J.21039 - UNIOLEO - CCS SCTU+C+TPCP For Customer

CCS-21039-126 rev.
012
PT UNILEVER OLEOCHEMICAL (UNIOLEO)

Sei Mangkei - Indonesia
CONTINUOUS FATTY ACIDS / NEUTRAL OILS SAPONIFICATION

AND
DRYING PLANT
SCTU+C 15000 KG/H
PNEUMATIC TRANSPORT PLANT
TPCP 15000 KG/H
INTERLOCK AND SEQUENCES LIST
2 18-11-2022 2nd revision (after FAT) M.G.Bressan

1 22-03-2022 1st revision M.G.Bressan
0 11-02-2022 1st issue M.G.Bressan
Rev. Issued on Description Name Signat. Name Signat.
Issued By Checked By
We reserve the ownership under the law of this document with prohibition of even partial reproduction and to make it
known to third persons without written authorization
1
SUMMARY
SUMMARY.........................................................................................................................................2
1 CONTROL LOOPS OF PROCESS VARIABLES..................................................................4
2 FEED FORWARD CONTROLS.............................................................................................8
3 MONITORING OF PROCESS VARIABLES........................................................................9
4 OTHER SIGNALS.................................................................................................................12
4.1 Motors................................................................................................................................17
5 VALVES FAILURE..............................................................................................................19
5.1 Shut-off valves (AV)..........................................................................................................19
5.2 Control valves (FV, PV, TV, LV)......................................................................................20
5.3 Electrovalves (XY).............................................................................................................21
5.4 Diverting valves (DV)........................................................................................................21
5.5 Throttle valves (VF)...........................................................................................................22
6 CALCULATIONS.................................................................................................................23
6.1 Caustic soda solution concentration calculation for FE/FIT-126.2 and brine concentration
calculation for FE/FIT-126.4..........................................................................................................23
6.2 Calculation for level controllers.........................................................................................25
7 INTERLOCKS.......................................................................................................................27
8 SEQUENCES.........................................................................................................................49
8.1 Pump P-1042.01 start-up....................................................................................................49
8.2 Pump P-1042.01 shut-down...............................................................................................49
8.3 EDTA automatic valves.....................................................................................................49
8.4 Glycerine automatic valves................................................................................................50
8.5 Pump P-1172.08 start-up....................................................................................................50
8.6 Pump P-1172.08 shut-down...............................................................................................51
8.7 EHDP automatic valves......................................................................................................51
8.8 Slop kettles PS-1242.03A/B automatic valves...................................................................51
8.9 F.A. / N.O. blend feed tanks D-1262.01A/B automatic valves..........................................52
8.10 F.A. / N.O. blend automatic valves....................................................................................52
8.11 Pump P-1262.02 start-up....................................................................................................53
8.12 Pump P-1262.02 shut-down...............................................................................................53
8.13 Pump P-1262.04 start-up....................................................................................................53
8.14 Pump P-1262.04 shut-down...............................................................................................53
8.15 Pump P-1262.20 start-up....................................................................................................54
2
8.16 Pump P-1262.20 shut-down...............................................................................................54
8.17 Turbomixer R-2012.01 start-up..........................................................................................54
8.18 Turbomixer R-2012.01 shut-down.....................................................................................54
8.19 Dryer automatic valves.......................................................................................................55
8.20 Water dosing to kettles PS-1242.03A/B.............................................................................55
8.21 Idle for reactor....................................................................................................................59
8.22 Saponification stand-by......................................................................................................62
8.23 Reactor feeding...................................................................................................................67
8.24 Vacuum chamber feeding...................................................................................................69
8.25 Additives feeding...............................................................................................................71
8.26 Soap pipes cleaning............................................................................................................72
8.27 Pneumatic transport............................................................................................................73
8.28 Silo bottom fluidization......................................................................................................88
9 MASS FLOW TOTALIZERS................................................................................................93
9.1 Raw materials totalizers.....................................................................................................93
9.2 Utilities totalizers...............................................................................................................94
10 SCHEDULED MAINTENANCE..........................................................................................96
11 PRODUCTION RECIPE AND PRODUCTION RATE VARIATION................................97
11.1 Recipe.................................................................................................................................97
11.2 Production rate...................................................................................................................97
3
1 CONTROL LOOPS OF PROCESS VARIABLES
All the PID (Proportional–Integral–Derivative) control loops will have the possibility to set an
alarm for
 very high alarm (HH) (without an intervention timer for delay),
 high alarm (H) (with an intervention timer for delay),
 low alarm (L) (with an intervention timer for delay),
 very low alarm (LL) (without an intervention timer for delay).
This feature will be completed with an adjustable intervention timer (only for H and L).
Exception is made for mass flow controls which will be developed as relative deviations (alarms
(%) – see note 29 for details).
The alarms for each loop can be enabled / disabled with a button (ON / OFF).
Every control loop will foresee:
 N.1 AI (Analog Input) or N.1 DI (Digital Input) from process transmitter,
 N.1 AO (Analog Output) for process controlling actuator (inverter or control valve or other
device).
Every control loop can be managed in automatic or in manual1:
 automatic – set point can be modified by operator and automatic control (SP vs PV) is
activated,
 manual – valve stroke (%) or motor speed (%) can be modified by operator and automatic
control (SP vs PV) is disabled.
Set point
Tag Number Description Loop input Output to Functions
input from
EDTA to reactor
Recipe or Deviation alarms (%)
FICQ-104.1 R-1262.02 FE/FIT-104.1 FZ-104.101
keyboard Totalizer
mass flow control
Glycerine to dryer Recipe or Deviation alarms (%)
FICQ-117.6 FE/FIT-117.6 FZ-117.106
mass flow control keyboard Totalizer
EHDP to reactor
FICQ-117.8 R-1262.02 FE/FIT-117.8 FZ-117.108
keyboard Totalizer
mass flow control
FICQ-124.3 Soap to reactor FE/FIT-124.3 Keyboard2 FZ-124.103A Deviation alarms (%)
R-1262.02 and Totalizer
4
Set point
input from
mass flow control FZ-124.103B
F.A. / N.O. blend to
FICQ-126.1A reactor R-1262.02 FE/FIT-126.1A FV-126.1A
keyboard Totalizer
mass flow control
Caustic soda
solution to reactor Recipe or Deviation alarms (%)
FICQ-126.2 FE/FIT -126.23 FV-126.2
R-1262.02 keyboard Totalizer
mass flow control
Process water to
FICQ-126.3 reactor R-1262.02 FE/FIT -126.3 FV-126.3
keyboard Totalizer
mass flow control
Brine to reactor
FICQ-126.4 R-1262.02 FE/FIT-126.44 FV-126.4
keyboard Totalizer
mass flow control
PIT-126.1A and
F.A. / N.O. blend PIT- 126.11A via
LIC-126.1A5 tank D-1262.01A software Keyboard LV-126.21A Alarms
level control calculation (P
 XT-126.1A)
PIT-126.1B and
F.A. / N.O. blend PIT- 126.11B via
LIC-126.1B5 tank D-1262.01B software Keyboard LV-126.21B Alarms
 XT-126.1B)
Caustic soda
solution tank
LIC-126.2 LIT-126.2 Keyboard LV-126.22 Alarms
D-1262.02
level control
Process water tank
LIC-126.3 D-1262.03 LIT-126.3 Keyboard LV-126.23 Alarms
level control
LIC-206.15 Semi-barometric PIT-206.1A and Keyboard LV-206.1 Alarms
5
Set point
input from
PIT- 206.1B via
C-2062.03 water software
 XT-206.1)
Reactor R-1262.02
PIC-126.10 PIT-126.10 Keyboard PV-126.10 Alarms6
pressure control
Soap to atomizer
PIC-204.10 SD-2042.01 PIT-204.10 Keyboard PV-204.10 Alarms
pressure control
Atomizer
SD-2042.01
PIC-206.11 PIT-206.11 Keyboard PV-206.11 Alarms
residual pressure
control
Glycerine tank
TIC-117.6 D-1172.06 TE/TT-117.6 Keyboard TV-117.6 Alarms
temperature control
Kettle PS-1242.03A
TIC-124.3A TE/TT-124.3A Keyboard TV-124.3A Alarms
temperature control
Kettle PS-1242.03B
TIC-124.3B TE/TT-124.3B Keyboard TV-124.3B Alarms
temperature control
F.A. / N.O. blend
TIC-126.1A tank D-1262.01A TE/TT-126.1A Keyboard TV-126.12A Alarms
temperature control
F.A. / N.O. blend
TIC-126.1B tank D-1262.01A TE/TT-126.1B Keyboard TV-126.12B Alarms
temperature control
HE E-1262.01
TIC-126.5 TE/TT-126.5 Keyboard TV-126.5 Alarms
temperature control
HE E-1262.02
TIC-126.6 TE/TT-126.6 Keyboard TV-126.6 Alarms
temperature control
Reactor R-1262.02
TIC-126.9 TE/TT-126.9 Keyboard TV-126.9 Alarms7
temperature control
6
2 FEED FORWARD CONTROLS
Every feed forward control manages one AO (Analog Output) for process actuator.
Tag Number Description Input from Output to Functions
Recipe or
EDTA pump P-1042.01 motor
HIC-104.101 keyboard or FZ-104.101 Speed variation
speed adjustment
local
Recipe or
Glycerine pump P-1172.06
motor speed adjustment
local
Recipe or
EHDP pump P-1172.08 motor
speed adjustment
local
Slop soap pump P-1242.03A Keyboard or
HIC-124.103A FZ-124.103A Speed variation
motor speed adjustment local
Slop soap pump P-1242.03B Keyboard or
HIC-124.103B FZ-124.103B Speed variation
Slop kettle PS-1242.03A motor Keyboard or
HIC-124.104A FZ-124.104A Speed variation
speed adjustment local
Slop kettle PS-1242.03B motor Keyboard or
HIC-124.104B FZ-124.104B Speed variation
speed adjustment local
Plodder PL-2042.01
Keyboard or
HIC-204.134 preliminary motor speed FZ-204.134 Speed variation
local
adjustment
Plodder PL-2042.01 final Keyboard or
HIC-204.135 FZ-204.135 Speed variation
Blower B-2502.01 speed Keyboard or
HIC-250.101 FZ-250.101 Speed variation
adjustment local
7
3 MONITORING OF PROCESS VARIABLES
Every process variable transmitter manages one AI (Analog Input) from process transmitter.
All transmitter values can be seen on PC screen.
Transmitters have the following functions:
 indication (I),
 very high alarm (HH) (without any intervention timer for delay),
 high alarm (H) (with an intervention timer for delay),
 low alarm (L) (with an intervention timer for delay),
 very low alarm (LL) (without any intervention timer for delay).
This feature will be completed with an adjustable intervention timer (only for H and L).
Tag number Description Input from

Inverter of
JI-124.104A Soap kettle PS-1242.03A stirrer torque
PS-1242.03A
Inverter of
JI-124.104A Soap kettle PS-1242.03B stirrer torque
PS-1242.03B
TI-126.23 Caustic soda solution to reactor R-1262.02 temperature TIT-126.2
DI-126.23 Caustic soda solution to reactor R-1262.02 density DIT-126.2
TI-126.44 Brine to reactor R-1262.02 temperature TIT-126.4
DI-126.44 Brine to reactor R-1262.02 density DIT-126.4
Inverter of P-1262.20
SI-126.120 Soap recycle pump P-1262.20 speed (RPM)
(PROFINET)
Inverter of P-1262.20
II-126.120 Soap recycle pump P-1262.20 absorbed current (Ampere)
(PROFINET)
TI-126.7 Soap recycle pump P-1262.20 outlet temperature TE/TT-126.7
FIQ-120.3A Instrument air flow and totalizer FE/FIT-120.3A
PI-120.3A Instrument air pressure PIT-120.3A
FIQ-120.3B Compressed air flow and totalizer FE/FIT-120.3 AB
PI-120.3B Compressed air pressure PIT-120.3AB
FIQ-120.7 Softened water flow and totalizer FE/FIT-120.7
PI-120.8 Softened water for mechanical seals pressure PIT-120.8
FIQ-249.1 Chilled water flow and totalizer FE/FIT-249.1
TI-249.1 Chilled water temperature TE/TT-249.1
8
PI-249.1 Chilled water pressure PIT-249.1
PI-120.1 Steam at 15 ÷ 16 barg pressure PIT-120.1
PI-120.2 Steam at 2 barg pressure PIT-120.2
PI-120.4 Steam at 4 barg pressure PIT-120.4
FIQ-120.4 Steam at 4 barg flow and totalizer FE/FIT-120.4
Inverter of SD-2042.01
JI-204.101 Vacuum chamber SD-2042.01 stirrer torque
(PROFINET)
PT-204.52
PI-204.52 Preliminary plodder PL-2042.01 pressure
(PROFINET)
Inverter of PL-2042.01
SI-204.134 Preliminary plodder PL-2042.01 screws speed (RPM) (preliminary)
(PROFINET)
Preliminary plodder PL-2042.01 absorbed current
II-204.134 (preliminary)
(Ampere)
(PROFINET)
PT-204.51
PI-204.51 Final plodder PL-2042.01 pressure
(PROFINET)
TE/TT-204.51
TI-204.51 Final plodder soap temperature
(PROFINET)
SI-204.135 Final plodder PL-2042.01 screws speed (RPM)
(final) (PROFINET)
II-204.135 Final plodder PL-2042.01 absorbed current (Ampere)
(final) (PROFINET)
Cooling water from semi-barometric condenser
TI-206.1 TE/TT-206.1
C-2062.03 temperature
Cooling water to semi-barometric condenser C-2062.03
TI-206.2 TE/TT-206.2
temperature
TI-206.3 Chilled water from vacuum pump P-2062.01 temperature TE/TT-206.3
Conveying air refrigerator E-2502.01 outlet air
TI-250.1 TE/TT-250.1
temperature
TI-250.1A Soap noodles silo D-2502.01A temperature TE/TT-250.1A
LI-250.1A Soap noodles silo D-2502.01A level LIT-250.1A
TI-250.1B Soap noodles silo D-2502.01B temperature TE/TT-250.1B
9
LI-250.1B Soap noodles silo D-2502.01B level LIT-250.1B
TI-250.1C Soap noodles silo D-2502.01C temperature TE/TT-250.1C
LI-250.1C Soap noodles silo D-2502.01C level LIT-250.1C
PDI-250.9A Exhaust air filter F-2502.05 differential pressure PDIT-250.9A
PDI-250.9B Exhaust air filter F-2502.06 differential pressure PDIT-250.9B
10
4 OTHER SIGNALS
Every process variable manages one / two DI (Digital Inputs) from field device.
Note: Delay “time”, the alarm will appear only when a predetermined delay time expires (delay can
be modified in dedicated video page).
Tag Description
XA-126.200 Plant emergency stop
XA-126.201 Plant emergency stop
ZSL-104.4 EDTA solution to feed tank D-1042.01 automatic valve AV-104.4 closed
ZSH-104.4 EDTA solution to feed tank D-1042.01 automatic valve AV-104.4 open
LAL-104.1 EDTA solution feed tank D-1042.01 low level alarm
LAH-104.1 EDTA solution feed tank D-1042.01 high level alarm
ZSL-104.3 EDTA solution feed tank D-1042.01 discharge automatic valve AV-104.3 closed
ZSH-104.3 EDTA solution feed tank D-1042.01 discharge automatic valve AV-104.3 open
PDAH-104.1 EDTA solution filters F-1042.01A/B high differential pressure alarm
FAL-104.11 EDTA solution to feed pump P-1042.01 low flow alarm
FAL-104.101 Seal water to EDTA solution feed pump P-1042.01 low flow alarm
ZSL-104.5 EDTA solution delivery automatic valve AV-104.5 closed
ZSH-104.5 EDTA solution delivery automatic valve AV-104.5 open
ZSL-104.6 EDTA solution recycle automatic valve AV-104.6 closed
ZSH-104.6 EDTA solution recycle automatic valve AV-104.6 open
ZSL-117.4A Glycerine to feed tank D-1172.06 automatic valve AV-117.4A closed
ZSH-117.4A Glycerine to feed tank D-1172.06 automatic valve AV-117.4A open
LAL-117.6 Glycerine feed tank D-1172.06 low level alarm
LAH-117.6 Glycerine feed tank D-1172.06 high level alarm
ZSL-117.3A Glycerine feed tank D-1172.06 discharge automatic valve AV-117.3A closed
ZSH-117.3A Glycerine feed tank D-1172.06 discharge automatic valve AV-117.3A open
PDAH-117.6 Glycerine filters F-1172.06A/B high differential pressure alarm
FAL-117.16 Glycerine to feed pump P-1172.06 low flow alarm
ZSL-117.5A Glycerine delivery automatic valve AV-117.5A closed
ZSH-117.5A Glycerine delivery automatic valve AV-117.5A open
ZSL-117.6A Glycerine recycle automatic valve AV-117.6A closed
11
Tag Description
ZSH-117.6A Glycerine recycle automatic valve AV-117.6A open
ZSL-117.4B EHDP solution to feed tank D-1172.08 automatic valve AV-117.4B closed
ZSH-117.4B EHDP solution to feed tank D-1172.08 automatic valve AV-117.4B open
LAL-117.8 EHDP solution feed tank D-1172.08 low level alarm
LAH-117.8 EHDP solution feed tank D-1172.08 high level alarm
ZSL-117.3B EHDP solution feed tank D-1172.08 discharge automatic valve AV-117.3B closed
ZSH-117.3B EHDP solution feed tank D-1172.08 discharge automatic valve AV-117.3B open
PDAH-117.8 EHDP solution filters F-1172.08A/B high differential pressure alarm
FAL-117.18 EHDP solution to feed pump P-1172.08 low flow alarm
FAL-117.108 Seal water to EHDP solution feed pump P-1172.08 low flow alarm
ZSL-117.5B EHDP solution delivery automatic valve AV-117.5B closed
ZSH-117.5B EDTA solution delivery automatic valve AV-117.5B open
ZSL-117.6B EDTA solution recycle automatic valve AV-117.6B closed
ZSH-117.6B EDTA solution recycle automatic valve AV-117.6B open
LAH-126.1A F.A. / N.O. blend feed tank D-1262.01A high level alarm
LAH-126.1B F.A. / N.O. blend feed tank D-1262.01B high level alarm
ZSL-126.11A F.A. / N.O. blend feed tank D-1262.01A outlet automatic valve AV-126.11A closed
ZSH-126.11A F.A. / N.O. blend feed tank D-1262.01A outlet automatic valve AV-126.11A open
ZSL-126.11B F.A. / N.O. blend feed tank D-1262.01B outlet automatic valve AV-126.11B closed
ZSH-126.11B F.A. / N.O. blend feed tank D-1262.01B outlet automatic valve AV-126.11B open
F.A. / N.O. blend recycle to feed tank D-1262.01A automatic valve AV-126.111A
ZSL-126.111A
closed
F.A. / N.O. blend recycle to feed tank D-1262.01A automatic valve AV-126.111A
ZSH-126.111A
open
F.A. / N.O. blend recycle to feed tank D-1262.01B automatic valve AV-126.111B
ZSL-126.111B
closed
F.A. / N.O. blend recycle to feed tank D-1262.01B automatic valve AV-126.111B
ZSH-126.111B
open
ZSL-126.3B Process water to kettles PS-1242.03A/B automatic valve AV-126.3B closed
ZSH-126.3B Process water to kettles PS-1242.03A/B automatic valve AV-126.3B open
ZSL-124.2A Soap from kettle PS-1242.03A automatic valve AV-124.2A closed
ZSH-124.2A Soap from kettle PS-1242.03A automatic valve AV-124.2A open
12
Tag Description
ZSL-124.2B Soap from kettle PS-1242.03B automatic valve AV-124.2B closed
ZSH-124.2B Soap from kettle PS-1242.03B automatic valve AV-124.2B open
PAH-124.3A Soap from kettles PS-1242.03A/B transfer pump P-1242.03A high pressure alarm
PAH-124.3B Soap from kettles PS-1242.03A/B transfer pump P-1242.03B high pressure alarm
Soap from kettles PS-1242.03A/B filters F-1242.03/03B high differential pressure
PDAH-124.3
alarm
PDAH-126.1A F.A. / N.O. blend filters F-1262.01A/B high differential pressure alarm
LAH-126.2 Caustic soda feed tank D-1262.02 high level alarm
ZSL-126.12 Caustic soda feed tank D-1262.02 discharge automatic valve AV-126.12 closed
ZSH-126.12 Caustic soda feed tank D-1262.02 discharge automatic valve AV-126.12 open
PDAH-126.2 Caustic soda filters F-1262.02A/B high differential pressure alarm
FAL-126.102A Seal water to caustic soda solution feed pump P-1262.02 low flow alarm
FAL-126.102B Seal water to caustic soda solution feed pump P-1262.02 low flow alarm
LAH-126.3 Process water feed tank D-1262.03 high level alarm
ZSL-126.13 Process water feed tank D-1262.03 discharge automatic valve AV-126.13 closed
ZSH-126.13 Process water feed tank D-1262.03 discharge automatic valve AV-126.13 open
PDAH-126.3 Process water filters F-1262.03A/B high differential pressure alarm
ZSL-126.24 Brine to feed tank D-1262.04 automatic valve AV-126.24 closed
ZSH-126.24 Brine to feed tank D-1262.04 automatic valve AV-126.24 open
LAL-126.4 Brine feed tank D-1262.04 low level alarm
LAH-126.4 Brine feed tank D-1262.04 high level alarm
ZSL-126.14 Brine feed tank D-1262.04 discharge automatic valve AV-126.14 closed
ZSH-126.14 Brine feed tank D-1262.04 discharge automatic valve AV-126.14 open
PDAH-126.4 Brine filters F-1262.04A/B high differential pressure alarm
FAL-126.104A Seal water to brine feed pump P-1262.04 low flow alarm
FAL-126.104B Seal water to brine feed pump P-1262.04 low flow alarm
PAH-126.6 F.A. / N.O. blend to reactor R-1262.02 high pressure alarm
PAH-126.7 Lye to reactor R-1262.02 high pressure alarm
ZSL-126.31 Lye to reactor R-1262.02 automatic valve AV-126.31 closed
ZSH-126.31 Lye to reactor R-1262.02 automatic valve AV-126.31 open
Soap from pumps P-1242.03A/B to reactor R-1262.02 automatic valve AV-126.32
ZSL-126.32
closed
13
Tag Description
Soap from pumps P-1242.03A/B to reactor R-1262.02 automatic valve AV-126.32
ZSH-126.32
open
ZSL-126.33 F.A. / N.O. blend to reactor R-1262.02 automatic valve AV-126.33 closed
ZSH-126.33 F.A. / N.O. blend to reactor R-1262.02 automatic valve AV-126.33 open
FAL-126.120 Seal water to soap recycle pump P-1262.20 low flow alarm
ZSL-126.7 Reactor R-1262.02 recycle inlet automatic valve AV-126.7 closed
ZSH-126.7 Reactor R-1262.02 recycle inlet automatic valve AV-126.7 open
ZSL-126.8 Reactor R-1262.02 recycle outlet automatic valve AV-126.8 closed
ZSH-126.8 Reactor R-1262.02 recycle outlet automatic valve AV-126.8 open
PAH-126.12 Reactor R-1262.02 high pressure alarm
ZSL-126.11 Reactor R-1262.02 outlet automatic valve AV-126.11 closed
ZSH-126.11 Reactor R-1262.02 outlet automatic valve AV-126.11 open
ZSL-126.90 Steam to reactor R-1262.02 outlet automatic valve AV-126.90 closed
ZSH-126.90 Steam to reactor R-1262.02 outlet automatic valve AV-126.90 open
ZSL-201.1 Soap to turbomixer R-2012.01 hand valve HV-201.1 closed
ZSH-201.1 Soap to turbomixer R-2012.01 hand valve HV-201.1 open
ZSL-201.2 Soap from turbomixer R-2012.01 hand valve HV-201.2 closed
ZSH-201.2 Soap from turbomixer R-2012.01 hand valve HV-201.2 open
ZSL-201.3 Turbomixer R-2012.01 by-pass hand valve HV-201.3 closed
ZSH-201.3 Turbomixer R-2012.01 by-pass hand valve HV-201.3 open
FAL-201.101 Seal water to turbomixer R-2012.01 low flow alarm
PAL-120.9 Nitrogen low pressure alarm
ZSL-204.1 Soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 closed
ZSH-204.1 Soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 open
ZSL-204.2 Soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 closed
ZSH-204.2 Soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 open
ZSL-204.3 Steam to vacuum chamber SD-2042.01 automatic valve AV-204.3 closed
ZSH-204.3 Steam to vacuum chamber SD-2042.01 automatic valve AV-204.3 open
ZSL-204.4 Steam to soap recycle line automatic valve AV-204.4 closed
ZSH-204.4 Steam to soap recycle line automatic valve AV-204.4 open
LAH-204.138 Vacuum chamber SD-2042.01 high level alarm
ZI-204.14 Vacuum chamber SD-2042.01 manhole open
14
Tag Description
ZI-205.1 First fines separator DC-2052.01 manhole open
LAH-205.1 First fines separator DC-2052.01 high level alarm
ZI-205.2 Second fines separator DC-2052.02 manhole open
LAH-205.2 Second fines separator DC-2052.02 high level alarm
LALL-206.3 Semi-barometric condenser C-2062.03 very low level alarm
LAHH-206.39 Semi-barometric condenser C-2062.03 very high level alarm
FAL-206.2 Water from semi-barometric condenser C-2062.03 low flow alarm
ZI-204.29 /
ZI-204.30 Preliminary plodder PL-2042.01 chamber OR final plodder PL-2042.01 head open
(PROFINET)
LAH-204.29
Preliminary plodder PL-2042.01 chamber high level alarm
(PROFINET)
PAH-250.1 Blower B-2502.01 high pressure alarm
LAH-250.1
Mixing chamber CM-2502.01 high level alarm
(PROFINET)
ZLL-250.11 Diverting valve DV-2502.0A to soap noodles storage silo D-2502.01A
ZLH-250.11 Diverting valve DV-2502.01A to soap noodles storage silos D-2502.01B/C
ZLL-250.12 Diverting valve DV-2502.0B to soap noodles storage silo D-2502.01B
ZLH-250.12 Diverting valve DV-2502.01B to soap noodles storage silo D-2502.01C
LAL-250.1A Soap noodles storage silo D-2502.01A low level alarm
LAH-250.1A Soap noodles storage silo D-2502.01A high level alarm
ZLL-250.15 Exhaust air throttle automatic valve VF-2502.01A closed
ZLH-250.15 Exhaust air throttle automatic valve VF-2502.01A open
LAL-250.1B Soap noodles storage silo D-2502.01B low level alarm
LAH-250.1B Soap noodles storage silo D-2502.01B high level alarm
ZLL-250.16 Exhaust air throttle automatic valve VF-2502.01B closed
ZLH-250.16 Exhaust air throttle automatic valve VF-2502.01B open
LAL-250.1C Soap noodles storage silo D-2502.01C low level alarm
LAH-250.1C Soap noodles storage silo D-2502.01C high level alarm
ZLL-250.17 Exhaust air throttle automatic valve VF-2502.01C closed
ZLH-250.17 Exhaust air throttle automatic valve VF-2502.01C open
LAH-250.10A Soap fines collecting bin of exhaust air filter F-2502.05 high level alarm
15
Tag Description
LAH-250.10B Soap fines collecting bin of exhaust air filter F-2502.06 high level alarm
Available external signal for fluidization solenoid valve XY-250.201A open/close
XY-250.201A
command
Available external signal for fluidization solenoid valve XY-250.201B open/close
XY-250.201B
command
Available external signal for fluidization solenoid valve XY-250.201C open/close
XY-250.201C
command
4.1 Motors
Tag Description
ZI-104.101(PROFINET)/
EDTA solution feed pump P-1042.01 motor status
201/301
Glycerine feed pump P-1172.06 motor status
206/306
EHDP solution feed pump P-1172.08 motor status
208/308
ZI-124.104A/204A/304A Kettle PS-124.03A stirrer AG-1242.03A motor status
ZI-124.104B/204B/304B Kettle PS-124.03B stirrer AG-1242.03B motor status
ZI-124.103A(PROFINET)/ Soap from kettle PS-1242.03A transfer pump P-1242.03A motor
203A/303A status
ZI-124.103B(PROFINET)/ Soap from kettle PS-1242.03B transfer pump P-1242.03B motor
203B/303B status
ZI-126.101A/201A/301A F.A. / N.O. blend feed pump P-1262.01A motor status
ZI-126.101B/201B/301B F.A. / N.O. blend feed pump P-1262.01B motor status
ZI-126.102/202/302 Caustic soda feed pump P-1262.02 motor status
ZI-126.103/203/303 Process water feed pump P-1262.03 motor status
ZI-126.104/204/304 Brine feed pump P-1262.04 motor status
ZI-126.120(PROFINET)/220/320 Soap recycle pump P-1262.20 motor status
ZI-201.101/201/301 Turbomixer R-2012.01 motor status
Chilled water transfer pump P-2492.01A motor status
ZI-249.301A
(TRIP ONLY)
ZI-249.301B Chilled water transfer pump P-2492.01B motor status
16
Tag Description
(TRIP ONLY)
ZI-204.101(PROFINET)/201/301 Vacuum chamber SD-2042.01 stirrer motor status
ZI-205.101/201/301 Soap fines reversible extruder / conveyor PL-2052.03 motor status
Bridge breaker of soap fines reversible extruder / conveyor PL-
ZI-205.101A/301A
2052.03 motor status
ZI-205.102/202/302 Soap fines worm conveyor T-2052.02 motor status
Bridge breaker of soap fines worm conveyor T-2052.02 motor
ZI-205.102A/302A
status
ZI-206.101/201/301 Vacuum pump P-2062.01 motor status
ZI-206.102/202/302 Semi-barometric ICS water recycle pump P-2062.02 motor status
234(PROFINET)/ Preliminary plodder PL-2042.01 motor status
334(PROFINET)
235(PROFINET)/ Final plodder PL-2042.01 motor status
335(PROFINET)
236(PROFINET)/ Plodder PL-2042.01 vacuum pump motor status
336(PROFINET)
ZI-250.101(PROFINET)/201/301 Blower B-2502.01 motor status
ZI-250.101A/301A Soundproof cabin PX-250.01 of blower B-2502.01 fan motor status
ZI-250.115A/215A/315A Exhaust air filter F-2502.05 fan motor status
ZI-250.115B/215B/315B Exhaust air filter F-2502.06 fan motor status
Noodles from silo D-2502.01A screw conveyor PL-2502.01A
ZI-250.301A
motor status (TRIP ONLY)
Noodles from silo D-2502.01B screw conveyor PL-2502.01B motor
ZI-250.301B
status (TRIP ONLY)
Noodles from silo D-2502.01C screw conveyor PL-2502.01C motor
ZI-250.301C
status (TRIP ONLY)
17
5 VALVES FAILURE
5.1 Shut-off valves (AV)
Automatic valves (AV) air failure:

- Double acting pneumatic actuator (air opens - air closes) ==> Air failure doesn't modify the
position of the valve,
- Single acting pneumatic actuator (air opens - spring closes).
SHUT-OFF VALVES
AV tag
Pneumatic Actuator
Air failure
Power failure
Microswitches (DI)
AV-104.4
Double acting
/
Closed
2
AV-104.3
Double acting
/
Closed
2
AV-104.5
Double acting
/
Closed
2
18
AV-104.6
Double acting
/
Open
2
AV-117.4A
Double acting
/
Closed
2
AV-117.3A
Double acting
/
Closed
2
AV-117.5A
Double acting
/
Closed
2
AV-117.6A
Double acting
/
Open
2
AV-117.4B
Double acting
/
Closed
2
AV-117.3B
Double acting
/
Closed
2
19
AV-117.5B
Double acting
/
Closed
2
AV-117.6B
Double acting
/
Open
2
AV-126.3B
Double acting
/
Closed
2
AV-124.2A
Double acting
/
Closed
2
AV-124.2B
Double acting
/
Closed
2
AV-126.11A
Double acting
/
Closed
2
AV-126.11B
Double acting
/
Closed
2
20
AV-126.111A
Double acting
/
Closed
2
AV-126.111B
Double acting
/
Closed
2
AV-126.12
Double acting
/
Closed
2
AV-126.13
Double acting
/
Closed
2
AV-126.24
Double acting
/
Closed
2
AV-126.14
Double acting
/
Closed
2
AV-126.31
Double acting
/
Closed
2
21
AV-126.32
Double acting
/
Closed
2
AV-126.33
Double acting
/
Closed
2
AV-126.7
Double acting
/
Closed
2
AV-126.8
Double acting
/
Closed
2
AV-126.11
Double acting
/
Closed
2
AV-126.90
Double acting
/
Closed
2
AV-204.1
Double acting
/
Closed
2
22
AV-204.2
Double acting
/
Open
2
AV-204.3
Double acting
/
Closed
2
AV-204.4
Double acting
/
Closed
2
5.2
5.3
5.4
5.5
5.6
5.7 Control valves (FV, PV, TV, LV)
CONTROL VALVES
Tag
Valve type
Air failure
Power failure (solenoid failure)
FV-126.1A
Globe
Closed
Closed
23
FV-126.2
Globe
Closed
Closed
FV-126.3
Globe
Closed
Closed
FV-126.4
Globe
Closed
Closed
LV-126.21A
Globe
Closed
Closed
LV-126.21B
Globe
Closed
Closed
LV-126.22
Globe
Closed
Closed
LV-126.23
Globe
Closed
Closed
LV-206.1
Globe
Closed
Closed
PV-126.121A
Globe
Closed
24
Closed
PV-126.121B
Globe
Closed
Closed
PV-126.10
Globe
Closed
Closed
PV-204.10
Globe
Closed
Closed
PV-206.11
Globe
Closed
Closed
TV-117.6
Globe
Closed
Closed
TV-124.3A
Globe
Closed
Closed
TV-124.3B
Globe
Closed
Closed
TV-126.12A
Globe
Closed
Closed
TV-126.12B
Globe
25
Closed
Closed
TV-126.5
Globe
Closed
Closed
TV-126.6
Globe
Closed
Closed
TV-126.9
Globe
Closed
Closed
26
5.8
5.9 5.10
5.11 5.12
5.13 5.14
5.15 5.16
5.17 5.18
5.19 5.20
5.21 5.22
5.23 5.24
5.25 5.26
5.27 5.28
5.29 5.30
5.31 5.32
5.33 5.34 Electrovalves (XY)
ELECTROVALVES
Tag
Power failure (solenoid failure)
XY-104.101
Closed
XY-117.108
27
Closed
XY-126.102
Closed
XY-126.104
Closed
XY-126.120
Closed
XY-201.101
Closed
XY-250.101A
Closed
XY-250.101B
Closed
XY-250.101C
Closed
XY-250.201A
Closed
XY-250.201B
Closed
XY-250.301C
Closed
5.35 Diverting valves (DV)
Diverting valves (DV) air failure:

- double acting pneumatic actuator (air opens - air closes) ==> Air failure doesn't modify the
- single acting pneumatic actuator (air opens - spring closes).
DIVERTING VALVESS
Pneumatic Power Microswitches
AV tag Air failure
Actuator failure (DI)
/ (double
DV-2502.01A Double acting / 2
solenoid)
DV-2502.01B Double acting / / (double 2
28
DIVERTING VALVESS
AV tag Air failure
solenoid)
5.36 Throttle valves (VF)
Throttle valves (VF) air failure:

- double acting pneumatic actuator (air opens - air closes) ==> Air failure doesn't modify the
- single acting pneumatic actuator (air opens - spring closes).
THROTTLE VALVES
AV tag Air failure
/ (double
VF-2502.01A Double acting / 2
solenoid)
/ (double
VF-2502.01B Double acting / 2
solenoid)
/ (double
VF-2502.01C Double acting / 2
solenoid)
29
6 CALCULATIONS
6.1 Caustic soda solution concentration calculation for FE/FIT-126.2 and brine
concentration calculation for FE/FIT-126.4
The PLC will use the following inputs from the field to calculate the concentration of caustic soda
solution and brine as follows:
Temperature Density
Estimated
Measurement Measurement Range °C
Concentration (%)
(°C) (kg/m3)
Caustic soda C1 = ((D1/1000-1)*102.2933)-3.841918 15 ÷ 30
solution C1 = ((D1/1000-1)*103.2514)-2.851916 30 ÷ 50
T1 = TIT 126.2 D1 = DIT 126.2
concentration C1 = ((D1/1000-1)*103.955)-1.727599 50 ÷ 70
C1 (%) C1 = ((D1/1000-1)*104.2768)-0.4229094 70 ÷ 90
C2 = ((D2/1000-1)*124.3799)+1.862589 15 ÷ 30
Brine
C2 = ((D2/1000-1)*126.1969)+2.55563 30 ÷ 50
concentration T2 = TIT 126.4 D2 = DIT 126.4
C2 = ((D2/1000-1)*127.5331)+3.764294 50 ÷ 70
C2 (%)
C2 = ((D2/1000-1)*127.6372)+5.294227 70 ÷ 90
The above values will be shown next to mass flow meters FE/FIT 126.2 and FE/FIT 126.4.
Two buttons “Concentration” will be foreseen near pumps P 126.02 and P 126.04; by pushing
them, a new video page will open and the following table will be shown:
Caustic soda
new
Value editable from operator
concentration
(%)
Caustic soda
current Value from recipe or from previous calculation (not editable from operator in this
concentration table) = FP20
(%)
Caustic soda
current flow
Caustic soda solution current set point (not editable from operator in this table)
rate set point
(kg/h)
30
New proposed
[ ] [ ]
kg NaOHCurrentConcentration [ % ]
caustic soda kg
NaOHNewSP =NaOHCurrentSP ×
flow rate set h h NaOHNewConcentration [ % ]
point (kg/h)
Brine new
concentration Value editable from operator
(%)
Brine current
Value from recipe or from previous calculation (not editable from operator in this
concentration
table) = FP40
(%)
Brine current
flow rate set Brine current set point (not editable from operator in this table)
point (kg/h)
New proposed
[ ] [ ]
kg NaClCurrentConcentration [ % ]
brine flow rate kg
NaClNewSP =NaClCurrentSP ×
set point h h NaClNewConcentration [ % ]
(kg/h)
Water current
flow rate set Water current set point (not editable from operator in this table)
point (kg/h)
New water
flow rate set WaterNewSP
[ ]
kg
h
=WaterCurrentSP
kg
h [ ]
−NaOHNewSP
kg
h [ ]
+ NaOHCurrentSP
kg
h
− NaClNew
[ ]
point (kg/h)
When the operator puts the values of caustic soda solution new concentration and brine solution
new concentration, the system will calculate the new set points for caustic soda, brine and water.
An additional button, called “Download”, is foreseen on the bottom of this video page: by pushing
it, the new set points are downloaded and set as set points for the control loops. In this case, also the
caustic soda new concentration and brine new concentration values will be memorized as caustic
soda current concentration and brine current concentration.
If the calculated value for water is less than zero, a pop-up “water proposed set point is negative:
check concentrations” is shown (only for acknowledgment) and the “Download” key will not
permit the download of the set points.
31
6.2 Calculation for level controllers
6.2.1 Calculation for fatty acids / neutral oil blend feed tank D-1262.01A level (LIC-
126.1A)
 input from PIT 126.11A and PIT 126.1A,
 transform the above signals from 4 ÷ 20 mA into mmH 20 (PIT-126.11A) / mbar (PIT-
126.1A),
 PIT-126.11A calibration: 0 ÷ 3100 mmH20,
 PIT-126.1A calibration: 0 ÷ 100 mbar,
 g = 9.81 m/s2,

(
∆ P= PIT 126.11 A [ mmH 2 O ] ×
g
100 )
−PIT 126.1 A [ mbar ] =( PIT 126.11 A [ mmH 2 O ] × 0.0981 )−PIT 126.1 A
[mbar],
 fatty acid = 870 kg/m3,
 air = function of pressure kg/m3,
 H = 3 m,
 X = correction for pressure value, this value can be modified in a proper video page,
( ∆ P ×102− X )
−ρair × H 2 2
 g ∆ P × 10 −X ∆ P× 10 − X [m] (simplified equation),
L m= ≅ ≅
( ρ fatty acid −ρair ) g × ρfatty acid 8534.7
 L%= ( LH ) ×100 [%].

m
6.2.2 Calculation for fatty acids / neutral oil blend feed tank D-1262.01B level (LIC-
126.1B)
 input from PIT 126.11B and PIT 126.1B,
 transform the above signals from 4 ÷ 20 mA into mmH 20 (PIT-126.11B) / mbar (PIT-
126.1B),
 PIT-126.11B calibration: 0 ÷ 3100 mmH20,
 PIT-126.1B calibration: 0 ÷ 100 mbar,
 g = 9.81 m/s2,

(
∆ P= PIT 126.11B [ mmH 2 O ] ×
g
100 )
−PIT 126.1 B [ mbar ] =( PIT 126.11 B [ mmH 2 O ] ×0.0981 ) −PIT 126.1 B [
[mbar],
32
 fatty acid = 870 kg/m3,
 H = 3 m,
( ∆ P ×102− X )
−ρair × H 2 2
 g ∆ P × 10 −X ∆ P× 10 − X [m] (simplified equation),
L m= ≅ ≅
( ρ fatty acid −ρair ) g × ρfatty acid 8534.7
 L%= ( LH ) ×100 [%].

m
6.2.3 Calculation for semi-barometric condenser C-2062.03 level (LIC-206.1)

 input from PIT 206.1B and PIT 206.1A,
 transform the above signals from 4 ÷ 20 mA into mmHg,
 PIT-206.1B and PIT-206.1A calibration: 0 ÷ 1500 mmHg,
 ∆ P=PIT 206.1 B−PIT 206.1 A [mmHg],
 water = 1000 kg/m3,
 g = 9.81 m/s2,
 H = 1.5 m,

( ∆ P × 101325
760
− X)
−ρ ×H [m] (simplified
air
g ∆ P ×133.32− X ∆ P ×133.32− X
L m= ≅ ≅
( ρwater −ρair ) g × ρwater 9810
equation),
 L%= ( LH ) ×100 [%].

m
33
7 INTERLOCKS
Interlocks can be enabled or disabled by means of a software button: this operation is allowed only
under password.
When an interlock is active, a padlock has to be shown on the video page next to the
interlocked item: by clicking on the padlock icon a pop-up will show all the causes which have
activated the relevant interlock (HELP PAGE).
The interlocks managed by the PLC of the saponification are the following:
N.
CONDITION (IF)
ACTIONS (THEN)
LSH-104.1
On10
EDTA transfer pump11
Locked on stop OR stopped if running
LSH-104.1
On10
Valve AV-104.411
Locked to close OR closed if open
LSL-104.1 on10 AND EDTA transfer selector on “AUTO”11

Started (one-shot command)
LSL-104.1 on10 AND EDTA transfer selector on “AUTO”11

Valve AV-104.411
Set to open (one-shot command)
LAL-104.1 AND LAH-104.1
34
On, at the same time
LAL-104.1 AND LAH-104.1

Valve AV-104.411
LAL-104.1
On for more than a pre-set time12
Pump P-1042.01
Valve AV-104.3
Not open
Pump P-1042.01
FAL-104.11
On
Pump P-1042.01
FAL-104.101
Pump P-1042.01
Pump P-1042.01
Running
Solenoid valve XY-104.101
Cannot be closed (locked)
Valves AV-104.5 AND AV-104.6
35
Not open13
Pump P-1042.01
LSH-117.6
On10
Glycerine transfer pump 114
LSH-117.6
On10
LSH-117.6
On10
Valve AV-117.4A14
LSL-117.6 on10 AND glycerine transfer selector on Glycerine transfer pump 1 -AUTO14
Valve AV-117.4A14
Valve AV-117.4A14
36
LAL-117.6 AND LAH-117.6
LAL-117.6 AND LAH-117.6

LAL-117.6 AND LAH-117.6

Valve AV-117.4A14
“Glycerine transfer pump selector”

Position 1 – AUTO
“Glycerine transfer pump selector”

Position 2 - AUTO
LAL-117.6
Pump P-1172.06
Valve AV-117.3A
Not open
Pump P-1172.06
37
FAL-117.16
On
Pump P-1172.06
Valves AV-117.5A AND AV-117.6A

Not open13
Pump P-1172.06
LSH-117.8
On10
EHDP transfer pump15
LSH-117.8
On10
Valve AV-117.4B15
LSL-117.8 on10 AND EHDP transfer selector on “AUTO”14

LSL-117.8 on10 AND EHDP transfer selector on “AUTO”14

Valve AV-117.4B15
LAL-117.8 AND LAH-117.8

LAL-117.8 AND LAH-117.8

38
Valve AV-117.4B15
LAL-117.8
Pump P-1172.08
Valve AV-117.3B
Not open
Pump P-1172.08
FAL-117.18
On
Pump P-1172.08
FAL-117.108
Pump P-1172.08
Pump P-1172.08
Running
Valves AV-117.5B AND AV-117.6B

Not open13
Pump P-1172.08
JAHH-124.104A16
On
39
Kettle PS-1242.03A motor
JAHH-124.104B17
On
Kettle PS-1242.03B motor
Valves AV-124.2A AND AV-124.2B

Not open
Pump P-1242.03A

Not open
Pump P-1242.03B

Open
Pump P-1242.03A

Open
Pump P-1242.03B
Pump P-1242.03A
Running
Pump P-1242.03B
Locked on stop
Pump P-1242.03A
Running
40
Pump P-1242.03B
Cannot be started (locked)
Pump P-1242.03B
Running
Pump P-1242.03A
Locked on stop
Pump P-1242.03B
Running
Pump P-1242.03A
PAH-124.3A
On
Pump P-1242.03A
PAH-124.3B
On
Pump P-1242.03B
LAH-126.1A (DI)
On
F.A. / N.O blend transfer pump 1
LAH-126.1A (DI)
On
LAH-126.1A (DI)
On
41
Control valve
LV-126.21A
Locked to close OR closed if open (LIC-126.21A on manual, opening 0% and relevant XY
solenoid valve locked to close)
LAHH-126.1A (AI)
On
LAHH-126.1A (AI)
On
LAHH-126.1A (AI)
On
Control valve
LV-126.21A
PAHH-126.1A (AI)
On
Control valve
PV-126.121A
Locked to close OR closed if open (PIC-126.121A on manual, opening 0% and relevant XY
PAHH-126.1A (AI)
On
Control valve
LV-126.21A
42
Control valve
PV-126.121A
Closed18
Pop-up “Blanketing to D-126.01A OFF”
Shown (next to D-126.01A)
Control valve
PV-126.121A
Closed18
Pop-up “Blanketing to D-126.01A ON”
Hidden
Control valve
PV-126.121A
Open18
Pop-up “Blanketing to D-126.01A ON”
Control valve
PV-126.121A
Open18
Pop-up “Blanketing to D-126.01A OFF”
Hidden
LAH-126.1B (DI)
On
LAH-126.1B (DI)
On
43
LAH-126.1B (DI)
On
Control valve
LV-126.21B
Locked to close OR closed if open (LIC-126.21B on manual, opening 0% and relevant XY
LAHH-126.1B (AI)
On
LAHH-126.1B (AI)
On
LAHH-126.1B (AI)
On
Control valve
LV-126.21B
Locked to close OR closed if open (LIC-126.21B on manual, opening 0% and relevant XY
PAHH-126.1B (AI)
On
Control valve
PV-126.121B
Locked to close OR closed if open (PIC-126.121B on manual, opening 0% and relevant XY
LAHH-126.1B (AI)
PAHH-126.1B (AI)
On
Control valve
44
LV-126.21B
Locked to close OR closed if open (LIC-126.21B PIC-126.21B on manual, opening 0% and
relevant XY solenoid valve locked to close)
Control valve PV-126.121B

Closed18
Pop-up “Blanketing to D-126.01B OFF”
Shown (next to D-126.01B)

Closed18
Pop-up “Blanketing to D-126.01B ON”
Hidden

Open18
Pop-up “Blanketing to D-126.01B ON”

Open18
Pop-up “Blanketing to D-126.01B OFF”
Hidden
LALL-126.1A (AI) on for more than a pre-set time12 AND AV-126.11A open
Pump P-1262.01A
LALL-126.1A (AI) on for more than a pre-set time12 AND AV-126.11A open
Pump P-1262.01B
LALL-126.1B (AI) on for more than a pre-set time12 AND AV-126.11B open
Pump P-1262.01A
45
LALL-126.1B (AI) on for more than a pre-set time12 AND AV-126.11B open
Pump P-1262.01B

Not open
Pump P-1262.01A

Not open
Pump P-1262.01B

Open
Pump P-1262.01A

Open
Pump P-1262.01B
Pump P-1262.01A
Running
Pump P-1262.01B
Locked on stop
Pump P-1262.01A
Running
Pump P-1262.01B
46
Pump P-1262.01B
Running
Pump P-1262.01A
Locked on stop
Pump P-1262.01B
Running
Pump P-1262.01A

Not open
Pump P-1262.01A

Not open
Pump P-1262.01B

Open
Pump P-1262.01A

Open
Pump P-1262.01B
Valves AV-126.11A AND AV-126.111B open

Pop-up “ATTENTION: F.A. / N.O. blend is recycled from D-1262.01A to D-1262.01B”
Shown (next to D-1262.01A/B)
Otherwise, it is hidden
47
Valves AV-126.11B AND AV-126.111A open
Pop-up “ATTENTION: F.A. / N.O. blend is recycled from D-1262.01B to D-1262.01A”
Shown (next to D-1262.01A/B)
Otherwise, it is hidden
LAH-126.2 (DI)
On
Caustic soda transfer pump 1
LAH-126.2 (DI)
On
LAH-126.2 (DI)
On
Control valve
LV-126.22
Locked to close OR closed if open (LIC-126.2 on manual, opening 0% and relevant XY solenoid
valve locked to close)
LAHH-126.2 (AI)
On
LAHH-126.2 (AI)
On
LAHH-126.2 (AI)
On
Control valve
48
LV-126.22
LALL-126.2 (AI)
Pump P-1262.02
Valve AV-126.12
Not open
Pump P-1262.02
FAL-126.102A
On for more than 5”12
Pump P-1262.02
FAL-126.102B
On for more than 5”12
Pump P-1262.02
Pump P-1262.02
Running
LAH-126.3 (DI)
On
Process water transfer pump 1
LAH-126.3 (DI)
49
On
LAH-126.3 (DI)
On
Control valve
LV-126.23
LAHH-126.3 (AI)
On
LAHH-126.3 (AI)
On
LAHH-126.3 (AI)
On
Control valve
LV-126.23
LALL-126.3 (AI)
Pump P-1262.03
Valve AV-126.13
Not open
50
Pump P-1262.03
LSH-126.4
On10
Brine transfer pump 119
LSH-126.4
On10
LSH-126.4
On10
Valve AV-126.2419
LSL-126.4 on10 AND brine transfer selector on Brine transfer pump 1 – AUTO19
LSL-126.4 on10 AND brine transfer selector on Brine transfer pump 1 – AUTO19
Valve AV-126.2419
LSL-126.4 on10 AND brine transfer selector on “Brine transfer pump 2 – AUTO”19
LSL-126.4 on10 AND brine transfer selector on “Brine transfer pump 2 – AUTO”19
Valve AV-126.2419
LAL-126.4 AND LAH-126.4
51
LAL-126.4 AND LAH-126.4

LAL-126.4 AND LAH-126.4

Valve AV-126.2419
“Brine transfer pump selector”

Position 1 – AUTO
“Brine transfer pump selector”

Position 2 - AUTO
LAL-126.4
Pump P-1262.04
Valve AV-126.14
Not open
Pump P-1262.04
FAL-126.104A
52
Pump P-1262.04
FAL-126.104B
Pump P-1262.04
Pump P-1262.04
Running
Valve AV-126.32
From open to closed
Pump P-1242.03A
Stopped (one-shot command)
Valve AV-126.32
From open to closed
Pump P-1242.03B
If valve AV-126.32 is closed and operator attempt to start pump P-1242.03A (or pump P-
1242.03B), a pop-up with written “Valve AV-126.32 is closed, confirm the start command of P-
1242.03A/B (check that manual recycle valves to PS-1242.03A or PS-1242.03B are open)” is
shown.
If operator selects “Yes”, the pump P-1242.03A (or P-1242.03B) is started and pop-up is closed.
If operator selects “No”, the pop-up is closed without starting pumps P-1242.03A/B.
FAL-126.120
Pump P-1262.20
53
Pump P-1262.20
Running
Valve AV-126.7
Not open
Pump P-1262.20
Valve AV-126.8
Not open
Pump P-1262.20
Pump P-1262.20
Running
Valve AV-126.7
Pump P-1262.20
Running
Valve AV-126.8
PAHH-126.10
On
Valves
AV-126.31/32/33
PAHH-126.10
On
Control valve
54
TV-126.9
Locked to close OR closed if open (TIC-126.9 on manual, opening 0% and relevant XY solenoid
PAHH-126.10
On
Pump P-1262.20
PAH-126.12
On
Valves
AV-126.31/32/33
PAH-126.12
On
Control valve
TV-126.9
Locked to close OR closed if open (TIC-126.9 on manual, opening 0% and relevant XY solenoid
PAH-126.12
On
Pump P-1262.20
Valve AV-126.11
Not closed
Valve AV-126.90
Valve AV-126.90
Open
Control valve
55
PV-126.10
Blocked open 100% (PIC-126.10 on manual, opening 100% and relevant XY solenoid valve
locked to open)
Valve AV-126.90
From open to closed
Control valve
PV-126.10
Set to close (PIC-126.10 on manual, opening 0% and relevant XY solenoid valve set to close) (one-
shot command)
Control valve PV-126.10

Not open18
Valve AV-117.5A
Locked to close OR closed if open20
Valve AV-126.11
Not open
Valve AV-117.5A
Valves HV-201.1 AND HV-201.3

Not open
Valve AV-126.90
Automatic valves AV-126.31/32/33 and AV-126.11 are not locked to close only if hand valves
((HV-201.1 and HV-201.2) are open and hand valve HV-201.3 is not open) or (hand valves (HV-
201.1 and HV-201.2) are closed and hand valve HV-201.3 is open)
Automatic valve AV-117.5A is not locked to close only if hand valves ((HV-201.1 and HV-201.2)
are open and hand valve HV-201.3 is not open) or (hand valves (HV-201.1 and HV-201.2) are
closed and hand valve HV-201.3 is open)
Turbomixer R-2012.01
56
Running
FAL-201.101
Valve HV-201.1
Not open
Valve HV-201.2
Not open
Valve HV-201.3
Open

Not open18
Valve AV-126.11
Not open
Valve AV-204.1
57
Not open
Valve AV-117.5A
Valve AV-204.1
From open to closed
Valve AV-204.3
Set to open21
Valve AV-204.3
Open
Blocked open 100% (PIC-204.10 on manual, opening 100% and relevant XY solenoid valve
locked to open)
Valve AV-204.3
From open to closed
Set to close (PIC-204.10 on manual, opening 0% and relevant XY solenoid valve set to close) (one-
shot command)
Valve AV-204.2
From open to closed
Valve AV-204.4
Set to open22
Valve AV-204.1
Not closed
Valve AV-204.3
Valve AV-204.2
Not closed
Valve AV-204.4
58
Not open13
Locked to close (PIC-126.10 on manual, opening 0% and relevant XY solenoid valve locked to
close)

Not open13
Valves AV-126.31/32/33 AND AV-126.11

Not open13
JAHH-204.10123
On
Vacuum chamber SD-2042.01 motor
JAHH-204.10123
On
Plodder PL-2042.01 motors (preliminary and final)
JAHH-204.10123
On
Soap fines reversible extruder / conveyor PL-2052.03 motor
PAHH-206.11
On
Valve AV-204.1
59
PAHH-206.11
On
Valve AV-204.3
Vacuum chamber SD-2042.01 inspection door (ZI-204.14)

Not closed (not off)
Vacuum chamber SD-2042.01 motor



Valve AV-204.1

Control valve
PV-204.10

60
Valve AV-204.3
First fines separator DC-2052.01 inspection door (ZI-205.1)

First fines separator DC-2052.01 inspection door (ZI-205.1)

Soap fines conveyor T-2052.02 motor
Second fines separator DC-2052.02 inspection door (ZI-205.2)

Soap fines conveyor T-2052.02 motor
LAH-206.1
On
Control valve LV-206.124
Set to open (LIC-206.1 on automatic, opening according to pre-set value that can be defined for
each single valve in a dedicated video page and relevant XY solenoid valve set to open) (one-shot
command)
LAL-206.1
On
Set to close (LIC-206.1 on manual, opening 0% and relevant XY solenoid valve set to close) (one-
shot command)
LALL-206.1
On
61
shot command)
LALL-206.3
On
shot command)
FAL-206.2
Pump P-2062.02
TAHH-206.3
On
Pump P-2062.02 stopped if running AND, after 15”12, pump P-2062.01 locked on stop OR
stopped if running
Preliminary plodder PL-2042.01 chamber (ZI-204.29) OR final plodder PL-

2042.01 head (ZI-204.30)
PAHH-204.52
On25
Preliminary plodder PL-2042.01 motor
LSH-204.29
On10
Stopped (pop-up “stand-by” appears next to the motor (blinking))26
LSH-204.29
62
From on to off10, after 10”12
Started again, if it was running, (pop-up “stand-by” disappears)26
LAH-204.29
Locked on stop OR stopped if running (pop-up “stand-by” disappears)
PAHH-204.51
On25
Final plodder PL-2042.01 motor

Not on automatic remote
Blower B-2502.01
“Silo #A” or “Silo #B” or Silo #C pushbuttons

Not green
Blower B-2502.01
Solenoid valve XY-250.11B

Not open
Blower B-2502.01
Blower B-2502.01
Running
Solenoid valve XY-250.12B not open AND valve DV-2502.01A open to D-2502.01B/C
63
Blower B-2502.01
Blower B-2502.01 running AND valve DV-2502.01A open to D-2502.01B/C

PAH-250.1
Blower B-2502.01
Blower B-2502.01
Not running
LAH-250.1
On
Valve DV-2502.01A open to D-2502.01A AND LAH-250.1A (DI) on

Valve DV-2502.01A open to D-2502.01A AND LLAH-250.1A (AI) on

Valve DV-2502.01A open to D-2502.01B/C AND valve DV-2502.01B open to D-2502.01B AND
LAH-250.1B (DI) on
64
LAHH-250.1B (AI) on
Valve DV-2502.01A open to D-2502.01B/C AND valve DV-2502.01B open to D-2502.01C AND
LAH-250.1C (DI) on
LAHH-250.1C (AI) on
LAH-250.1A (DI) (OR LAHH-250.01A (AI)) AND LAH-250.1B (DI) (OR LAHH-250.01B (AI))
AND LAH-250.01C (DI) (OR LAHH-250.01C (AI))
On
Valve DV-2502.01A
Open to
D-2502.01A
Valve VF-2502.01A
Locked to open OR open if close
Valve DV-2502.01A open to D-2502.01B/C AND valve DV-2502.01B open to D-2502.01B

Valve VF-2502.01B
Valve DV-2502.01A open to D-2502.01B/C AND valve DV-2502.01B open to D-2502.01C

Valve VF-2502.01C
65
Valve DV-2502.01A open to D-2502.01A AND valve VF-2502.01A not open
Blower B-2502.01
VF-2502.01B not open
Blower B-2502.01
valve VF-2502.01C not open
Blower B-2502.01
Valve DV-2502.01A (not open to D-2502.01A AND not open to D-2502.01B/C) for more than
10”12
Blower B-2502.01
Valve DV-2502.01A open to D-2502.01B/C AND valve DV-2502.01B (not open to D-2502.01B
AND not open to D-2502.01C) for more than 10”12
Blower B-2502.01
Valves VF-2502.01A AND VF-2502.01B AND VF-2502.01C

Not open13
Blower B-2502.01
Exhaust air filter F-2502.05 fan running AND Exhaust air filter F-2502.06 fan not running
Blower B-2502.01
Can be started by operator, but with selectable maximum speed limited to 80%27
Pop-up “B-2502.01 maximum speed is limited to 80%27 to optimize powder recovery of filters”
66
Shown (next to B-2502.01)
Blower B-2502.01
Can be started by operator, but with selectable maximum speed limited to 80%27
Shown (next to B-2502.01)
Exhaust air filters

F-2502.05 AND F-2502.06 fans
Running
Blower B-2502.01
Can be started by operator, without limit on selectable maximum speed (100%)27
Exhaust air filters

F-2502.05 AND F-2502.06 fans
Running
Hidden
Exhaust air filters

F-2502.05 AND F-2502.06 fans
Not running
Blower B-2502.01
Exhaust air filters

F-2502.05 AND F-2502.06 fans
Not running
Hidden
Solenoid valve XY-250.101A
67
Open
Valve VF-2502.01A
Solenoid valve XY-250.101A open AND valve VF-2502.01A not open for more than a pre-set
time”12
Solenoid valve
XY-250.101A
Set to close (one-shot command)

From open to closed
Valve VF-2502.01A
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.101A

Open
Pop-up “D-2502.01A fluidization ON”

Closed
Pop-up “D-2502.01A fluidization ON”
Hidden

Open
68
Valve VF-2502.01A
Solenoid valve XY-250.201A open AND valve VF-2502.01A not open for more than a pre-set
time”12
Solenoid valve
XY-250.101A
XY-250.201A

From open to closed
Valve VF-2502.01A
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.201A

Open
Valve VF-2502.01B
Solenoid valve XY-250.101B open AND valve VF-2502.01B not open for more than a pre-set
time”12
Solenoid valve
XY-250.101B
69
From open to closed
Valve VF-2502.01B
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.101B

Open
Pop-up “D-2502.01B fluidization ON”

Closed
Pop-up “D-2502.01B fluidization ON”
Hidden

Open
Valve VF-2502.01B
Solenoid valve XY-250.201B open AND valve VF-2502.01B not open for more than a pre-set
time”12
Solenoid valve
XY-250.101B
XY-250.201B
70
From open to closed
Valve VF-2502.01B
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.201B
Solenoid valve XY-250.101C

Open
Valve VF-2502.01C
Solenoid valve XY-250.101C open AND valve VF-2502.01C not open for more than a pre-set
time”12

From open to closed
Valve VF-2502.01C
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.101C
71
Open
Pop-up “D-2502.01C fluidization ON”
Shown (next to D-2502.01C)

Closed
Pop-up “D-2502.01C fluidization ON”
Hidden

Open
Valve VF-2502.01C
Solenoid valve XY-250.201C open AND valve VF-2502.01C not open for more than a pre-set
time”12
Solenoid valve
XY-250.101C
XY-250.201C

From open to closed
Valve VF-2502.01C
Exhaust air filters

F-2502.05 OR AND
F-2502.06 fans
Not running
Solenoid valve
XY-250.201C
72
LALL-250.01A
Available DO1 signal
Given
LAL-250.01A (DI)
Given
LALL-250.01B
Given
LAL-250.01B (DI)
Given
LALL-250.01C
Given
LAL-250.01C (DI)
Given
Legend:
HV: hand valve
AV: automatic valve
XY: solenoid valve
“Set to …” means a one-shot command
73
“Locked to …” always prevails over “Set to …”
74
8 SEQUENCES
8.1 Pump P-1042.01 start-up
The start command of pump P-1042.01:

 opens solenoid valve XY-104.101,
 checks FAL-104.101  if, after 10”12, it is off proceed, otherwise stop the sequence and
give alarm,
 starts the motor of pump P-1042.01.
If it’s started from LOCAL, when ZI-104.101 goes from OFF to ON  open solenoid valve XY-
104.101.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).
8.2 Pump P-1042.01 shut-down
The stop command of pump P-1042.01 (given by operator or through an interlock):

 stops pump P-1042.01,
 after 10”12, solenoid valve XY-104.101 is closed.
If it’s stopped from LOCAL, when ZI-104.101 goes from ON to OFF  close solenoid valve XY-
104.101.
8.3 EDTA automatic valves
The open command for automatic valve AV-104.5 will:

 open automatic valve AV-104.5,
 then, when ZSH-104.5 is ON, automatic valve AV-104.6 will be closed.
The close command for automatic valve AV-104.5 will:
75
Automatic valves AV-104.5 and AV-104.6 can’t be both “not open” at the same time, otherwise
alarm is given.
Sequence is functioning, either if the open / close commands are given by operator, interlocks or
other sequences.
8.4 Glycerine automatic valves
The open command for automatic valve AV-117.5A will:

 open automatic valve AV-117.5A,
 then, when ZSH-117.5A is ON, automatic valve AV-117.6A will be closed.
The close command for automatic valve AV-117.5A will:
Automatic valves AV-117.5A and AV-117.6A can’t be both “not open” at the same time, otherwise
alarm is given.
other sequences.

give alarm,
117.108.
signal is given).
76

117.108.
8.7 EHDP automatic valves
The open command for automatic valve AV-117.5B will:

 open automatic valve AV-117.5B,
 then, when ZSH-117.5B is ON, automatic valve AV-117.6B will be closed.
The close command for automatic valve AV-117.5B will:
Automatic valves AV-117.5B and AV-117.6B can’t be both “not open” at the same time, otherwise
alarm is given.
other sequences.
8.8 Slop kettles PS-1242.03A/B automatic valves

 then, when ZSH-124.2A is ON, automatic valve AV-124.2B will be closed.
 close automatic valve AV-124.2A.
 then, when ZSH-124.2B is ON, automatic valve AV-124.2A will be closed.
77
 close automatic valve AV-124.2B.
other sequences.
8.9 F.A. / N.O. blend feed tanks D-1262.01A/B automatic valves

 then, when ZSH-126.11A is ON, automatic valve AV-126.11B will be closed,
 then, when ZSH-126.11B is ON, automatic valve AV-126.11A will be closed,
other sequences.
8.10 F.A. / N.O. blend automatic valves

78
other sequences.

 checks FAL-126.102A and FAL-126.102B  if, after 10”12, both are off proceed, otherwise
stop the sequence and give alarm,
126.102.
signal is given).

126.102.

 checks FAL-126.104A and FAL-126.104B  if, after 10”12, both are off proceed, otherwise
stop the sequence and give alarm,
126.104.
signal is given).

79
126.104.

give alarm,
126.120.
signal is given).

126.120.
8.17 Turbomixer R-2012.01 start-up
The start command of turbomixer R-2012.01:

give alarm,
 starts the motor of turbomixer R-2012.01.
201.101.
signal is given).
8.18 Turbomixer R-2012.01 shut-down
The stop command of turbomixer R-2012.01 (given by operator or through an interlock):

80
 stops turbomixer R-2012.01,
201.101.
8.19 Dryer automatic valves

Automatic valves AV-204.1 and AV-204.2 can’t be both not open at the same time, otherwise alarm
is given.
other sequences.
8.20 Water dosing to kettles PS-1242.03A/B
The purpose of the “Water dosing to kettles” sequence is to carry on the feeding of the requested
quantity of process water to kettles PS-1242.03A/B, by decision of the operator hitting the relevant
keys below described.
Water dosing to kettles PS-1242.03A/B can be done batch wise manually or by means of an
automatic sequence.
On the video page of kettles PS-1242.03A/B,
 a table with the following values:
 water feeding set point A [kg]: editable value, input from keyboard,
 water feeding actual value B [kg]: output from the totalizer of mass flow meter FE/FIT-
126.3B (FIQ-126.3B),
81
NOTE: totalizer will be active only if process water feed pump P-1262.03 is running and
process water to kettles PS-1242.03A/B automatic valve AV-126.3B is open.
 flight time for water C [kg]: editable value, input from keyboard,
 water flow rate D [kg/h]: output from the mass flow meter FE/FIT-126.3B,
 control timer for water charge step X (s): editable value, input from keyboard.
 the following graphic pushbuttons:
 start button,
 stop button,
 reset button.
have to be shown.
Control
PS-1242.03A/B Set [kg] Actual [kg] Flight time [kg] Water flow rate [kg/h]
timer [s]
PROCESS WATER A (input) B (output) C (input) D (input) X (input)
Note: all input data must be bigger than or equal to 0.
 Water dosing to kettles automatic sequence.

Conditions for “water dosing to kettles automatic” sequence to be effective are:
 interlocks activated,
 process water feed pump P-1262.03 running,
 process water to kettles PS-1242.03A/B automatic valve AV-126.3B closed (this only as
starting condition).
If one or more of the above conditions is not matched, the dosing sequence can't be activated or
it is interrupted if running (the system will be set in the same conditions as if the “Stop” button
is pushed and an alarm is given); restart has to be given by operator.
If all the conditions which allow the activation of the sequence are effective, the “Start” button
will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
(blinking - impossibility of activating the sequence).
A dedicated help video page has to be foreseen in order to show all the conditions that are
necessary to activate the “Water dosing to kettles” sequence and which ones are currently
activated or missing.
Function of timer:
o total timer of the sequence t 1 [s]: it is the timer which shows the duration of the complete
sequence.
Functions of the pushbuttons:
82
o “Start” button: once the “Start” button is pushed, the operations described in the list
below will be done.
At this point, the “Start” button will become green to show that the feeding sequence is
active.
83
Conditions to be
Starting Conditions to be verified
Duration Actions verified during the
condition at the end of the step
duration of the step
1. t1 is reset and started

2. AV-126.3B is set to open
Sequence ends (when B
“Start” button 3. FE/FIT-126.3B starts to totalize the flow (D  AV-126.3B open
≥ A – C) or (if t1,  ZSL-126.3B ON
pushed by 12 and B) (ZSH-126.3B ON)
started from X ,  B = A ± C28
operator 4. When B ≥ A – C, then AV-126.3B will be  B<A+C
expires and B < A – C)
locked to close and value B is locked until
reset
84
o “Stop” button: once the “Stop” button is pushed, automatic valves AV-126.3B will be
closed and timer t1 will be stopped; if “Stop” key is pushed before reaching the set point,
“actual value” B will remain as it is without being reset and, when “Start” button is
pushed again, the automatic sequence will continue from where it was stopped and FIQ-
126.3B will continue to increase actual value B from the previous one.
“Stop” button’s colour is grey; when the “Stop” button is pushed before the automatic
feeding has been completed, the “Start” button will return grey to show that the feeding
sequence is not active.
o “Reset” button: once the “Reset” button is pushed, a pop-up “Water dosing to kettles
sequence will be reset: YES / NO” will be shown. If “NO” is selected, the pop-up will
be closed, if “YES” is pushed, the following operation will be done:
 “actual value” B is reset,
 timers t1 is reset,
“Reset” button can be pushed only if the sequence is not running and automatic valve
AV-126.3B is closed. In this case, the button will be grey, otherwise it is yellow
Additional notes:
 set point for the water to be charged can’t be modified if the sequence is running,
 if the sequence is stopped by an interlock, the system will be set in the same conditions
as if the “Stop” button is pushed,
 when the interlock that previously blocked the sequence is removed (and the alarm
recognized), the automatic sequence has to be started / restarted by operator.
 Water dosing to kettles manual use.

Safety will be done by interlocks only (see details in section 7).
All the locks due to the “Water dosing to kettles” automatic sequence on valve AV-126.3B will
be removed.
All the operations have to be done manually by operators (opening / closing of valve).
8.21 Idle for reactor
The purpose of the “Reactor idle” sequence for reactor R-1262.02 is to recirculate the soap in the
reactor loop, by decision of the operator hitting the “Reactor idle” key.
85
On the video page of reactor R-1262.02, next to the soap recycle pump P-1262.20, a table with the
following values:
 timer trun12 [min],
 timer tstop12 [min]
has to be shown. Both timers work as countdown.
Conditions for “Reactor idle” sequence to be effective are:

 “Reactor feeding” sequence not active,
 reactor R-1262.02 feeding automatic valves AV-126.31/32/33 closed,
 soap from reactor R-1262.02 automatic valve AV-126.11 closed,
 reactor R-1262.02 recycle inlet automatic valve AV-126.7 open,
 reactor R-1262.02 recycle outlet automatic valve AV-126.8 open,
 reactor R-1262.02 high pressure PISH-126.12 alarm (PAH-126.12) off,
 reactor R-1262.02 high pressure PIT-126.10 alarm (PAH-126.10) off,
 reactor R-1262.02 very high pressure PIT-126.10 alarm (PAHH-126.10) off,
 reactor R-1262.02 high temperature TE/TT-126.9 alarm (TAH-126.9) off,
 reactor R-1262.02 very high temperature TE/TT-126.9 alarm (TAHH-126.9) off.
The activation of the “Reactor idle” sequence, through the relevant pushbutton, will have the
following effects (sequential actions):
1. soap recycle pump P-1262.20 is started for an interval of time trun (countdown is shown on
the video page of P-1262.20),
2. when timer trun expires, the soap recycle pump P-1262.20 is stopped and the timer trun is
reset,
3. when the soap recycle pump P-1262.20 is stopped, timer tstop is started (countdown is shown
on the video page of P-1262.20),
4. when timer tstop expires, the “Reactor idle” sequence is restarted and the timer tstop is reset.
Conditions for “Reactor idle” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched (exception PAH-126.10
and TAH-126.9 on – see below),
 activation of an interlock on soap recycle pump P-1262.20,
 fault on soap recycle pump P-1262.20,
86
 decision of the operator of stopping the sequence by pushing the “Reactor idle” key while
the sequence is running.
When the sequence is stopped, soap recycle pump P-1262.20 is stopped and the timers t run and tstop
are reset.
Additional notes:
 if reactor R-1262.02 high pressure PIT-126.10 alarm (PAH-126.10) goes from off to on 6
while the sequence is running, the sequence is suspended:
o timers trun and tstop are stopped and reset,
o soap recycle pump P-1262.20 is stopped,
o alarm is given and the “Reactor idle” pushbutton becomes blue,
o pop-up ““Reactor idle” sequence suspended” is shown,
 if reactor R-1262.02 high pressure PIT-126.10 alarm (PAH-126.10) goes from on to off 6
while the sequence is suspended, the sequence is restarted from the step number 1
previously described,
 if reactor R-1262.02 high temperature TE/TT-126.9 alarm (TAH-126.9) goes from off to on 7
while the sequence is running, the sequence is suspended:
o timers trun and tstop are stopped and reset,
o soap recycle pump P-1262.20 is stopped,
o alarm is given and the “Reactor idle” pushbutton becomes blue,
o pop-up ““Reactor idle” sequence suspended” is shown,
 if reactor R-1262.02 high temperature TE/TT-126.9 alarm (TAH-126.9) goes from on to off 7
while the sequence is suspended, the sequence is restarted from the step number 1
previously described.
If all the conditions which allow the activation of the sequence are effective, the “Reactor idle”
button becomes grey to indicate the possibility to activate the sequence, otherwise it is yellow
When “Reactor idle” sequence is active, the key will be green.
When “Reactor idle” sequence is active, but suspended, the key will be blue.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Reactor idle” sequence and which ones are currently activated or missing.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.
87
8.22 Saponification stand-by
The purpose of the “Saponification stand-by” sequence is to bring the plant to a safe situation in one
of the following events:
 general power / utilities failure,
 steam 15 ÷ 16 barg very low pressure alarm PIT-120.1 (PALL-120.1 ON),
 steam 4 barg very low pressure alarm PIT-120.4 (PALL-120.4 ON),
 steam 2 barg very low pressure alarm PIT-120.2 (PALL-120.2 ON),
 instrument air very low pressure alarm PIT-120.3A (PALL-120.3A ON),
 decision of the operator by hitting the software “Saponification stand-by” key,
 decision of the operator by hitting the field emergency buttons (HS-126.200 or HV-
126.201),
 anomalous conditions during steady plant operation as indicated in the following
paragraphs.
Any of the above events can be by-passed (password required) to allow easier operation during
start-up and shutdown (one ON / OFF button for each alarm).
Above very low pressure alarms activate after a delay time12 (one timer for all the switches).
Start-up, shutdown, pipe draining and steam blowing operation had to be done manually by
operators (combined operation from PC and “on-field”).
The anomalous conditions during steady plant operation that must be taken in account to activate
“Saponification stand-by” sequence are the following:
1. Deviation of actual flow rate versus set point of the mass dosing loops (FICQ-104.1, FICQ-
117.8, FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4) feeding the reactor 29 (only
if relevant set point is different from 0 kg/h30),
2. Generic failure on reactor R-1262.02 dosing pumps:
 EDTA solution feed tank D-1042.01 discharge automatic valve AV-104.3 fault or
change of status (i.e. from open to not open) (only if AV-104.5 is open and set point of
FICQ-104.1 is different from 0 kg/h30),
 EDTA feed pump P-1042.01 fault or change of status (i.e. from running to stopped)
(only if AV-104.5 is open and set point of FICQ-104.1 is different from 0 kg/h30),
 EDTA to reactor R-1262.02 automatic valve AV-104.5 fault or change of status (i.e.
from open to not open) (only if set point of FICQ-104.1 is different from 0 kg/h30),
 EDTA recycle automatic valve AV-104.6 fault or change of status (i.e. from closed to
not closed) (only if set point of FICQ-104.1 is different from 0 kg/h30),
88
 EHDP solution feed tank D-1172.08 discharge automatic valve AV-117.3B fault or
change of status (i.e. from open to not open) (only if AV-117.5B is open and set point of
FICQ-117.8 is different from 0 kg/h30),
 EHDP feed pump P-1172.08 fault or change of status (i.e. from running to stopped)
(only if AV-117.5B is open and set point of FICQ-117.8 is different from 0 kg/h30),
 EHDP to reactor R-1262.02 automatic valve AV-117.5B fault or change of status (i.e.
from open to not open) (only if set point of FICQ-117.8 is different from 0 kg/h30),
 EHDP recycle automatic valve AV-117.6B fault or change of status (i.e. from closed to
not closed) (only if set point of FICQ-117.8 is different from 0 kg/h30),
 F.A. / N.O. blend feed tank D-1262.01A outlet automatic valve AV-126.11A and F.A. /
N.O. blend feed tank D-1262.01B outlet automatic valve AV-126.11B not open (or one
of the valves in reference on fault),
 F.A. / N.O. blend feed pump P-1262.01A fault or change of status (i.e. from running to
stopped) (only if P-1262.01B is not running),
 F.A. / N.O. blend feed pump P-1262.01B fault or change of status (i.e. from running to
stopped) (only if P-1262.01A is not running),
 F.A. / N.O. blend recycle to feed tank D-1262.01A automatic valve AV-126.111A and
F.A. / N.O. blend recycle to feed tank D-1262.01B automatic valve AV-126.111B not
open (or one of the valves in reference on fault),
 caustic soda feed tank D-1262.02 discharge automatic valve AV-126.12 fault or change
of status (i.e. from open to not open),
 caustic soda feed pump P-1262.02 fault or change of status (i.e. from running to
stopped),
 process water feed tank D-1262.03 discharge automatic valve AV-126.13 fault or change
of status (i.e. from open to not open),
 process water feed pump P-1262.03 fault or change of status (i.e. from running to
stopped),
 brine feed tank D-1262.04 discharge automatic valve AV-126.14 fault or change of
status (i.e. from open to not open) (only if set point of FICQ-126.4 is different from 0
kg/h30),
 brine feed pump P-1262.04 fault or change of status (i.e. from running to stopped) (only
if set point of FICQ-126.4 is different from 0 kg/h30),
3. Generic failure on reactor R-1262.02:
 recycle pump P-1262.20 fault or change of status (i.e. from running to stopped),
89
 raw materials feeding automatic valves (AV-126.31 or AV-126.33) fault or change of
status (i.e. from open to not open),
 reactor R-1262.02 recycle inlet automatic valve AV-126.7 or reactor R-1262.02 recycle
outlet automatic valve AV-126.8 fault or change of status (i.e. from open to not open),
 reactor R-1262.02 very high pressure PIT-126.10 alarm (PAHH-126.10 ON),
 reactor R-1262.02 high pressure PISH-126.12 alarm (PAH-126.12 ON),
4. Generic failure on reactor R-1262.02 outlet:
 reactor R-1262.02 outlet automatic valve AV-126.11 fault (valve can be manually closed
by operator if it is required). For “Reactor feeding” activation the position of the valve
(open or closed) is not relevant,
 reactor R-1262.02 outlet automatic valve AV-126.11 change of status (i.e. from open to
not open) (only if AV-204.1 is open),
 turbomixer R-2012.01 fault or change of status (i.e. from running to stopped) (only if
AV-126.11 is open),
 soap to turbomixer R-2012.01 hand valve HV-201.1 fault or change of status (i.e. from
open to not open) (only if HV-201.3 is closed),
 soap from turbomixer R-2012.01 hand valve HV-201.2 fault or change of status (i.e.
from open to not open) (only if HV-201.3 is closed),
 turbomixer R-2012.01 by-pass hand valve HV-201.3 change of status (i.e. from not open
to open) (only if HV-201.1 OR HV-201.2 are open),
 soap to turbomixer R-2012.01 hand valve HV-201.1 fault or change of status (i.e. from
closed to not closed) (only if HV-201.3 is open),
 soap from turbomixer R-2012.01 hand valve HV-201.2 fault or change of status (i.e.
from closed to not closed) (only if HV-201.3 is open),
 turbomixer R-2012.01 by-pass hand valve HV-201.3 fault or change of status (i.e. from
open to not open) (only if HV-201.1 or HV-201.2 are closed),
 soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 and soap recycle to
kettles PS-1242.03A/B automatic valve AV-204.2 not open (or one of the valves in
reference on fault),
5. Generic failure on additives section (only if AV-204.1 is open):
 glycerine feed tank D-1172.06 discharge automatic valve AV-117.3A fault or change of
status (i.e. from open to not open) (only if AV-117.5A is open and set point of FICQ-
117.6 is different from 0 kg/h30),
 glycerine feed pump P-1172.06 fault or change of status (i.e. from running to stopped)
(only if AV-117.5A is open and set point of FICQ-117.6 is different from 0 kg/h30),
90
 deviation of actual flow rate versus set point of the glycerine mass dosing loop (FICQ-
117.6) feeding the dryer29 (only if AV-117.5A is open and set point of FICQ-117.6 is
different from 0 kg/h30),
 glycerine to dryer automatic valve AV-117.5A fault or change of status (i.e. from open
to not open) (only if set point of FICQ-117.6 is different from 0 kg/h30),
 glycerine recycle automatic valve AV-117.6A fault or change of status (i.e. from closed
to not closed) (only if set point of FICQ-117.6 is different from 0 kg/h30),
6. Generic failure on dryer vacuum chamber SD-2042.01 (only if AV-204.1 is open):
 vacuum chamber SD-2042.01 motor fault or change of status (i.e. from running to
stopped),
 very high torque JI-204.101 alarm (JAHH-204.101 ON) on vacuum chamber SD-
2042.01 motor23,
 high level LSH-204.13 alarm (LAH-204.13 ON) on vacuum chamber SD-2042.01 for
more than 10”8, 12,
7. Generic failure on vacuum pump P-2062.01 and condensation system (only if AV-204.1 is
open):
 vacuum pump P-2062.01 fault or change of status (i.e. from running to stopped),
 very high pressure PIT-206.11 alarm (PAHH-206.11 ON) on vacuum chamber SD-
2042.01,
 semi-barometric ICS water recycle pump P-2062.02 fault or change of status (i.e. from
running to stopped),
 low flow FSL-206.2 alarm (FAL-206.2 ON) on semi-barometric ICS water recycle
pump P-2062.02 suction line for more than a pre-set time12,
 very high level LSHH LIT-206.1 alarm (LAHH-206.1 ON) on semi-barometric
condenser C-2062.03 for more than 5”12,
 very high level LSHH-206.3 alarm (LAHH-206.3 ON) on semi-barometric condenser C-
2062.03 for more than 5”9, 12,
 very low level LSLL LIT-206.1 alarm (LALL-206.1 ON) on semi-barometric condenser
C-2062.03,
 very low level LSLL-206.3 alarm (LALL-206.3 ON) on semi-barometric condenser C-
2062.03,
 very high temperature TE/TT-249.1 alarm (TAHH-249.1) for chilled water,
8. Generic failure on feeding sequences activation:
 time-out timer for “Reactor feeding” sequence alarm31,
 time-out timer for “Vacuum chamber feeding” sequence alarm31,
91
 time-out timer for “Additives feeding” sequence alarm31,
9. Generic failure on recycle sequences activation:
 time-out timer for “Vacuum chamber recycle” sequence alarm31,
 time-out timer for “Additives recycle” sequence alarm31,
10. Generic failure on system:
 interlocks from enabled to disabled.
The activation of the “Saponification stand-by” sequence will have the following effects:
 put on manual loops FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4 with output
0% to control valves and close relevant XY solenoid valves,
 open EDTA recycle automatic valve AV-104.6 and close EDTA to reactor R-1262.02
automatic valve AV-104.5 (further info in sequences section 8.3),
 open glycerine recycle automatic valve AV-117.6A and close glycerine to dryer automatic
valve AV-117.6B5A (further info in sequences section 8.4),
 open EHDP recycle automatic valve AV-117.6B and close EHDP to reactor R-1262.02
automatic valve AV-117.5B (further info in sequences section 8.7),
 close the reactor R-1262.02 feeding automatic valves AV-126.31/32/33,
 put on manual loops TIC-126.5 and TIC-126.6 with output 0% to control valves and close
relevant XY solenoid valves,
 stop soap from kettles PS-1242.03A/B transfer pumps P-1242.03A/B,
 close reactor R-1262.02 outlet automatic valve AV-126.11 and put on manual loop PIC-
126.10 with output 0% to control valve and close relevant XY solenoid valve. This
operation has a delay time of 5”12 in relation to stand-by sequence activation,
 stop turbomixer R-2012.01. This operation has a delay time of 5” 12 in relation to stand-by
sequence activation (same timer which delay the closure of AV-126.11 and XY-126.10),
 close soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 and open soap
recycle to kettles PS-1242.03A/B automatic valve AV-204.2 (further info in sequences
section 8.19). After 5”, PIC-204.10 is set on manual mode and control valve PV-204.10 is
blocked open 100% (relevant XY solenoid valve is set to open), then valve AV-204.3 opens
for 5” (time can be changed in a dedicated video page). When the blowing time expires, the
automatic steam valve AV-204.3 is closed. At this point, also PV-204.10 is closed (relevant
XY solenoid valve is set to close),
 stop preliminary plodder PL-2042.01’s motor,
 stop final plodder PL-2042.01’s motor,
 time-out timers for feeding sequences stopped and reset31.
92
If any anomalous condition that has previously caused the stand-by sequence is still active, the
“Saponification stand-by” key becomes yellow (blinking), otherwise it is grey.
A dedicated help video page has to be foreseen in order to show all the conditions that can activate
the “Saponification stand-by” sequence and which ones are currently activated.
8.23 Reactor feeding
The purpose of the “Reactor feeding” sequence is to allow to start or restart the plant (i.e. to feed
reactor R-1262.02), by decision of the operator hitting the “Reactor feeding” key.
If any anomalous condition that has previously caused the stand-by sequence is still active, the
“Reactor feeding” key cannot have any effect.
Conditions for “Reactor feeding” sequence to be effective are:

 any anomalous condition that can cause the “Saponification stand-by” sequence not active,
 “Idle for reactor” sequence not active,
 “Soap pipes cleaning” sequence not active,
 EDTA feed pump P-1042.01 running (only if set point of FICQ-104.1 is different from 0
kg/h30),
 EHDP feed pump P-1172.08 running (only if set point of FICQ-117.8 is different from 0
kg/h30),
 F.A. / N.O. blend feed pump P-1262.01A or F.A. / N.O. blend feed pump P-1262.01B
running,
 caustic soda feed pump P-1262.02 running,
 process water feed pump P-1262.03 running,
 brine feed pump P-1262.04 running (only if set point of FICQ-126.4 is different from 0
kg/h30),
 reactor R-1262.02 recycle inlet automatic valve AV-126.7 open,
 reactor R-1262.02 recycle outlet automatic valve AV-126.8 open,
 reactor R-1262.02 very high pressure PIT-126.10 alarm (PAHH-126.10) off,
 reactor R-1262.02 high pressure PISH-126.12 alarm (PAH-126.12) off,
 ((soap to turbomixer R-2012.01 hand valve HV-201.1 and soap from turbomixer R-2012.01
hand valve HV-201.2 open) and turbomixer R-2012.01 by-pass hand valve HV-201.3 not
93
open) or ((soap to turbomixer R-2012.01 hand valve HV-201.1 and soap from turbomixer R-
2012.01 hand valve HV-201.2 closed) and turbomixer R-2012.01 by-pass hand valve HV-
201.3 open),
 soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 open and soap to vacuum
chamber SD-2042.01 automatic valve AV-204.1 closed.
When the operator wants to start the production (soap to reactor R-1262.02), the “Reactor feeding”
key has to be pushed. This operation will:
 put all the raw materials feeding the reactor (FICQ-104.1, FICQ-126.1A, FICQ-126.2,
FICQ-126.3, FICQ-126.4 and FICQ-117.8) on auto mode (FICQ settings remain as they are
because we are not giving any shot command here when we go to stand-by) (only if
relevant set point is different from 0 kg/h30),
 open EDTA to reactor R-1262.02 automatic valve AV-104.5 and close EDTA recycle
automatic valve AV-104.6 (only if set point of FICQ-104.1 is different from 0 kg/h 30)
(further info in sequences section 8.3),
 open EHDP to reactor R-1262.02 automatic valve AV-117.5B and close EHDP recycle
automatic valve AV-117.6B (only if set point of FICQ-117.8 is different from 0 kg/h 30)
 mass flow control valves FV-126.1A, FV-126.2, FV-126.3 and FV-126.4 start opening from
pre-set values that can be defined for each single valve in a dedicated video page ( only if
relevant set point is different from 0 kg/h30),
 put on auto mode loops TIC-126.5 and TIC-126.6 (TIC settings remain as they are because
we are not giving any shot command here when we go to stand-by) and open relevant XY
solenoid valves,
 temperature control valves TV-126.5/6 start opening from pre-set values that can be defined
for each single valve in a dedicated video page,
 open the reactor R-1262.02 feeding automatic valves AV-126.31/33,
 open the reactor R-1262.02 outlet valve AV-126.11 (automatic valve can be, afterwards,
manually closed by operator, if it is required, without activating the “Saponification stand-
by”, but only if AV-204.1 is closed), open solenoid valve XY-126.10 and put on auto mode
pressure control loop PIC-126.10 (PIC setting remains as it is because we are not giving any
shot command here when we go to stand-by),
 pressure control valve PV-126.10 starts opening from pre-set value that can be defined for
each single valve in a dedicated video page,
94
 open soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 and close soap to
vacuum chamber SD-2042.01 automatic valve AV-204.1 (further info in sequences section
8.19),
 show a pop-up to start P-1262.20, if it’s not running (pump P-1262.20 start-up sequence, see
sequence 8.15). The choice to start the item is up to the operator,
 time-out timer for “Reactor feeding” sequence started31.
If all the conditions which allow the activation of the sequence are effective, the “Reactor feeding”
button will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
When “Reactor feeding” sequence is active (i.e. relevant pushbutton pressed and AV-126.31 and
AV-126.33 are open), the colour of the key will be green.
to activate the “Reactor feeding” sequence and which ones are currently activated or missing.
8.24 Vacuum chamber feeding
The purpose of the “Vacuum chamber feeding” sequence is to allow to start the production (i.e.
soap to vacuum chamber SD-2042.01), by decision of the operator hitting the “Vacuum chamber
feeding” key.
Conditions for “Vacuum chamber feeding” sequence to be effective are:

 “Reactor feeding” sequence active,
 soap recycle pump P-1262.20 running,
 soap from reactor R-1262.02 automatic valve AV-126.11 open,
 chilled water very high temperature TE/TT-249.1 alarm (TAHH-249.1) off,
 soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 open and soap to vacuum
chamber SD-2042.01 automatic valve AV-204.1 closed,
 atomizer SD-2042.01 motor running,
 vacuum chamber SD-2042.01 very high pressure PIT-206.11 alarm (PAHH-206.11) off,
 vacuum chamber SD-2042.01 high level LSH-204.13 alarm (LAH-204.13) off8,
 vacuum pump P-2062.01 running,
 semi-barometric ICS water recycle pump P-2062.02 running,
95
 semi-barometric ICS water recycle pump P-2062.02 suction line low flow FSL-206.2 alarm
(FAL-206.2) off,
 semi-barometric condenser C-2062.03 very high level LSHH-206.1 alarm (LAHH-206.1)
off,
 semi-barometric condenser C-2062.03 very high level LSHH-206.3 alarm (LAHH-206.3)
off9,
 semi-barometric condenser C-2062.03 very low level LSLL-206.1 alarm (LALL-206.1) off,
 semi-barometric condenser C-2062.03 very low level LSLL-206.3 alarm (LALL-206.3) off.
When the operator wants to start the production (soap to vacuum chamber SD-2042.01), the
“Vacuum chamber feeding” key has to be pushed. This operation will:
 open soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 (further info in
sequences section 8.19),
 close recycle to kettles PS-1242.03A/B automatic valve AV-204.2 (valve AV-204.4 is set to
open for 10”22) (further info in sequences section 8.19),
 at the same time, open XY-204.10 and put on automatic mode loop PIC-204.10 (PIC setting
remains as it is because we are not giving any shot command here when we go to stand-by),
 pressure control valve PV-204.10 starts opening from pre-set value that can be defined for
each single valve in a dedicated video page,
 pop-ups for direct opening/closing of soap to vacuum chamber SD-2042.01 automatic valve
AV-204.1 and soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 are
disabled (when “Vacuum chamber feeding” sequence is active, to manually operate on these
valves, only the sequences pushbuttons can be used),
 time-out timer for “Vacuum chamber feeding” sequence started 31 (time-out timer for this
sequence is given by the timer of interlock n. of AV-204.4 plus 10”).
If all the conditions which permit the activation of the sequence are effective, the “Vacuum
chamber feeding” button will become grey to indicate the possibility to activate the sequence itself,
otherwise it is yellow (blinking - impossibility of activating the sequence).
When “Vacuum chamber feeding” sequence is active (i.e. relevant pushbutton pressed, AV-204.1
open, solenoid valve XY-204.10 open and motor of atomizer SD-2042.01 running), the colour of
the key will be green.
to activate the “Vacuum chamber feeding” sequence and which ones are currently activated or
missing.
96
Plodder's motors have to be restarted manually by operator at the proper moment.
The operator can end the previous sequence, without activating the “Saponification stand-by”
sequence, by pushing the “Recycle” key (when the sequence is already running). This operation
will:
 open soap recycle to kettles PS-1242.03A/B automatic valve AV-204.2 (further info in
sequences section 8.19),
 close soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 (further info in
sequences section 8.19). After 5”, PIC-204.10 is set on manual mode and control valve PV-
204.10 is blocked open 100% (relevant XY solenoid valve is set to open), then valve AV-
204.3 opens for 5” (time can be changed in a dedicated video page). When the blowing time
expires, the automatic steam valve AV-204.3 is closed. At this point, also PV-204.10 is
closed (relevant XY solenoid valve is set to close),
valve AV-117.5A (further info in sequences section 8.4),
 start time-out timer for “Vacuum chamber recycle” sequence 31 (time-out timer for this
sequence is given by the timer of interlock n. of AV-204.3 plus 10”).
8.25 Additives feeding
The purpose of the “Additives feeding” sequence is to allow to start the feeding of the additives to
the soap, by decision of the operator hitting the “Additives feeding” key.
Conditions for “Additives feeding” sequence to be effective are:

 “Vacuum chamber feeding” sequence activated,
 glycerine feed pump P-1172.06 running (only if set point of FICQ-117.6 is different from 0
kg/h30),
 turbomixer R-2012.01 running (only if HV-201.1 and HV-201.2 are open).
By pressing the “Additives feeding” key, the following operation will be done:
 all the additives feeding pumps will be put in production, this means:
97
 put all the additives feeding the dryer (FICQ-117.6) on auto mode (FICQ settings remain
as they are because we are not giving any shot command here when we go to stand-by)
(only if relevant set point is different from 0 kg/h30),
 open glycerine to dryer automatic valve AV-117.5A and close glycerine recycle
automatic valve AV-117.6A (only if set point of FICQ-117.6 is different from 0 kg/h30)
 time-out timer for “Additives feeding” sequence started31.
If all the conditions which permit the activation of the sequence are effective, “ Additives feeding”
key will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
(blinking - impossibility of activating the sequence). If all the additives are off 30, the “Additives
feeding” key will be yellow (blinking - impossibility of activating the sequence).
When “Additives feeding” sequence is active (i.e. relevant pushbutton pressed and AV-117.5A
open - only if set point of FICQ-117.6 is different from 0 kg/h 30), the colour of the key will be
green.
to activate the “Additives feeding” sequence and which ones are currently activated or missing.
The operator can end the previous sequence, without activating the “Saponification stand-by”
sequence, by pushing the “Recycle” key, which involves:
valve AV-117.5A (further info in sequences section 8.4),
 start time-out timer for “Additives recycle” sequence31.
8.26 Soap pipes cleaning
The purpose of the “Soap pipes cleaning” sequence is to allow the cleaning of the soap recycle pipe
and the soap to vacuum chamber pipe, by decision of the operator hitting the “Soap pipes cleaning”
key.
Conditions for “Soap pipes cleaning” sequence to be effective are:

 “Reactor feeding” sequence not active,
 “Vacuum chamber feeding” sequence not active,
98
 “Additives feeding” sequence not active,
 “Idle for reactor” sequence not active,
 glycerine to dryer automatic valve AV-117.5A closed,
 soap from reactor R-1262.02 automatic valve AV-126.11 closed,
 pressure control valve PV-126.10 closed (relevant XY solenoid valve closed and control on
manual with opening on 0%),
 vacuum chamber SD-2042.01 very high pressure PIT-206.11 alarm (PAHH-206.11) off.
When the operator wants to start the sequence, the “Soap pipes cleaning” key has to be pushed. This
operation will:
 open AV-204.1 (AV-204.2 closes - further info in sequences section 8.19) and open valve
AV-204.422,
 at the end of the previous operation, close the atomizer feeding valve AV-204.1 (AV-204.2
opens - further info in sequences section 8.19), valve PV-204.10 is blocked open 100% and
valve AV-204.3 opens21.
If all the conditions which allow the activation of the sequence are effective, the “Soap pipes
cleaning” button becomes grey to indicate the possibility to activate the sequence itself, otherwise
the button is yellow (blinking - impossibility of activating the sequence).
When “Soap pipes cleaning” sequence key is active (i.e. relevant pushbutton pressed), the colour of
the key will be green (blinking).
to activate the “Soap pipes cleaning” sequence and which ones are currently activated or missing.
“Soap pipes cleaning” sequence can be stopped by decision of the operator hitting the “Reset” key
or the “Saponification stand-by” button.
By pushing the “Reset” key (when the sequence is already running), the system will:
 close soap to vacuum chamber SD-2042.01 automatic valve AV-204.1 and open soap
recycle to kettles PS-1242.03A/B automatic valve AV-204.2 (further info in sequences
section 8.19),
 close steam valves AV-204.3 and AV-204.4,
 After 5”, PIC-204.10 is set on manual mode and control valve PV-204.10 is closed (relevant
XY solenoid valve is set to close).
When cleaning sequence is on, if any automatic valve of cleaning, production or recycle goes on
fault or changes position (i.e. operators choice) or “Reset” key is pushed or one (or more) of the
99
sequence activation conditions is not met, then the cleaning sequence must be terminated by PLC
(same operation done when “Reset” button is pushed).
8.27 Pneumatic transport
The purpose of the “Pneumatic transport” sequence is to allow the fast and safe change of the
noodles storage silo, by decision of the operator hitting the relevant key.
It will be possible to select the desired silo through proper graphic pushbuttons shown on the
pneumatic transport video page (pushbuttons “Silo #A”, “Silo #B” and “Silo #C”).
Conditions for silo D-2502.01A to be selected are:

 silo D-2502.01A high level LSH-250.1A (DI) alarm (LAH-250.1A (DI)) off,
 silo D-2502.01A very high level LSHH-250.1A (AI) alarm (LAHH-250.1A (AI)) off,
 exhaust air throttle automatic valve VF-2502.01A not in fault,
 exhaust air filter F-2502.05 fan or exhaust air filter F-2502.06 fan running.
100
By pressing the “Silo #A” button, the following operations will be done (2 different possibilities are foreseen):
Step Action Duration Action Duration

DV-2502.01A open in the direction of silo D-2502.01A DV-2502.01A not open in the direction of silos D-2502.01A
IF
(ZLL-250.11 ON) (ZLL-250.11 not ON)
 Final plodder PL-2042.01 stopped, if running.  Final plodder PL-2042.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”12 5”12
PL-2042.01 (blinking). 2042.01 (blinking).
 Countdown tS12 reset and started.  Countdown tS12 reset and started.
 Blower B-2502.01. stopped, if running.  Blower B-2502.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”12  Pop-up “stand-by” appears next to blower B- 5”12
2502.01 (blinking). 2502.01 (blinking).
 Solenoid valve XY-250.11B set to open.
3  Exhaust air throttle automatic valve VF- 3”12  Solenoid valve XY-250.11B set to close. 3”12
2502.01A set to open.
 Pop-up “stand-by” next to blower B-2502.01
Until ZLL-
disappears.  Diverting valve DV-2502.01A set to open in the
4 10”12 250.11 is ON
 Blower B-2502.01 started again, only if it was direction of D-2502.01A.
+ 6”12
running.
5  Pop-up “stand-by” next to final plodder PL- Y”12  Solenoid valve XY-250.11B set to open. 3”12
2042.01disappears.  Exhaust air throttle automatic valve VF-2502.01A
 Final plodder PL-2042.01 started again, only if set to open.
it was running, with a speed equal to the one
101
before pressing pushbutton “Silo #A” plus X
[%]32 for Y”12, then it will return to the speed
before pressing pushbutton “Silo #A”.
 Solenoid valve XY-250.101A set to open.
Sequence completed.
If timer tS expires before completing the
sequence, the sequence is stopped and alarm is
given.
The pop-ups “stand-by” next to final plodder
PL-2042.01 and blower B-2502.01 disappears
and the two items are stopped.
disappears.
6 / / 10”12
 Blower B-2502.01 started again, only if it was
running.
7 / /  Pop-up “stand-by” next to final plodder PL-2042.01 Y”12
disappears.
 Final plodder PL-2042.01started again, only if it
was running, with a speed equal to the one before
pressing pushbutton “Silo #A” plus X [%] 32 for Y”12,
then it will return to the speed before pressing
pushbutton “Silo #A”.
 Solenoid valve XY-250.101A set to open.
102
Sequence completed.
If timer tS expires before completing the sequence,
the sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
2042.01 and blower B-2502.01 disappears and the
two items are stopped.
If all the conditions which permit the selection of soap noodles storage silo D-2502.01A are effective, the “Silo #A” button will become grey to
indicate the possibility to activate the sequence itself, otherwise it is yellow (blinking - impossibility of activating the sequence).
When “Silo #A” key is active (i.e. relevant pushbutton pressed, DV-2502.01A open in the direction of D-2502.01A, XY-250.11B open and VF-
2502.01A open), its colour will be green (still).
While the sequence to open DV-2502.01A in the direction of silo D-2502.01A is still running, the colour of “Silo #A” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-2502.01A and which ones are
currently activated or missing.
Conditions for silo D-2502.01B to be selected are:

 silo D-2502.01B high level LSH-250.1B (DI) alarm (LAH-250.1B (DI)) off,
 silo D-2502.01B very high level LSHH-250.1B (AI) alarm (LAHH-250.1B (AI)) off,
 exhaust air throttle automatic valve VF-2502.01B not in fault,
103
By pressing the “Silo #B” button, the following operations will be done (4 different possibilities are foreseen):

DV-2502.01A open in the direction of silos D-2502.01B/C DV-2502.01A open in the direction of silos D-2502.01B/C (ZLH-250.11
IF (ZLH-250.11 ON) AND DV-2502.01B open in the direction of ON) AND DV-2502.01B not open in the direction of silo D-2502.01B
silo D-2502.01B (ZLL-250.12 ON) (ZLL-250.12 not ON)
1 5”12 5”12
 Blower B-2502.01 stopped, if running.  Blower B-2502.01 stopped, if running.
 Solenoid valve XY-250.12B set to open.  Solenoid valve XY-250.11B set to open.
3 3”12 3”12
 Exhaust air throttle automatic valve VF-  Solenoid valve XY-250.12B set to close.
2502.01B set to open.
Until ZLL-
disappears.  Diverting valve DV-2502.01B set to open in the
4 10”12 250.12 is ON
 Blower B-2502.01 started again, only if it was direction of D-2502.01B.
+ 6”12
running.
5  Pop-up “stand-by” next to final plodder PL- Y”12  Solenoid valve XY-250.12B set to open. 3”12
104
2042.01 disappears.
 Final plodder PL-2042.01 started again, only if
before pressing pushbutton “Silo #B” plus X
before pressing pushbutton “Silo #B”.
 Solenoid valve XY-250.101B set to open.  Exhaust air throttle automatic valve VF-2502.01B
Sequence completed. set to open.
given.
disappears.
6 / / 10”12
running.
disappears.
 Final plodder PL-2042.01 started again, only if it
pressing pushbutton “Silo #B” plus X [%] 32 for Y”12,
105
pushbutton “Silo #B”.
Sequence completed.

DV-2502.01A not open in the direction of silos D-2502.01B/C DV-2502.01A not open in the direction of silos D-2502.01B/C (ZLH-
IF (ZLH-250.11 not ON) AND DV-2502.01B open in the direction 250.11 not ON) AND DV-2502.01B not open in the direction of silo D-
of silo D-2502.01B (ZLL-250.12 ON) 2502.01B (ZLL-250.12 not ON)
1 5”12 5”12
 Countdown tS11 reset and started. Countdown tS11 reset and started.
 Solenoid valve XY-250.11B set to close.
3  Solenoid valve XY-250.11B set to close. 3”12 3”12
106
Until Until (ZLH-
 Diverting valve DV-2502.01A set to open in the
ZLH- 250.11 is ON
 Diverting valve DV-2502.01A set to open in the direction of D-2502.01B/C.
4 250.11 is AND ZLL-
direction of D-2502.01B/C.  Diverting valve DV-2502.01B set to open in the
ON + 250.12 is ON)
direction of D-2502.01B.
6”12 + 6”12
 Solenoid valve XY-250.12B set to open  Solenoid valve XY-250.12B set to open
5 3”12 3”12
 Exhaust air throttle automatic valve VF-  Exhaust air throttle automatic valve VF-2502.01B
2502.01B set to open. set to open.
 Pop-up “stand-by” next to blower B-2502.01  Pop-up “stand-by” next to blower B-2502.01
disappears. disappears.
6 1012 1012
 Blower B-2502.01 started again, only if it was  Blower B-2502.01 started again, only if it was
running. running.
7  Pop-up “stand-by” next to final plodder PL- Y”12  Pop-up “stand-by” next to final plodder PL-2042.01 Y”12
2042.01 disappears. disappears.
 Final plodder PL-2042.01 started again, only if  Final plodder PL-2042.01 started again, only if it
it was running, with a speed equal to the one was running, with a speed equal to the one before
before pressing pushbutton “Silo #B” plus X pressing pushbutton “Silo #B” plus X [%] 32 for Y”12,
[%]32 for Y”12, then it will return to the speed then it will return to the speed before pressing
before pressing pushbutton “Silo #B”. pushbutton “Silo #B”.
 Solenoid valve X-250.101B set to open.  Solenoid valve X-250.101B set to open.
Sequence completed. Sequence completed.
If timer tS expires before completing the If timer tS expires before completing the sequence,
107
given.
If all the conditions which permit the selection of soap noodles storage silo D-2502.01B are effective, the “Silo #B” button will become grey to
When “Silo #B” key is active (i.e. relevant pushbutton pressed, DV-2502.01A open in the direction of D-2502.01B/C, XY-250.11B open, DV-
2502.01B open in the direction of D-2502.01B, XY-250.12B open and VF-2502.01B open), its colour will be green (still).
While the sequence to open DV-2502.01A/B in the direction of silo D-2502.01B is still running, the colour of “Silo #B” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-2502.01B and which ones are
Conditions for silo D-2502.01C to be selected are:

 silo D-2502.01C high level LSH-250.1C (DI) alarm (LAH-250.1C (DI)) off,
 silo D-2502.01C very high level LSHH-250.1C (AI) alarm (LAHH-250.1C (AI)) off,
 exhaust air throttle automatic valve VF-2502.01B not in fault,
108
By pressing the “Silo #C” button, the following operations will be done (4 different possibilities are foreseen):

DV-2502.01A open in the direction of silos D-2502.01B/C DV-2502.01A open in the direction of silos D-2502.01B/C (ZLH-250.11
IF (ZLH-250.11 ON) AND DV-2502.01B open in the direction of ON) AND DV-2502.01B not open in the direction of silo D-2502.01C
silo D-2502.01C (ZLH-250.12 ON) (ZLH-250.12 not ON)
1 5”12 5”12
3 3”12 3”12
 Exhaust air throttle automatic valve VF-  Solenoid valve XY-250.12B set to close.
2502.01C set to open.
Until ZLH-
disappears.  Diverting valve DV-2502.01B set to open in the
4 10”12 250.12 is ON
 Blower B-2502.01 started again, only if it was direction of D-2502.01C.
+ 6”12
running.
109
 Pop-up “stand-by” next to final plodder PL-
2042.01 disappears.
 Final plodder PL-2042.01 started again, only if
before pressing pushbutton “Silo #C” plus X
before pressing pushbutton “Silo #C”.  Solenoid valve XY-250.12B set to open.
5  Solenoid valve XY-250.101C set to open. Y”12  Exhaust air throttle automatic valve VF-2502.01C 3”12
Sequence completed. set to open.
given.
disappears.
6 / / 10”12
running.
disappears.
 Final plodder PL-2042.01 started again, only if it
110
pressing pushbutton “Silo #C” plus X [%] 32 for Y”12,
pushbutton “Silo #C”.
 Solenoid valve XY-250.101C set to open.
Sequence completed.

DV-2502.01A not open in the direction of silos D-2502.01B/C DV-2502.01A not open in the direction of silos D-2502.01B/C (ZLH-
IF (ZLH-250.11 not ON) AND DV-2502.01B open in the direction 250.11 not ON) AND DV-2502.01B not open in the direction of silo D-
of silo D-2502.01C (ZLH-250.12 ON) 2502.01C (ZLH-250.12 not ON)
1 5”12 5”12
 Countdown tA11 reset and started. Countdown tA11 reset and started.
3  Solenoid valve XY-250.11B set to close. 3”12  Solenoid valve XY-250.11B set to close. 3”12
111
Until Until (ZLH-
 Diverting valve DV-2502.01A set to open in the
ZLH- 250.11 is ON
 Diverting valve DV-2502.01A set to open in the direction of D-2502.01B/C.
4 250.11 is AND ZLH-
direction of D-2502.01B/C.  Diverting valve DV-2502.01B set to open in the
ON + 250.12 is ON)
direction of D-2502.01C.
6”12 + 6”12
 Solenoid valve XY-250.12B set to open  Solenoid valve XY-250.12B set to open
5 3”12 3”12
 Exhaust air throttle automatic valve VF-  Exhaust air throttle automatic valve VF-2502.01C
2502.01C set to open. set to open.
 Pop-up “stand-by” next to blower B-2502.01  Pop-up “stand-by” next to blower B-2502.01
disappears. disappears.
6 10”12 10”12
 Blower B-2502.01 started again, only if it was  Blower B-2502.01 started again, only if it was
running. running.
7  Pop-up “stand-by” next to final plodder PL- Y”12  Pop-up “stand-by” next to final plodder PL-2042.01 Y”12
2042.01 disappears. disappears.
 Final plodder PL-2042.01 started again, only if  Final plodder PL-2042.01 started again, only if it
it was running, with a speed equal to the one was running, with a speed equal to the one before
before pressing pushbutton “Silo #C” plus X pressing pushbutton “Silo #C” plus X [%] 32 for Y”12,
[%]32 for Y”12, then it will return to the speed then it will return to the speed before pressing
before pressing pushbutton “Silo #C”. pushbutton “Silo #C”.
 Solenoid valve XY-250.101C set to open.  Solenoid valve XY-250.101C set to open.
Sequence completed. Sequence completed.
112
If timer tA expires before completing the
If timer tA expires before completing the sequence,
given.
If all the conditions which permit the selection of soap noodles storage silo D-2502.01C are effective, the “Silo #C” button will become grey to
When “Silo #C” key is active (i.e. relevant pushbutton pressed, DV-2502.01A open in the direction of D-2502.01B/C, XY-250.11B open, DV-
2502.01B open in the direction of D-2502.01C, XY-250.12B open and VF-2502.01C open), its colour will be green (still).
While the sequence to open DV-2502.01A/B in the direction of silo D-2502.01C is still running, the colour of “Silo #C” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-2502.01C and which ones are
113
If the LAH (DI) or LAHH (AI) of the selected silo goes from off to on, then an alarm is given so
that operator is alerted to manually change the silo. In this case the relevant silo pushbutton
becomes yellow (as per above description), but the valves will remain in the same position until the
operator selects another silo.
Notes:
 if interlocks are activated, to select a silo, it will be necessary to push on the relevant
pushbutton (a proper sequence will put all the valves in the correct position); it will not be
possible to directly open / close any of the diverting valves (DV-2502.01A/B),
 to open / close any of the diverting valves (DV-2502.01A/B) by pushing on it, interlocks
have to be disabled.
8.28 Silo bottom fluidization
The purpose of the “Silos bottom fluidization” sequences is to allow the injection of compressed air
in the bottom of the silos D-2502.01A/B/C to fluidize the noodles providing vigorous pulse shaking
to the noodles in the bottom parts facilitating the relevant discharges, by:
 decision of the operator opening the relevant valves,
 external inputs.
On the video page of TPCP, next to the silo D-2502.01A, a table with the following values:
 timer trun, A12 [s],
 timer tstop, A12 [s]
has to be shown. The timers work as countdown.
Conditions for “Silo D-2502.01A bottom fluidization” sequence to be effective are:

When the operator wants to start the injection of air in the bottom part of silo D-2502.01A, the
solenoid valve XY-250.201A has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-2502.01A,
2. open solenoid valve XY-250.201A for an interval of time t run, A (countdown is shown on the
video page of D-2502.01A),
3. when timer trun, A expires, the solenoid valve XY-250.201A is closed and the timer trun, A is
reset,
114
4. when the solenoid valve XY-250.201A is stopped, timer tstop, A is started (countdown is
shown on the video page of D-2502.01A),
5. when timer tstop, A expires, the “Silo D-2502.01A bottom fluidization” sequence is restarted
from point 2 and the timer tstop, A is reset.
The “Silo D-2502.01A bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101A XY-250.201A (one-shot command),
 available open/close signal (available external DI) on (one-shot command)33.
Conditions for “Silo D-2502.01A bottom fluidization” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched,
 exhaust air throttle automatic valve VF-2502.01A not open after the sequence is started (it’s
not a condition necessary to start the sequence, since it is open by the sequence itself),
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201A
while the sequence is running.
 available open/close signal (available external DI) off33.
When the sequence is stopped, the timers trun, A and tstop, A are reset.
If all the conditions which allow the activation of the sequence are effective, the solenoid valve XY-
250.101A XY-250.201A becomes grey without lock to indicate the possibility to activate the
sequence, otherwise it is grey with a lock (impossibility of activating the sequence).
When “Silo D-2502.01A bottom fluidization” sequence is active, pop-up “D-2502.01A bottom
fluidization ON” is shown, while when the sequence is stopped, the pop-up is hidden.
to activate the “Silo D-2502.01A bottom fluidization” sequence and which ones are currently
On the video page of TPCP, next to the silo D-2502.01B, a table with the following values:
 timer trun, B12 [s],
 timer tstop, B12 [s]
Conditions for “Silo D-2502.01B bottom fluidization” sequence to be effective are:

115
When the operator wants to start the injection of air in the bottom part of silo D-2502.01B, the
solenoid valve XY-250.201B has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-2502.01B,
2. open solenoid valve XY-250.201B for an interval of time t run, B (countdown is shown on the
video page of D-2502.01B),
3. when timer trun, B expires, the solenoid valve XY-250.201B is closed and the timer trun, B is
reset,
4. when the solenoid valve XY-250.201B is stopped, timer tstop, B is started (countdown is
shown on the video page of D-2502.01B),
5. when timer tstop, B expires, the “Silo D-2502.01B bottom fluidization” sequence is restarted
from point 2 and the timer tstop, AB is reset.
The “Silo D-2502.01B bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101B XY-250.201B (one-shot command),
Conditions for “Silo D-2502.01B bottom fluidization” sequence to be stopped:

 exhaust air throttle automatic valve VF-2502.01B not open after the sequence is started (it’s
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201B
When the sequence is stopped, the timers trun, AB and tstop, AB are reset.
250.101B XY-250.201B becomes grey without lock to indicate the possibility to activate the
When “Silo D-2502.01B bottom fluidization” sequence is active, pop-up “D-2502.01B bottom
to activate the “Silo D-2502.01B bottom fluidization” sequence and which ones are currently
116
On the video page of TPCP, next to the silo D-2502.01C, a table with the following values:
 timer trun, C12 [s],
 timer tstop, C12 [s]
Conditions for “Silo D-2502.01C bottom fluidization” sequence to be effective are:

When the operator wants to start the injection of air in the bottom part of silo D-2502.01C, the
solenoid valve XY-250.201C has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-2502.01C,
2. open solenoid valve XY-250.201C for an interval of time t run, C (countdown is shown on the
video page of D-2502.01C),
3. when timer trun, C expires, the solenoid valve XY-250.201C is closed and the timer trun, C is
reset,
4. when the solenoid valve XY-250.201C is stopped, timer tstop, C is started (countdown is
shown on the video page of D-2502.01C),
5. when timer tstop, C expires, the “Silo D-2502.01C bottom fluidization” sequence is restarted
from point 2 and the timer tstop, C is reset.
The “Silo D-2502.01C bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101C XY-250.201C (one-shot command),
Conditions for “Silo D-2502.01C bottom fluidization” sequence to be stopped:

 exhaust air throttle automatic valve VF-2502.01C not open after the sequence is started (it’s
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201C
When the sequence is stopped, the timers trun, AC and tstop, AC are reset.
117
250.101C XY-250.201C becomes grey without lock to indicate the possibility to activate the
When “Silo D-2502.01C bottom fluidization” sequence is active, pop-up “D-2502.01C bottom
to activate the “Silo D-2502.01C bottom fluidization” sequence and which ones are currently
118
9 MASS FLOW TOTALIZERS
9.1 Raw materials totalizers
The following totalizers have to be foreseen for the raw materials and additives:
- FICQ-104.1 (EDTA to saponification),
- FICQ-117.6 (glycerine to dryer),
- FICQ-117.8 (EHDP to saponification),
- FICQ-124.3 (soap to saponification),
- FICQ-126.1A (F.A. / N.O. blend to saponification),
- FICQ-126.2 (caustic soda to saponification),
- FICQ-126.3 (water to saponification),
- FIQ-126.3B (water to kettles),
- FICQ-126.4 (brine fed to saponification).
Totalizer FICQ-104.1 will be active only if:

- P-1042.01 running, AV-104.5 open and AV-126.31 open.
- P-1172.06 running, AV-117.5A open and AV-204.1 open.
- P-1172.08 running, AV-117.5B open and AV-126.31 open.
- (P-1242.03A or P-1242.03B) running and AV-126.32 open.
Totalizer FICQ-126.1A will be active only if:
- (P-1262.01A or P-1262.01B) running, FV-126.1A open (XY-126.1A open)18 and AV-
126.33 open.
- P-1262.02 running, FV-126.2 open (XY-126.2 open) 18 and AV-126.31 open.
Totalizer FICQ-126.3B will be active only if:
- P-1262.03 running and AV-126.3B.
119
Five columns have to be foreseen, showing the complete list of raw materials / additives totalizers:
- Partial,
- Total,
- Day (“Shift Production”),
- Week,
- Month.
For the “Day (“Shift Production”)” totalizers only, the number of shifts (1, 2 or 3) can be chosen
through a dedicated selector shown on the same video page of the totalizers.
One “Reset” button to clear the values has to be foreseen for each column:
- the reset button for the “Partial” totalizers will require a further confirmation (pop-up) to be
activated,
- the reset button for the “Total” totalizers will require a password to be activated,
- the reset button for the “Day” (“Shift Production”) totalizers will require a password to be
activated, but in any case, these totalizers will be automatically reset
o every 24 hours, if n.° 1 shift is selected,
o every 12 hours, if n.° 2 shifts are selected,
o every 8 hours, if n.° 3 shifts are selected.
- the reset button for the “Week” totalizers will require a password to be activated, but in any
case, these totalizers will be automatically reset every 7 days,
- the reset button for the “Month” totalizers will require a password to be activated, but in any
case, these totalizers will be automatically reset every month.
The reset hours / days for the “Day” (“Shift Production”), “Week” and “Month” totalizers can be
changed in a dedicated video page.
An ON / OFF button has to be foreseen for each totalizer in order to enable / disable it (one ON /
OFF button in common for all the totalizers of the same raw material / additive).
The values of the totalizers (total, partial, day, week and month) and the number of shifts selected
have to be recorded in the Data Logging File of the DCS and a facility to print out the production
report has to be foreseen.
9.2 Utilities totalizers
The following totalizers have to be foreseen for the utilities:

- FIQ-120.3A (instrument air),
- FIQ-120.3B (compressed air),
- FIQ-120.7 (softened water),
- FIQ-249.1 (chilled water),
120
- FIQ-120.4 (steam).
Five columns have to be foreseen, showing the complete list of utilities totalizers:
- Partial,
- Total,
- Day (“Shift Production”),
- Week,
- Month.
For the “Day (“Shift Production”)” totalizers only, the number of shifts (1, 2 or 3) can be chosen
through a dedicated selector shown on the same video page of the totalizers.
One “Reset” button to clear the values has to be foreseen for each column:
- the reset button for the “Partial” totalizers will require a further confirmation (pop-up) to be
activated,
- the reset button for the “Total” totalizers will require a password to be activated,
- the reset button for the “Day” (“Shift Production”) totalizers will require a password to be
activated, but in any case, these totalizers will be automatically reset
o every 24 hours, if n.° 1 shift is selected,
o every 12 hours, if n.° 2 shifts are selected,
o every 8 hours, if n.° 3 shifts are selected.
- the reset button for the “Week” totalizers will require a password to be activated, but in any
case, these totalizers will be automatically reset every 7 days,
- the reset button for the “Month” totalizers will require a password to be activated, but in any
case, these totalizers will be automatically reset every month.
The reset hours / days for the “Day” (“Shift Production”), “Week” and “Month” totalizers can be
changed in a dedicated video page.
An ON / OFF button has to be foreseen for each totalizer in order to enable / disable it (one ON /
OFF button in common for all the totalizers of the same raw material / additive).
The values of the totalizers (total, partial, day, week and month) and the number of shifts selected
have to be recorded in the Data Logging File of the DCS and a facility to print out the production
report has to be foreseen.
121
10 SCHEDULED MAINTENANCE
The control system is to be provided with a proper device so to allow to schedule a maintenance
activity for each motor / rotating part (i.e. pumps, agitators etc…).
The required functions of the maintenance device are the following:
- The current running time (hours)
is to be recorded for each motor.
- The maximum continuous running
time (hours) for a given start is to
be recorded for each motor; this
value can be reset only under
password.
- The total accumulated running
time (hours) is to be recorded for
each motor; this value can be reset
only under password.
- The total number of motor starts
or attempts is to be recorded for
each motor; this value can be reset
only under password.
- A pushbutton to enable / disable maintenance is to be foreseen.
- Maintenance alarm is to be shown when timer expires (the maintenance set point is to be
editable by means of relevant input window).
- The timer is reset by pushing (under password) the “Actual accumulated running time
(hours)” reset key; the actual accumulated running time (hours) window shows the
accumulated running time since the last maintenance activity.
- The maintenance device is to be provided with possibility of edit notes so to show the
maintenance activity to be carried on: i.e. lubricating oil change, bearings check etc...
The picture shows an example of how to implement the maintenance device.
122
11 PRODUCTION RECIPE AND PRODUCTION RATE
VARIATION
11.1 Recipe
The control systems must include a facility called “Recipe” that basically consists in a calculation
program providing initial set points for the raw materials and additives flow rates.
In the recipe calculation pages, it must be possible to input data (red cells) and to read values (black
and blue cells) coming from calculations.
It must be possible to save the recipe and to open a saved recipe.
In another page called “Production rate”, three columns must be shown:
- a first column with recipe new values (set points downloaded in this column from recipe by
pushing a button shown on the calculation page),
- a second column for the changing of production capacity,
- a third column with actual set points for the plant referred to actual production.
The values of the first column are downloadable in the second column by pushing “Transfer” key.
In this second column the values will be related to the production rate:
- changing production rate will change the values as per following chapter (these changes will
be performed by pressing the button called “Capacity change”),
- it must be possible to edit all the data,
- pressing another button called “Download”, the second column's values are downloaded to
the third column and set as new set points for all the relevant loops.
The values of the third column are directly related to the set points on the FICQs and XICs: if the
operator change a value of the cells, it is directly refreshed on the field and, in the same way, if a
value is changed on FICQ / XIC pages, it is refreshed in this column.
With “Refresh” button the values of the third column are transferred to the second one, for new
capacity calculation.
 Please refer to “J.21039 - UNIOLEO - recipe rev. 01.XLS” document
11.2 Production rate
The change of production rate must be made easier by means of a “recalculating” facility of raw
material set – points as follows:
123
SCTU+C plant
Capacity at present moment (R-1262.02
C1
outlet), kg/h
Capacity required (R-1262.02 outlet),
C2
kg/h
Change of capacity: confirm download Yes / No
Flow rate
Mass flow loop Service Actual set
New set points
points
F.A. / N.O. Blend to Reactor
FICQ-126.1A FP 1A [kg/h] FP 1A [kg/h] * (C 2 / C 1)
R-1262.02 Mass Flow Control
Caustic Soda to Reactor
FICQ-126.2 FP 2 [kg/h] FP 2 [kg/h] * (C 2 / C 1)
R-1262.02 Mass Flow Control
XI-126.2 Caustic Soda Concentration FP 20 [%] FP 20 [%]
Water to Reactor R-1262.02
Mass Flow Control
Brine to Reactor R-1262.02
FICQ -126.4 FP 4 [kg/h] FP 4 [kg/h] * (C 2 / C 1)
Mass Flow Control
XI-126.4 Brine Concentration FP 40 [%] FP 40 [%]
EDTA to Reactor R-1262.02
FICQ -104.1 FP 104 [kg/h] FP 104 [kg/h] * (C 2 / C 1)
Mass Flow Control
EHDP to Reactor R-1262.02
Mass Flow Control
Reactor R-1262.02 Mass flow
outlet (to be shown next to FP R [kg/h] FPR (new set points) [kg/h]
reactor)
Glycerine to dryer Mass Flow
Control
Soap Noodles Production (to
FP S [kg/h] FP S (new set points) [kg/h]
be shown next to PL-2042.01)
Green fields: input from keyboard.

Yellow fields: current set point in PLC loops (Remark: DO NOT USE THE RECIPE VALUE,
BUT THE ACTUAL CURRENT SET POINTS).
Blue fields: results (new set points).
C1 = capacity at present moment from recipe (“Transfer” key) or from capacity calculation (C2)
(“Capacity change” key) or from field (FPR) (“Refresh” key).
124
Capacity (base soap capacity from reactor) must be limited between 5000 6000 and 20000 17500
kg/h.
FP 20 = caustic soda concentration from recipe or from caustic soda concentration calculation (if
the calculated value has been downloaded through the relevant pop-up).
FP 40 = brine concentration from recipe or from brine concentration calculation (if the calculated
value has been downloaded through the relevant pop-up).
FP R = FP 1A + FP 2 + FP 3 + FP 4 + FP 104 + FP 1178 [kg/h].
FP NEV = constant from recipe.
FP S = (FP R + FP 1176) * FP NEV.
125
1
For each control loop, a proper pop-up has to be shown on the video page next to the relevant loop with:
- set point (SP),
- present value (PV),
- output (%) (e.g. valve stroke or motor speed),
- “automatic” / “manual” control selection,
- access to trends visualization and PID management.
2
The maximum flow for FICQ-124.3 control loop (and thus for pumps P-1242.03A/B) has to be limited as described here
below:
- if the control loop FICQ-124.3 is in automatic, the maximum set point, that the operator can write, will be 1500
kg/h (10% of the maximum flow of the saponification),
- if the control loop FICQ-124.3 is in manual, the maximum speed (%), that the operator can write, will be 87 100%
(100% speed corresponds to 60 50 Hz).
3
PLC will receive n° 3 input signals from FE/FIT-126.2: n° 3 “4 ÷ 20 mA inputs” to be converted into mass flow rate (FIT-
126.2), temperature (TIT-126.2) and density (DIT-126.2) measurement.
4
PLC will receive n° 3 input signals from FE/FIT-126.4: n° 3 “4 ÷ 20 mA inputs” to be converted into mass flow rate (FIT-
126.4), temperature (TIT-126.4) and density (DIT-126.4) measurement.
5
LIC calculation can be found in section 6.2 - Calculation for level controllers.
6
Auto reset of reactor R-1262.02 high pressure PIT-126.10 alarm (PAH-126.10) and reactor R-1262.02 low pressure PIT-
126.10 alarm (PAL-126.10) must be foreseen.
7
Auto reset of reactor R-1262.02 high temperature TE/TT-126.9 alarm (TAH-126.9) and reactor R-1262.02 low
temperature TE/TT-126.9 alarm (TAL-126.9) must be foreseen.
8
This signal must have a button (shown on the video page of SD-2042.01) to enable (ON - green colour) / disable (OFF -
red colour) the function. If it is disabled, the alarm can be given, but any interlock / sequence relevant to it will not be
activated.
9
This signal must have a button (shown on the video page of C-2062.03) to enable (ON - green colour) / disable (OFF - red
colour) the function. If it is disabled, the alarm can be given, but any interlock / sequence relevant to it will not be activated.
10
Connected to physical signal and not to the delay of the alarm (auto reset).
11
EDTA feed tank D-1042.01 must have a button to select if the EDTA transfer pump and automatic valve AV-104.4 will
be used on automatic (LSL-104.1 interlocks n. and enabled) or on manual (LSL-104.1 interlocks n. and disabled). If
LSH-104.1 is on, the transfer pump will be locked on stop and the automatic valve AV 104.4 will be locked to close
position with both the operating modes, manual or automatic (LSH-104.1 interlocks n. , , and ); when LSH-104.1 (physical
signal) goes from on to off, the locks on the pump and valve will be removed and the automatic mode will be enabled, if it
was previously selected.
12
Time can be changed in a dedicated video page.
13
“Fault” has to be considered as “not open”. Elements (valves or motors) listed int the “ACTIONS (THEN)” of the
interlock will not be locked only if at least one of the valves listed in the “CONDITIONS (IF)” is open.
14
Glycerine feed tank D-1172.06 must have a button to select if the glycerine transfer pumps 1 and 2 and automatic valve
AV-117.4A will be used on automatic (“Glycerine transfer pump 1 – AUTO” with LSL-117.6 interlocks n. and enabled or
“Glycerine transfer pump 1 – AUTO” with LSL-117.6 interlocks n. and enabled) or on manual (LSL-117.6 interlocks n. , ,
and disabled). If LSH-117.6 is on, the transfer pumps will be locked on stop and the automatic valve AV 117.4A will be
locked to close position with both the operating modes, manual or automatic (LSH-117.6 interlocks n. , , , , and ); when
LSH-117.6 (physical signal) goes from on to off, the locks on the pumps and valve will be removed and the automatic mode
will be enabled, if it was previously selected.
15
EHDP feed tank D-1172.08 must have a button to select if the EHDP transfer pump and automatic valve AV-117.4B will
be used on automatic (LSL-117.8 interlocks n. and enabled) or on manual (LSL-117.8 interlocks n. and disabled). If
LSH-117.8 is on, the transfer pump will be locked on stop and the automatic valve AV 117.4B will be locked to close
position with both the operating modes, manual or automatic (LSH-117.8 interlocks n. , , and ); when LSH-117.8 (physical
signal) goes from on to off, the locks on the pump and valve will be removed and the automatic mode will be enabled, if it
was previously selected.
16
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH -124.104A, start AG-
124.03A and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-124.104A gives only an alarm (only
when signal is on for more than a pre-set time), JAHH-124.104A activates immediately the interlock.
17
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH -124.104B, start AG-
124.03B and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-124.104B gives only an alarm (only
when signal is on for more than a pre-set time), JAHH-124.104B activates immediately the interlock.
18
Control valve is closed when controller is on manual mode with output equal to 0% and relevant XY solenoid valve
closed, while the control valve has to be considered open when controller is on a position different from (manual mode with
output equal to 0%) and relevant XY solenoid valve open.
Example: if the valve is in automatic control with the XY solenoid valve open and output equal to 0%, the valve has to be
considered open.
19
Brine feed tank D-1262.04 must have a button to select if the brine transfer pumps 1 and 2 and automatic valve AV-
126.24 will be used on automatic (“Brine transfer pump 1 – AUTO” with LSL-126.4 interlocks n. , enabled or “Brine
transfer pump 2 – AUTO” with LSL-126.4 interlocks n. and enabled) or on manual (LSL-126.4 interlocks n. , , and
disabled). If LSH-126.4 is on, the transfer pumps 1 and 2 will be locked on stop and the automatic valve AV 126.24 will be
locked to close position with both the operating modes, manual or automatic (LSH-126.4 interlocks n. , , , , and ); when
LSH-126.4 (physical signal) goes from on to off, the locks on the pumps and valve will be removed and the automatic mode
will be enabled, if it was previously selected.
20
This interlock must have a button (shown on the video page of AV-117.5A) to enable (ON - green colour) / disable (OFF
- red colour) the interlock itself.
21
When AV-204.1 goes from open to closed, after 5” PIC-204.10 is set on manual mode and control valve PV-204.10 is
blocked open 100% (relevant XY solenoid valve is set to open), then valve AV-204.3 opens for 5” (time can be changed in
a dedicated video page). When the blowing time expires, the automatic steam valve AV-204.3 is closed. At this point, also
PV-204.10 is closed (opening 0%, PIC on manual and relevant XY solenoid valve set to close).
22
When AV-204.2 goes from open to closed, after 5” valve AV-204.4 opens for 10” (time can be changed in a dedicated
video page), then the automatic steam valve closes.
23
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH-204.101, start SD-2042.01
and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-204.101 gives only an alarm (only when
signal is on for more than a pre-set time), JAHH-204.101 activates immediately the interlock / stand-by sequence.
24
Semi-barometric condenser C-2062.03 must have a button to select if the level switch LSH-206.3 will be used on
automatic (LSH-206.3 interlocks n. and enabled) or on manual (LSH-206.3 interlocks n. and disabled).
25
High and Very High pressures sets are 25 barg and 40 barg fixed not changeable. Consensus to restart after very high
pressure situation has to be given by operator. Contact type normally closed: in case of wire cutting, system gives alarm.
26
Plodder PL-2042.01 must have a button to enable (ON - green colour) / disable (OFF - red colour) the interlocks n. and .
27
The value for the maximum selectable speed of blower B-2502.01 can be changed in a dedicated video page. The
maximum speed should be limited around 80% (100% - 50 Hz).
28
To be indicated as “Water charge within tolerance” in help page.
29
In general, the “HH”, “H”, “L” and “LL” alarms of all control loops of mass flows will be developed as deviations (%)
between process value and set point.
The deviations will follow the logic here below described.
A dedicated video page will be programmed to:
- input max  % allowed deviation vs. set point for every mass flow meter loop (can be a different value for any of
the loop),
- input max allowed time (seconds) within which the above deviation is tolerated for every mass flow meter loop
(can be a different value for any of the loop).
Example:
Loop FICQ-126.1A: set point 3000 kg/h (oil #1 to reactor), max allowed deviation  0.5% (that is 15 kg/h), max
allowed time 30” (time can be changed in a dedicated video page).
Suppose that FICQ-126.1A measures at a certain point >3016 (or <2984) kg/h for more than 30” consecutively: this
will activate the “anomalous condition of flow rate deviation”.
It is sufficient that only one of the several mass flow meters goes under this condition to activate the “anomalous condition”.
Another timer has to be set in order to give the time after which the “deviation of actual flow” will be activated (until the
timer is not expired, the deviation alarms, and their effects, will be disabled):
- for FICQ-104.1, FICQ-117.8, FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4, the timer (one common
timer) will be started with the “Reactor feeding” sequence activation,
- for FICQ-117.6, the timer will be started with the “Additives feeding” sequence activation,
- for FICQ-124.3, the timer will be started when pump P-1242.03A (or P-1242.03B) is started.
High / Low deviations give alarm only (without delay).
Very high / Very low deviations (after the delay described above) activate “Saponification stand-by” sequence (exception
FICQ-124.3 which only gives an alarm).
A button has to be foreseen for each raw material in order to enable (ON) / disable (OFF) the deviation control.
30
For the pumps P-1042.01, P-1172.06, P-1172.08 and P-1262.04, the possibility of excluding the single pumps from the
sequence is foreseen (i.e. don’t need in the current production recipe). If a raw material / additive has been excluded from
the actual recipe (i.e. set point “0” kg/h), it will be ignored by the control system. Exception is made for “Saponification
stand-by” sequence.
31
“Time-out” timers (time can be changed, for each timer, in a dedicated video page) have the purpose to check that the
operations requested by the relevant feeding / recycle sequences have been completed (opening / closing valves) within the
“time-out”.
If one or more operations that should be done by a feeding / recycle sequence have not been completed within the “time-
out”, alarm will be given (further information can be found in sequences section).
If a condition which should trigger the stand-by goes ON or a condition necessary to activate the relevant feeding / recycle
sequence goes OFF, “Saponification stand-by” sequence is immediately activated, also if the time-out timer is still running.
32
The value for the final plodder PL-2042.01 speed increasing can be changed in a dedicated video page. If the speed of
final plodder PL-2042.01 given by the speed before silo selection plus X is bigger than 100%, the speed will be limited to
100%.
33
This signal must have a button (shown on the video page of D-2502.01A) to enable (ON - green colour) / disable (OFF -
red colour) the function. If it is disabled, the sequence relevant to it will not be activated.
34
This signal must have a button (shown on the video page of D-2502.01B) to enable (ON - green colour) / disable (OFF -
35
This signal must have a button (shown on the video page of D-2502.01C) to enable (ON - green colour) / disable (OFF -

J.21039 - UNIOLEO - CCS SCTU+C+TPCP For Customer

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

J.21039 - UNIOLEO - CCS SCTU+C+TPCP For Customer

Uploaded by

Copyright:

Available Formats

CCS-21039-126 rev.

PT UNILEVER OLEOCHEMICAL (UNIOLEO)

CONTINUOUS FATTY ACIDS / NEUTRAL OILS SAPONIFICATION

INTERLOCK AND SEQUENCES LIST

2 18-11-2022 2nd revision (after FAT) M.G.Bressan

Tag Number Description Input from Output to Functions

Tag number Description Input from

5.1 Shut-off valves (AV)

Automatic valves (AV) air failure:

5.7 Control valves (FV, PV, TV, LV)

5.33 5.34 Electrovalves (XY)

5.35 Diverting valves (DV)

Diverting valves (DV) air failure:

5.36 Throttle valves (VF)

Throttle valves (VF) air failure:

 L%= ( LH ) ×100 [%].

 L%= ( LH ) ×100 [%].

6.2.3 Calculation for semi-barometric condenser C-2062.03 level (LIC-206.1)

 L%= ( LH ) ×100 [%].

LSL-104.1 on10 AND EDTA transfer selector on “AUTO”11

LSL-104.1 on10 AND EDTA transfer selector on “AUTO”11

LAL-104.1 AND LAH-104.1

LAL-104.1 AND LAH-104.1

Valves AV-104.5 AND AV-104.6

LAL-117.6 AND LAH-117.6

LAL-117.6 AND LAH-117.6

“Glycerine transfer pump selector”

“Glycerine transfer pump selector”

Valves AV-117.5A AND AV-117.6A

LSL-117.8 on10 AND EHDP transfer selector on “AUTO”14

LSL-117.8 on10 AND EHDP transfer selector on “AUTO”14

LAL-117.8 AND LAH-117.8

LAL-117.8 AND LAH-117.8

Valves AV-117.5B AND AV-117.6B

Valves AV-124.2A AND AV-124.2B

Valves AV-124.2A AND AV-124.2B

Valves AV-124.2A AND AV-124.2B

Valves AV-124.2A AND AV-124.2B

Control valve PV-126.121B

Control valve PV-126.121B

Control valve PV-126.121B

Control valve PV-126.121B

Valves AV-126.11A AND AV-126.11B

Valves AV-126.11A AND AV-126.11B

Valves AV-126.11A AND AV-126.11B

Valves AV-126.11A AND AV-126.11B

Valves AV-126.111A AND AV-126.111B

Valves AV-126.111A AND AV-126.111B

Valves AV-126.111A AND AV-126.111B

Valves AV-126.111A AND AV-126.111B

Valves AV-126.11A AND AV-126.111B open

LAL-126.4 AND LAH-126.4

LAL-126.4 AND LAH-126.4

LAL-126.4 AND LAH-126.4

“Brine transfer pump selector”

“Brine transfer pump selector”

Control valve PV-126.10

Valves HV-201.1 AND HV-201.3

Control valve PV-126.10

Valves AV-204.1 AND AV-204.2

Valves AV-204.1 AND AV-204.2

Vacuum chamber SD-2042.01 inspection door (ZI-204.14)

Vacuum chamber SD-2042.01 inspection door (ZI-204.14)