could
result in death or serious injury.
Internal
Operations Manual
Copyright Information
Copyright 2015 Tetra Pak International SA. All rights reserved.

No part of this document may be reproduced or copied in any form or by any means without
written permission from Tetra Pak® Processing Systems AB.
Tetra Pak®, the Tetra Pak®house mark and the names of the Tetra Pak® products are registered
trademarks belonging to the Tetra Pak® Group.
This document was produced by:
Tetra Pak Processing Systems
Additional copies can be ordered from the nearest Tetra Pak® office. When ordering additional
copies, always provide the document number. This can be found in the project documentation. It
is also printed on the front cover and in the footer on each page of the manual.
Internal
1 Introduction
This manual is valid for:
BINH DUONG NUTIFOOD NUTRITION
FOOD JOINT STOCK COMPANY.
Lot E3-E4 My Phuoc Industrial Park Binh

2 Safety Precautions
Duong Province, Vietnam.
3 Start of System
4 General Layout and Tools
5 Window Structure
6 Production Control
7 Production support windows
8 Service Windows
9 Process Windows
10 Appendix
Issued by:
Tetra Pak Processing Systems
Internal
Operation Manual
Revision History
Rev Revision date
Issued by Reviewed by Approved by Comments
number (yyyyy/mm/dd)
0 2018/04/23 LT NH NH First Issue
Abbreviation & Definitions

Sr. no Terminology Description
1. TPM Tetra PlantMasterTM
2. OM Operation Manual
3. I/O Server Input-Output Server (i.e. Database server in this case)
4. UPS Uninterrupted Power Supply
5. PLC Programmable Logic controller
6. PC Personal computers (Operator stations in this case)
7. TCP-IP Transmission Control Protocol/Internet Protocol
8. Doc Document
9. S88 Batch Philosophy defined by ISA (Instrumentation systems and automation)
10. PID Proportional Integral and Derivative Controller
11. Ack Acknowledge
12. FQ Flow Totalizer
13. AI Analog Input
14. AO Analog Output
15. DI Digital Input
16. DO Digital Output
17. CMiS Control Module Information System
18. CM Control Module
19. IO or I/O Input – Output (Signal in this case)
20. CIP Cleaning In Place
Internal
Table of content
Contents
1 Introduction ............................................................................................................................................. 7
1.1 General ........................................................................................................................................ 8
1.2 Mouse Handling ........................................................................................................................... 8
1.3 Modules ....................................................................................................................................... 9
1.4 Document Information ................................................................................................................ 11
2 Safety Precautions ............................................................................................................................ 12
2.1 General ...................................................................................................................................... 13
2.2 Use of Hazard Information ......................................................................................................... 13
2.3 Warning Signs............................................................................................................................ 13
2.4 Electrical Cabinets ..................................................................................................................... 14
2.5 Chemical Products ..................................................................................................................... 15
2.6 Hot Surfaces .............................................................................................................................. 15
2.7 Hearing Protection ..................................................................................................................... 15
3 Start of System ................................................................................................................................. 16
3.1 On Start-up ..................................................................................................................................... 17
4 General Layout and ........................................................................................................................... 19
4.1 General ...................................................................................................................................... 20
5 Window Structure .............................................................................................................................. 23
5.1 General ...................................................................................................................................... 24
5.2 Window Layout .......................................................................................................................... 24
6 Production Control ............................................................................................................................ 26
6.1 General ...................................................................................................................................... 27
6.2 Log-in and Log-out ..................................................................................................................... 27
6.3 Plant Overview Window ............................................................................................................. 28
6.4 Process Cell Windows ............................................................................................................... 30
6.4.1 Process Cell General Status Information............................................................................. 32
6.4.2 Process Cell Window General Symbols .............................................................................. 33
6.5 Unit Faceplate ............................................................................................................................ 34
6.5.1 Function Manoeuvre ........................................................................................................... 34
6.5.2 Condition Window ............................................................................................................... 35
6.5.3 Production Menu ...................................................................................................................... 36
6.6 Process Cell and Menu Symbols................................................................................................ 38
6.6.1 General ............................................................................................................................... 38
6.6.2 Symbols and Icons ................................................................................................................... 38
6.7 PID Loop .................................................................................................................................... 39
7.2 Active Alarm Window ................................................................................................................. 42
Internal
8 Service Windows ................................................................................................................................... 44
8.3 Parameters ................................................................................................................................ 48
8.4 Control Module Information System (CMiS) ............................................................................... 63
9 Process Windows.............................................................................................................................. 55
9.1 General ...................................................................................................................................... 56
9.2 Recombination with Almix section ................................................................................................... 57
9.3 Milk Pasteurisation and Buffer Storage ........................................................................................... 59
9.4 Flash Cooling and Lactose Dosing.................................................................................................. 64
9.5 Crystallisation ................................................................................................................................. 69
10 Appendix ....................................................................................................................................... 71
10.1 General ...................................................................................................................................... 72
10.2 Button Bar .................................................................................................................................. 72
10.3 Tetra Pak Software –Symbols .................................................................................................... 73
Internal
1 Introduction
1 Introduction
7
1 Introduction
1.1 General
Operation Manual (OM) is a platform for process control, centralised
supervision and reports in liquid food production, developed by Tetra
Pak.
Operation Manual includes User Interface, giving the operator an
overview of production status and ongoing activities. The User
Interface provides effortless access to process information, such as
level, temperature, pressure, etc. User Interfaces are placed where
they are most efficiently utilised, normally in a control room or in the
process environment.
User Interfaces are delivered with pre-installed application programs.
The application requires license keys, which are included in the
delivery. These keys must be installed to be able to run the User
Interface. If a key is lost, Tetra Pak can replace it at the cost of a new
license.
Operation Manual also includes Process Controllers, which control
the process by activating the necessary valves and pumps, based on
operator commands and information from the process. The control is
done to ensure a safe and proper function of production and cleaning.
Interlocks prevent the operator from; for example, start cleaning when
production is running.
1.2 Mouse Handling

In this document the following terms are used to describe the
actions which operator can perform using mouse:
POINT To move the pointer on the screen until

it rests on the object you want to select.
DRAG To hold the left mouse button down
while moving the mouse. (On Pop-up
windows)
SELECT and CLICK Point at the object (unit) or function
button. Press and release the left mouse
button quickly. All objects and buttons,
possible to click on, display a frame
when you point at them.
In case of any issues with the screen, please contact Maintenance

personal or System Administrator.
8
1 Introduction
1.3 Modules
Operation Manual is a complete package inclusive of User interface,
PLC database and Logic and reporting package that Tetra Pak® calls
as Production Integrator.
Following software are used to develop each one:
• User Interface: Developed using TPOP HMI
• PLC program: Developed using Rockwell’s RSLogix5000
• Production Integrator: NOT HAVE
All software’s are delivered with pre-installed application programs
along with License keys. The application requires license keys, which
are purchased on the name of “BINH DUONG NUTIFOOD
NUTRITION FOOD JOINT STOCK COMPANY” and included in the
delivery. These keys must be installed for process system to run
smoothly.
The software keys are in the form of activation codes or CD’s and
need to be placed at safe place (with lock and key arrangement),
under dry atmosphere and at ambient temperatures. Once delivered
it is responsibility of BINH DUONG NUTIFOOD NUTRITION FOOD
JOINT STOCK COMPANY to take care of licensing keys.
However, if a key is lost, Tetra Pak® can replace it at the cost of a
new license.
1.3.1 User Interface
User interface allows operator to control and monitor various plant
operations. It gives an Overview of production status and ongoing
activities to operator. It provides effortless access to process
information, such as levels, temperatures, flow and pressures. User
Interfaces are placed where they are most efficiently utilised, normally
in a control room or in the process environment.
1.3.2 I/O-Server
An I/O-server holds the tag-database and handles communication
between user interfaces and process controllers.
1.3.3 Process Control

Process Controllers (PLC’s in this case) control the process by
activating the necessary valves and pumps, based on operator
commands and information from the process. The control is done to
ensure a safe and proper function of production and cleaning (limited
to scope as per contract documents). Interlocks prevent the operator
to start any process of activity through User Interface when
9
1 Introduction
it should not be started; for example, start cleaning when production
is running.
1.3.4 Network Switch

In order to establish communication between User Interface, PLC,
which works on TCP-IP protocol.
10
1 Introduction
1.4 Document Information

1.4.1 About this Operations Manual (OM)
The purpose of this Operations Manual is to provide the operators
with the necessary information on handling the Tetra Pak process
system. This manual enables system user to identify all functions and
features available in the system. This also enables operations
resources to understand symbols, terminologies and definitions to
operate plant using Tetra Pak process system.
It is important that you:
• Keep the manuals for the lifetime of the equipment.
• Pass the manuals on to any subsequent holder or user of the
equipment.
1.4.2 Product Documentation
The documentation for this equipment consists of:
• Operation Manual
• Maintenance Manual
1.4.3 Design Modifications
The information in this document is in accordance with the design of
the equipment at the time it was released by Tetra Pak®.
1.4.4 Further Copies
Additional copies can be ordered from the nearest Tetra Pak® service
station.
When ordering technical publications, always quote the document
number printed on the document.
1.4.5 Copyright2015
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without the written permission of
Tetra Pak Processing Systems.
11
12
2.1 General
To ensure maximum safety, always read the "Safety precautions"
pages before performing any work on the equipment.
2.2 Use of Hazard Information

Hazard information in this document has the following significance:
Failure to observe this information results in immediate danger of
life!
Failure to observe this information can result in personal injury!
Caution! Failure to observe this information can result in damage to or
destruction of the equipment!
2.3 Warning Signs

Enclosures, which do not clearly show that they contain electrical
devices, are marked with this sign showing a black lightning flash on
a yellow background within a black triangle.
13
2.4 Electrical Cabinets

2.4.1 Risk of Electro shock
The voltage inside electrical cabinets and computer equipment can
Caution! cause electroshock or serious injury.
Work inside the electrical cabinet must be performed by skilled or
instructed persons only.
Always make sure that the computer equipment and the electrical
cabinets are closed up during normal operation.
2.4.2 Process Control
The Tetra Pak process system controls the process. Any attempts to
Caution!
tamper with the system could cause the complete production to stop.
Many of the operations described in this manual may have a major
effect on your system. Therefore, use them with care.
2.4.3 Computer Virus
The spreading of computer viruses is an ever-growing problem. A
Caution!
computer virus infection in your system could make it completely
inoperative. Therefore, always take the following precautions:
• Do not use diskettes, external storage device on
Tetra Pak software machines and server.
• Do not install any programs in the computers and server.
• Do not connect the system to other computer networks.
• Do not update or change IP address and settings.
• Without proper training and / or authorization, please do not
exit any running application or restart any component of
Tetra Pak software.
14
2.4.4 Emergency Procedures
Electric power can be dangerous! Risk of electroshock! If an
accident happens, you must hurry! Immediately call for medical
attention!
Do like this:
• Cut the electrical power.
If you do not know where the switch is located, find out.
Or in exceptional cases like this:
• Get the accident victim away from electric contact!
Do not touch the victim with your bare hands - use some dry,
nonconductive material, such as a piece of clothing.
• If the victim is breathing but unconscious, place him in the
recovery position (prone on his side with his mouth and air
passage unobstructed).
• If the victim appears not to breath, immediately comment
artificial respiration. If you don’t know how to do it, try to find
someone who can.
• In case of cardiac arrest, give cardiac massage if you are
instructed in how to do.
2.5 Chemical Products

Risk of personal injury! Can be hazardous to health. Read warning
texts!
When handling cleaning solutions, carefully follow the warning texts
on the container labels.
Always use safety equipment according to the instructions on the
container labels.
For final handling of solutions, follow the instructions from the
supplier.
2.6 Hot Surfaces

Hot surfaces can cause serious injuries. Never run the equipment if
any safety covers are not fitted.
Pipes and heat exchangers may have hot surfaces. Do not remove
covers during normal operation.
2.7 Hearing Protection

Risk of impaired hearing! Use hearing protection to minimize the risk
of impaired hearing.
Always wear hearing protection while the machine is running.
15
3 Start of System
3 Start of System
16
3 Start of System
3.1 On Start-up
When the start-up of Tetra Pak process system user interface (the
Operator Station) is finished the Plant Overview Window is shown. By
click at a process cell the Process Cell Window is displayed. A
process cell is a logical group of units, equipment and control module
17
3 Start of System
Figure 1 Plant Overview window - Process.
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18
4 General Layout and

Tools
19
4.1 General
This section specifies various features, buttons and navigation tools
available on Main Process screen.
4.2 Layout
Below figure indicates the general layout of the system with proper
legends.
20
Button Bar
Note: All windows have the following layout and general tools.
Figure 2 General layout.
21
4.2.1 Alarm Bar

The alarm bar is shown above the button bar, displaying the latest
unacknowledged alarm. The alarm shows Time, Alarm description
and Area.
4.2.2 Button Bar
At the bottom of the screen you find the Button Bar. The Button Bar
has function buttons and link buttons.
The function buttons vary from plant to plant, depending on plant
features. However, there are some buttons which always is there.
Please see appendix for graphic presentation.
The link buttons are shortcuts to selected process and system
windows. The process windows, of course, vary from plant to plant.
Among the system windows you normally find the Maintenance
Window link button and some others.
To select a desired function or link, just click with the mouse on the
corresponding button.
4.2.3 Header
The header is placed on top of the screen and displays the window
name.
4.2.4 Logged on User
The name of the logged-on user is displayed to the left of the header
Please, see also chapter Login below.
4.2.5 Alarm List Button
This button navigates operator to central alarm list where all alarms
which are recorded by system are logged and can be acknowledged.
22
5 Window Structure
5 Window Structure
23
5 Window Structure
5.1 General
This section defines navigation and overall windows structure
available for operations.
5.2 Window Layout

The plant has mainly four areas of windows:
• Tetra Pak Software Production Control
• Tetra Pak Software Navigator
• Production Support
• Service
Each of the areas has a set of windows as shown below:
Tetra Pak software Production Control:

Process Cell
Index Level Detailed Level Object Level
Level
Plant Overview Pop-up Object

Process cell Process Unit
Window Info,
windows
One per site Parameters,
Window
Maintenance
Pop-up
Process cell 2 Manoeuvre
Window window (Unit)
Mode window
Tetra Pak software Production Integrator:
:
Production
Production User Admin
Tracking
CIP
Production Support Windows:
Parameter Alarm Trend

Windows Windows Windows
Service Windows:
Plant Communication
parameters info
Figure 3 Window Layout.
24
5 Window Structure
5.3 Window Navigation

Navigation between the various windows is primarily done through
the button bar, see above.
In addition to the button bar it is possible to navigate between
windows with buttons placed in the main pictures.
There are also “magnifying glasses” planted in the main pictures.
These are used to navigate down to the third level pictures.
25
26
6.1 General
The Production Control area is the normal operating area for the
Operator. This is where the process is monitored and functions are
started and stopped.
The plant is divided into sections called process cells, shown in
process cell windows. A process cell window displays the necessary
information to operate the related process.
To increase readability of a process cell window, some detail
information is hidden and appears only on operator’s request.
The operator executes his command through faceplates, which is
activated within the process cell window.
6.2 Log-in and Log-out

Access and User Rights
In order to prevent unauthorized use and allow authorisation to
Operators, Engineering and Administrative personnel, an Access and
User rights matrix is made for each user, specifying where and what
he/she is allowed to view and operate.
Every user has personal access and user rights. Available criteria are
User group, Node group (Computer) and Access area (Process area).
Depending on the user rights, different windows and functions will be
available.
Note: This Operation Manual is described having full access to
windows and functions.
The plant system administrator handles the user’s access and rights
from the Tetra Pak software Production Integrator system. For more
information see the Tetra Pak software Production Integrator Manual.
Login
In order to give the correct access and rights to the user, the user
must identify him by logging in to the system.
To log in press the button with the key sign in the button bar.
When the Login Window appears, the user can log in with the
operator station user rights belonging to that user.
To log in, in the Login Window
• Type your User name and press enter in the User name field.
• Type your Password and press enter in the Password field.
• Acknowledge by clicking button
27
Figure 4 Login Screen.

Logout
To logout press the button with the crossed key sign in the button bar.
When this button is pressed the OP- station will automatically

log-in as a Viewer, i.e. anyone can see the information on the screen,
but it is not possible to operate the plant.
The user needs to logout when leaving the Operator Station. If a user
leaves without logging out, the system automatically logs him out after
some time.
6.3 Plant Overview Window

When start-up is finished the Plant Overview window is shown. It
shows all process areas in the plant.
28
Figure 5 Start-up Screen.
Doc. No. 0213-10390387-5004
29
Areas with links to Process Cell Windows are shown with a raised
frame and are clickable. When you click on them, the corresponding
process cell window appears.
6.4 Process Cell Windows

A process cell window is designed for the Operator to Control and
Supervise production.
Doc. No. 0213-10390387-5004
30
Figure 6 Process Cell Window.
31
6.4.1 Process Cell General Status Information

A process cell window contains status indication. Following
indications are general in all process cell windows.
Status Indication
Actual Flow 0 l/h
Actual Temperature 0.0 °C
Actual Conductivity 0.0 mS (if any)
Actual Pressure 0.0 Bar
Actual Level 0.0 Kg
Table 1 Process parameters and units
32
6.4.2 Process Cell Window General Symbols
The symbols below are used within the process cells.
Description Symbol Description Symbol
Production Tetra
Line Almix
HW Add Tank
Figure 7 Process Cell – General Symbols
33
6.5 Unit Faceplate

The unit faceplates are used as a dialogue with the operator, and
described below.
It is possible to move around the faceplate on the screen. Point at the
Title bar and drag. When you change to another process cell window,
the faceplates will close automatically.
6.5.1 Function Manoeuvre
The unit faceplate is called up by clicking on the Tank unit symbol in
the process cell window.
Title Bar
Function button
Condition information
Setting Time
Figure 8 Function Manoeuvre – Part 1

The faceplate consists of a number of functions related to the unit.
From here it is possible to control and view status of the functions.
It is possible to select a function button when it is not dimmed. When
clicking the function button, the function text becomes blue. One or
several command buttons can now be used to operate the selected
function by clicking it.
The condition information button to the right of the function button will
become blue if any condition is active. Please see next section for
more information about conditions.
By clicking at the parameter button, the parameter related to the
function will be displayed in a parameter faceplate.
34
6.5.2 Condition Window

When clicking on the condition information button, the condition
window appears.
This window represents the conditions which prevent the function to
be manoeuvred.
There are two types of conditions:
• Interlock and
• Running Fault.
The Interlocks are only valid when the function is not running. The
Running faults are always valid. The active Interlocks and Running
faults are marked in red.
The checkbox at each condition is the possible to bypass a condition.
Normally only a few conditions are possible to bypass. By clicking the
enabled check box the condition is bypassed. When the phase is
started the bypass is reset.
A condition may be a group several errors.
At the bottom of the condition window the condition which caused the
function to go to held state is displayed.
If the function is not running the window shows both Interlock and
Running Fault in the list. See example below regarding Production
phase of Flash Cooler function.
Figure 9 Condition Window

In this case the phase is in held, therefore only the Running Faults are shown.
35
In the example 4 conditions are Red, to give the operator an indication which
condition caused the function go to held.
6.5.3 Production Menu
When clicking a production line symbol, you get a faceplate similar to the one below. It
is used to select Source and a Destination tanks for the production line and manoeuvre the
actual line functions.
Figure 10 Production Faceplate – Part 1

In this faceplate it is possible to select which material to produce and the amount. Next
step is to select which source and destination tank to use, by clicking the function button for
each tank. When selections are made click the production function button and start the
function with the command buttons. It is also possible to select more source and destination
tanks in queue, which will be used for example when one source tank becomes empty etc.
36
When Source tank is emptying, emptying symbol will be a triangle pointing down
Similarly, at destination side triangle will be indicated with direction pointing up.
Description Symbol
Selected source tank
Running source tank
Source tank in held
Figure 11 Symbols on Production Faceplate
37
6.6 Process Cell and Menu Symbols

6.6.1 General
This section provides details about meaning and colour scheme for
each symbol used.
• All symbols on a menu may be dimmed meaning that they
will not be allowed to operate.
• Green icons indicate running status.
• Yellow icons indicate halted status.

6.6.2 Symbols and Icons
See appendix for symbols
38
6.7 PID Loop

PID control window show actual inputs and outputs from PID Loop.
The PID Trend is a real-time trend. It starts the trend when the PID
Control window opens. Recorded information is lost when the PID
control window is closed.
Real Time Trend Graph
Setpoint
Input value Output value
Figure 12 Symbols on Production faceplate
The setpoint and output value can be set in manual mode by clicking
the manual symbol(s). Once in manual mode it is possible to set a
value in the input filed(s).
By clicking the parameter button, the faceplate for PID parameters
appears. In this faceplate the actual PID set is displayed at the top
and below are three sets of parameters which can be used for
different process situations. The selection is made by the automation
system.
39
Active
parameter set
Figure 13 Symbols on Production faceplate
40
7 Production support
windows
41
7.1 General
Support windows are used to find reasons of production
disturbance, tools to make evaluation and optimisation.
7.2 Active Alarm Window

By clicking on the Alarm window symbol in the Button Bar, one
will reach the Active Alarm Window. The alarm list describes the
plants active alarms. If there are several active alarms it is possible
to filter alarms by Process Area.
There is tree different Alarm Acknowledge buttons. “Ack Current”-
Reset the current alarm, “Ack Page”- Reset the alarms on the page
and “Ack All”- Reset all alarms.
Note! When logged in as an Operator, alarms can only be
acknowledged when an area selection is done.
42
Alarm Acknowledge
Figure 14 Active Alarms Button
Doc. No. 0213-10390387-5004
43
8 Service Windows
8 Service Windows
44
8 Service Windows
8.1 General
The Service window provides vital information on the control system’s
condition, and supply maintenance engineer with powerful tools to
change various settings while the system is controlling the production.
Every change needs to be done with care since the system may not
operate properly after a change.
By clicking in the bottom bar the general maintenance window

opens.
45
8 Service Windows
Figure 15 Service Windows
46
8 Service Windows
8.2 Equipment, Cleaning and Sterile Status
CIP Button Step Number
Figure 16 CIP Status

By clicking on this button, the equipment and Line clean status is
shown/ not shown in the process picture and detail CIP circuit.
• Step Number
On the window, the step number text is shown/ not shown in the
process picture.
47
8 Service Windows
8.3 Parameters
Plant parameters are available in order to control the process. These
can be changed either to make a change of a process function or to
make the process work more efficiently.
Every change needs to be done with care since the system may not
operate properly after a change.
Since there are thousands of parameters used in a control system,
use below described filtering system to monitor and change
parameters.
When selecting parameter, a parameter window opens.
48
8 Service Windows
Function(s) Process area(s)

Object(s) Parameters
Figure 17 Plant Parameters Window
Doc. No. 0213-10390387-5004 49
8 Service Windows
• Area
Select area to see the available units in that specific area.
• Object
Select object to view its function with parameters.
• Function
Select function to show related parameters (Object parameter /
Register selection).
8.4 Control Module Information System (CMiS)

The control module faceplate is accessible from the detail process
windows.
• Control Module Faceplate
The control module faceplates are built in a similar way. Status of the
control module is shown and there are possibilities control it in
different modes, which are explained below
Unit Name
.
Figure 18 Faceplate
63
8 Service Windows
The faceplate describes the present status of a control module. Texts
which are dimmed are not relevant on current control module.
The first statuses are named auto and is displaying if the control
system is activating the control module.
The next part is Run, Reverse statuses and this is the actual signal to
the IO of the control module. If the control module is in manual mode
and activated manually the status Run will be green but the status
Run auto might not be green because the control system is not
activating the control module. This information is useful when
switching back to automatic mode to know if the control module will
be activated or not when it is placed in automatic mode again.
By clicking the manual symbol, it is possible to control the control
module from the faceplate. This is can be used to manually control
the object e.g. at maintenance. In manual mode you override the
control system.
Use this function with caution!
Alarm Suppress is used to by-pass an incorrect feedback signal from

a control module. When alarm masking is selected, the alarm from
the object is ignored.
Simulation is used to simulate feedback signal from an object. When

simulation is selected, the appropriate feedback signals will be
simulated by the control system.
Note: As Manual mode, Alarm Suppress and Simulation can be done

on a control module at the same time as it is in production, the control
system will have no control over the production.
51
8 Service Windows
Valve Faceplate
Figure 19 Valve Faceplate

By clicking the manual symbol, it is possible to control the control
module from the face plate This is can be used to manually control
the object e.g. at maintenance. In manual mode you override the
control system.
Alarm Suppress is used to by-pass an incorrect feedback signal from

a control module. When alarm masking is selected, the alarm from
the object is ignored.
Simulation is used to simulate feedback signal from an object. When

simulation is selected, the appropriate feedback signals will be
simulated by the control system.
Note: As Manual mode, Alarm Suppress and Simulation can be done
on a control module at the same time as it is in production, the control
system will have no control over the production.
52
8 Service Windows
• Digital Input Object Window
Example of a digital input control module in manual mode and
manually activated.
CM Tag with Area
Manual and automatic buttons
Undo from window
Figure 20 Digital Input Faceplate

The IO value is the input from the IO. The Value Auto is the value
which will be used by the control system when the control module is
in automatic mode.
Alarm Suppress is used to by-pass a hard ware fault signal from the
control module. When alarm masking is selected, the alarm from the
object is ignored.
53
8 Service Windows
• Analogue Input Faceplate
Example of an Analog input control module in manual mode and a
manual value set (56).
Figure 21 Analog Input Faceplate

The EU value Auto is the value which will be used by the control
system when the control module is in automatic mode. In this current
case the control system is using the value 56.00 as long as the control
module is in manual mode and when it set to automatic mode is will
receive value 0.00
Alarm Suppress is used to by-pass a hardware fault signal from the
control module. When alarm masking is selected, the alarm from the
object is ignored.
54
9 Process Windows
9 Process Windows
55
9 Process Windows
9.1 General
Below follow pictures of the Process Cell Windows. Their names are
the same as indicated on the process cell symbols on the overview
picture.
56
9 Process Windows
9.2 Recombination with Almix section
Figure 22 Recombination (Detail View)
57
9 Process Windows
The Process
In this section, water is heated and filled to a pre-set volume into one
of the Recombination tanks. When the Recombination tank is filled to
20 % of full volume, the mixing circulation can start.
When product in Recombination tank is circulated over the Vacuum
mixer, Milk Powder, Sugar (added through tipping station), Stabilisers
(added through funnel) and Palm Oil (added through overhead
Batching tank) will be added into mixer.
When the mixture is ready, it is recommended that the milk mix is
stored for 20 minutes but not longer than 2 hours before further
processing.
The transfers, mixing is initiated from a local panel. The product
destination tank is selected from the HMI or at a local panel.
A milk mixing tank cannot be filled and emptied at the same time,
except in the circulation loop.
58
9 Process Windows
9.3 Milk Pasteurisation and Buffer Storage
Figure 23 Milk Pasteurisation and Buffer Storage

59
9 Process Windows
60
9 Process Windows
Figure 24 Milk Pasteurisation and Buffer Storage (Detail View)
61
9 Process Windows
The Process
Recombined milk enters the milk pasteuriser, where the milk is
pasteurised, homogenised to require for the fat content of the milk.
The milk is cooled with suitable temperature and fed to the milk
storage tanks (buffer Tank).
The main functions of the pasteuriser, i.e. start, stop, CIP, and
sterilisation, are controlled from the Local panel.
On the local panel of the pasteuriser detailed pictures and the status
of the valves are displayed, valves may be controlled and recipes are
created
Pasteurisation Destination
Source
Homogenisation Pasteurised Milk
Recombined
Milk Storage Storage
Figure 25 Pasteurisation
Some of the phases run on the pasteurizer are:
Water Circulation
This phase is not started by operator. The control system will enter
water circulation phase as a result of the control and completion of
another phase, for example sterilization or production. The
pasteurizer stays in water circulation until the operator starts
production, CIP or finalizes the water circulation. If finalized by
operator, the phase transits into the Shutdown phase wherein the unit
is cooled down before being drained or going into idle.
Product Circulation
This phase is started by production unit. The control system will enter
the product circulation status as a result of the control of another
phase, for example production. The pasteurizer stays in product
circulation until the operator starts production, CIP, Shutdown. When
Product Circulation Max Time elapses, Operator has the option to
RESTART Production or go to Shut Down.
Production
Milk enters the balance tank of the pasteuriser and purges the water
and mix phase to drain. When the pasteuriser is filled with milk it is
ready for production.
From the balance tank the milk is pumped to a heat regenerative
section of the plate heat exchanger, where it is heated up to
homogenised temperature. The milk is homogenised and heated to
pasteurisation temperature in a heating section by hot water
generated by steam in a hot water circuit. After holding, the milk is re-
generatively cooled by water in hot water loop, and final cooling takes
place in a cooling section of the plate heat exchanger by means of
62
9 Process Windows
tower water.
The pasteuriser is emptied by purging the milk with water into the
selected pasteurised milk tank. The mix phase of water and milk is
diverted to drain.
The pasteuriser re-circulates in the following cases:
Pasteurisation temperature too low
Low level in balance tank
Pump or valve fault
Source or destination tank not selected
By operator command
Shutdown
This function is selected by Operator / Production Unit. This is a
systematic Shutdown of the unit where in all the product is transferred
to selected destination by flushing and the unit is cooled down below
cooling limit before draining.
For all Running Faults, system goes to hold for a defined time limit
after which the phase will abort. During the Hold Time the operator
can choose to restart or abort.
63
9 Process Windows
9.4 Flash Cooling and Lactose Dosing
Figure 26 Flash Cooling

64
9 Process Windows
65
9 Process Windows
Figure 27 Flash Cooling and Lactose Dosing (Detail View)
66
9 Process Windows
The Process
Flash cooler is used in this process. To bring down temperature of
product at the same time increasing product’s total solids
approximately by 3%
The overall process flow can be described as below
Figure 28 Flash Cooling
Flash cooling
In order to bring the RSCM concentrate up to its final state the product
needs to be cooled down to around ambient temperature. Due to the
high total solids of the product, the product has a high viscosity.
During cooling the viscosity will strongly rise. For that reason, the
quick flash cooling principle equipped with positive, lobe, pumps is
required.
Lactose dosing
To stimulate a fine crystallization of sugar, extra seeding of lactose is
foreseen. To be flexible in the process, the lactose seeding can be
done in between the flash vessels or after the second flash vessel in
the final RSCM concentrate. Selection of dosing position can be done
with sanitary flow plates equipped with proximity switches.
TVR
The vapours of the 2nd flash vessel are discharged over a steam
driven vapour recompressed. Herewith a very low vacuum can be
realized and with that the required end temperature of the RSCM
liquid.
67
9 Process Windows
Condensation
Vapours from the 1st and 2nd flash cooler are led to the condenser,
condensation takes place by means of cooling water.
All the condensate is pumped out with a centrifugal pump.
Venting
The condenser is provided with a vent line. These venting will remove
the non-condensable gasses and the leakage air, if any. From the
vent line these gasses are discharged by a liquid ring vacuum pump.
Figure 29 Lactose Seeding (Detail View)
68
9 Process Windows
9.5 Crystallisation
Start-up of Crystallisation tanks
The crystallisation tanks are first disinfected by steam of 95°C for a time
of 15 minutes. After disinfection these tanks is ready to be filled with
product.
Production
SCM based milk, is fed to crystallisation tanks. The total solid of product
is adjusted by pasteurised process water.
When a tank is filled with SCM based milk at crystallisation temperature,
it is crystallised during approx. 4-6 hours.
In the crystallisation tanks, the agitator runs for a few minutes to mix well
the lactose into the milk. The crystallisation of the SCM milk will start.
A sanitary air low overpressure system is maintained inside the
inoculation tanks, preventing air contamination from entering and secure
quality
Figure 30 Crystallisation (Detail View)
69
9 Process Windows
Process
Process water enters the plate heat exchanger where the process
water is pasteurised.
In the pasteuriser the process water is heated to 90-95°C and
cooled to 20-60°C by ice water
The main functions of the process water pasteuriser, start, stop, and
controlled from the local panel.
Crystallisation tanks are selected from the local panel.
Overall process can be described as follows
Figure 31 Standardization Water System Process
70
10 Appendix
10 Appendix
71
10 Appendix
10.1 General
The Purpose of this section is to provide legends for all buttons and
symbols as ready reference.
10.2 Button Bar

The following buttons on the button bar take you to a full-size window.
The names in brackets are shortcut keys taking you to the same
window
Description Button Description Button

Cleaning CIP
Plant overview
Sub Area Previous Window
Log out
Calculator
Print Faceplate
Log in Batch viewer
Service
Alarms
Figure 32 Legends – Button Bar
72
10 Appendix
10.3 Tetra Pak Software –Symbols

Below follows a list of symbols and icons, located along or nearby a
unit or on a menu. The symbols and icons are used to indicate any
selected functions.
Status Symbol Status Symbol
Abort Air filter sterilized
Agitation Check
Circulation with CIP Cleaned

Product
Cooling Circulation with
Water
Drain Emptying
Transport In
Picture
Emptying Finished
Filling Filling Transport In

Picture
Finalize Go step - Manual

Stepping
Guide Heating
Help Login Logout
Level Switch High Level Switch

Medium
73
10 Appendix
Level Switch Low Mixing
Manual Add Maintenance
Navigate to Alarm Navigate to Trend

List
Navigate to Navigate to Filling
Fermentation
Navigate to Navigate to CIP

Overview
Manual mode Automatic mode
Open PID Go to navigator
Process Value Previous picture

Out
Production Print
Quality approval ProcessvalueIn
Start Separator Pump
Start Restart
Sterilising / Start Shutdown Pasteuri

water ser
TP Logo Set-point
74
10 Appendix
Water Steam Filter
Additional Control Magnifying glass

Window
Figure 33 Legends –Symbols
75

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Operations

Copyright 2015 Tetra Pak International SA. All rights reserved.

Tetra Pak Processing Systems

Lot E3-E4 My Phuoc Industrial Park Binh

Tetra Pak Processing Systems

Abbreviation & Definitions

1.2 Mouse Handling

POINT To move the pointer on the screen until

In case of any issues with the screen, please contact Maintenance

1.3.3 Process Control

1.3.4 Network Switch

1.4 Document Information

2.2 Use of Hazard Information

2.3 Warning Signs

2.4 Electrical Cabinets

2.5 Chemical Products

2.6 Hot Surfaces

2.7 Hearing Protection

Figure 1 Plant Overview window - Process.

4 General Layout and

Figure 2 General layout.

4.2.1 Alarm Bar

5.2 Window Layout

Tetra Pak software Production Control:

Plant Overview Pop-up Object

Tetra Pak software Production Integrator:

Production Support Windows:

Parameter Alarm Trend

Figure 3 Window Layout.

5.3 Window Navigation

6.2 Log-in and Log-out

• Acknowledge by clicking button

Figure 4 Login Screen.

When this button is pressed the OP- station will automatically

6.3 Plant Overview Window

Figure 5 Start-up Screen.

Doc. No. 0213-10390387-5004

6.4 Process Cell Windows

Doc. No. 0213-10390387-5004

Figure 6 Process Cell Window.

6.4.1 Process Cell General Status Information

Description Symbol Description Symbol

Figure 7 Process Cell – General Symbols

6.5 Unit Faceplate

Figure 8 Function Manoeuvre – Part 1

6.5.2 Condition Window

Figure 9 Condition Window

Figure 10 Production Faceplate – Part 1

Selected source tank

Running source tank

Source tank in held

Figure 11 Symbols on Production Faceplate

6.6 Process Cell and Menu Symbols

• Green icons indicate running status.

• Yellow icons indicate halted status.

6.7 PID Loop

Real Time Trend Graph

Input value Output value

Figure 12 Symbols on Production faceplate

7.2 Active Alarm Window

Doc. No. 0213-10390387-5004

By clicking in the bottom bar the general maintenance window

Figure 15 Service Windows