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Accord Template Summary

AT_CIP_1T1L_C1_Summary_R01 of 22

Accord

Template Summary

AT_CIP_1T1L_C1_Summary_R01

Document: Accord Template Summary.

System: CIP Set 1 Tank : AT_CIP_1T1L_C1

Function: Clean In Position System with 1 CIP Tank

Revision: R01 20th May 2016



Introduction

Accord Template for CIP Set with 1 Tank and 1 Line

This document is to assist Engineering staff with installation and usage of Accord Template, it is

assumed that the reader is familiar with PLC programming, Scada setup, and Accord Builder.

This Accord Template for a small CIP Set, to provide cleaning for Process Equipment in Dairy,

Food, Beverage or Pharmaceutical type process plants.

The template maybe easily adapted for specific installations by renaming and modifying

equipment and program items in Accord Builder and in HMI applications.



Index

1. System Description ............................................................................................................. 4

2. Process Summary ............................................................................................................... 5

2.1 P&ID ............................................................................................................................ 5

2.2 Process Steps .............................................................................................................. 6

3. Installation ........................................................................................................................... 8

3.1 Requirements .............................................................................................................. 8

3.2 Installation ................................................................................................................... 9

3.2.1 Restoration in Builder ............................................................................................ 9

3.2.2 Import to Server ...................................................................................................10

3.2.3 Setup HMI Communication Service in Server ......................................................13

3.2.4 Setup Device Logging and Log Data Archiving ....................................................14

3.2.5 Loading HMI Design project .................................................................................16

4 Customisation.................................................................................................................19

4.1 Changing the Model Name. ........................................................................................19

4.2 Importing Modified Project ..........................................................................................20

4.3 Changing the Model reference in HMI .........................................................................20

4.4 To add an Equipment Item ..........................................................................................21

4.5 To add a Program Item ...............................................................................................21

4.6 To rename an Item ......................................................................................................22

4.7 To modify an Item .......................................................................................................22



1. System Description

The system will provide

1. Automatic and Manual Operation of all devices and instruments.

2. Automatic Control of CIP Program, with selectable Steps, Decisions and Setpoints

The system provides CIP for target system. There is full automatic operation, including the

ability to change step on or steps at any time. The program will run according to selections and

using the setpoints chosen and will automatically stop on critical alarms and resume on Alarms

reset and resume commands..

The system may be easily customised; It is easy to add or delete a tank, phase, step and also to

change any Step Time or Temperature Setpoint for any step in the system.

Step Order may be changed in Builder or Recipe Manager

Setpoint Values may also be changed in Builder or HMI or Recipe Manager.

Decision States may also be changed in Builder or HMI or Recipe Manager.

Template Contents

The Template includes the following

Item Name Editor

Process Drawing AT_CIP_1T1L_C1_DWG_R01.vsd/pdf Visio

Accord Builder Model AT_CIP_1T1L_C1_M_R01.bak Builder

Accord HMI project AT_CIP_1T1L_C1_HMI_R01 HMI

Accord S7 Library AT_CIP_1T1L_C1_S7_R01 Simatic Manager

Accord TIA Library AT_CIP_1T1L_C1_TIA_R01 Siemens TIA

Process Description CIP 1 Tank 1 Line Process Description R01 MS Word

Each part may be downloaded separately or as a combined file.



2. Process Summary

2.1 P&ID

LT 01

LSH 01

LSL 02

Heat

exchanger

TT 03 CT 03

FS

03

TT 02

V 02 V 04

V 05

V 07

CV 01

P 01

DRAIN

STEAM

WATER

SUPPLY

RETURN

V 09

TT 01

CIP

TANK

V 03 VSD 01

V 08

V 01

Detergent

LSL 11

Sterilant

LSL 12

P 11

V 11 V 12

V 06

DRAIN

AT_CIP_1T1L_C1

T Sexton

Accord Template CIP 1 Tank 1 Line

R 0.0 12/05/16

SV 01

P 12

The required CIP routine of Rinse, Detergent and Sterilant is selected by Operator making

selection Decisions on HMI.

The available selection Decisions are

Cold Detergent Wash A Cold Detergent Wash is Selected

Cold Final Rinse A Cold Final Rinse is Selected

Cold Middle Rinse A Cold Middle Rinse is Selected

Cold PreRinse A Cold Initial Rinse is Selected

Hot Detergent Wash A Hot Detergent Wash is Selected

Hot Middle Rinse A Hot Middle Rinse is Selected

Hot PreRinse A Hot Initial Rinse is Selected

Sterilant Wash A Sterilant Wash is Selected



2.2 Process Steps

There are 43 Steps configured in the Program and Steps are run according to Decisions.

1 Fill CIP Tank for Cold PreRinse

2 Cold PreRinse

3 Drain CIP Tank after PreRinse

4 Fill CIP Tank for Hot PreRinse

6 Hot PreRinse

5 Circulate to Heat Tank for Hot PreRinse

7 Drain Tank after Hot PreRinse

8 Fill CIP Tank for Cold Detergent Wash

9 Dose Detergent Cold

10 Cold Detergent Wash Circulate Tank

11 Cold Detergent Wash Check Strength

12 Push with Cold Detergent to Drain

13 Achieve Cold Detergent at CIP return

14 Cold Detergent Wash

15 Push Cold Detergent to Drain

16 Drain CIP Tank after Cold Detergent Wash

17 Fill CIP Tank for Hot Detergent Wash

18 Dose Detergent Hot

19 Hot Detergent Wash Circulate Tank

20 Hot Detergent Wash Check Strength

21 Push with Hot Detergent to Drain

22 Achieve Hot Detergent at CIP return

23 Hot Detergent Wash

24 Push Hot Detergent to Drain

25 Drain CIP Tank after Hot Detergent Wash

26 Fill CIP Tank for Cold Middle Rinse

27 Cold Middle Rinse

28 Drain CIP Tank after Cold Middle Rinse

29 Fill CIP Tank for Hot Middle Rinse

30 Heat Tank for Hot Middle Rinse

31 Hot Middle Rinse

32 Drain CIP Tank after Hot Middle Rinse

33 Fill CIP Tank for Sterilant Wash

34 Dose Sterilant

35 Push with Sterilant to Drain



36 Sterilant Wash

37 Drain CIP Tank after Sterilant Wash

38 Fill CIP Tank for Cold Final Rinse

39 Cold Final Rinse

40 Drain CIP Tank after Final Rinse

41 Fill CIP Tank to Flush CIP System

42 Flush System

43 Drain CIP Tank after Flush System

See AT_CIP_1T1L C1 Model Development.doc for more information.



3. Installation

This Template acts as a working system and a good template for similar systems. Systems may

differ in many ways; Item naming, Nr of items, Nr of Tanks, Nr of crystallisation stages, etc. The

following are brief guides to help customisation.

Please remember that changes made to the Model in Accord Builder will be also in Builder

documents and in PLC or Emulator after import and download. Changes will also be

automatically available in Accord Recipe, Plan and Reports.

3.1 Requirements

The use of the Template to deliver a working system requires Installation of Software and PLC

Hardware, PC Hardware.

Software

Accord Builder

Accord Server

Accord HMI or InTouch (64 tag licence)

PLC Editor: (Simatic Manager or TIA or equivalent)

OPC Server (Kepware or equivalent)

Optional Software

Accord Recipe Manager

Accord Batch

Accord Reports

MS Word, Excel

MS Visio to change drawing

InTouch Version 10.1

Hardware

Siemens PLC or compatible equipment, VIPA, Helmholtz..

Desktop or Panel PC with Windows 7 or later

Networking of PC and PLC via Ethernet



3.2 Installation

The following assumes that required editors and PLC hardware are installed and set-up.

3.2.1 Restoration in Builder

The Model .bak is loaded to Accord Builder. In Builder File menu select Restore and browse for

the .bak file AT_CIP_1T1L_C1_M R01.bak. Open this and the Model will be loaded in Builder.

The Model is loaded and may be modified.

Run the Consistency Check when ready to import to Server.



3.2.2 Import to Server

Following customisation the Model may be imported to Accord Server.

An OPC profile must be setup in Server before import. If the project is being downloaded to a

PLC then the PLC must be connected to the PC and the Accord PLC Library must be installed

in the PLC.

Setup of an OPC Profile for Emulator

For more information on this please refer to Accord Server Manual.

For this document the Accord Emulator is used. After testing Emulation the Project may be

downloaded to PLC at any time.



To Import the Module from Builder, use Import Project button in Server Project Manager Tab.

Import Project Screen

Use the Refresh button in bottom Right Hand corner to refresh project list if necessary.

Space may be reserved in Server for spare items to be added using Partial Downloads.



The import is then completed by pressing Download.

The Project should appear in the Server Project Manager tab field as above. The project is now

ready for Emulator. If downloaded to a PLC then it is ready for Operation.



3.2.3 Setup HMI Communication Service in Server

In Server Settings tab select Communications, Advanced and select the Connection type and IP

Address as required.

Select Remote clients if the HMI Runtime is being run on another PC.



3.2.4 Setup Device Logging and Log Data Archiving

Device Logging

All Devices may be logged. Logging is set up in the Settings Tab.

Select Historian and then select Devices to be logged and in the case of Values select the log

deadband, which is the change required to generate a new entry. Deadband values should be

large enough to not cause excessive logging to PC hard-drive. Types of devices for logging are

in the Groups drop down list and all the devices of a type will be presented when the Group is

selected.



Log Database Archiving

Archiving is the storage of logged data to an archive database. These archives may be copied

from the PC using SQL copying.

Archiving is a background function, it does not require any events or interaction.

The Archive will occur when the log database is of the filesize specified in Max Size or after the

number of days specified and it may also be specified to only occur at an off-peal time.

Archiving uses PC resources and is usually set up for a time when background functions can be

implemented without causing any delay on other functionality.



3.2.5 Loading HMI Design project

Open Accord HMI Design and load project by accessing the file AT_CIP_1T1L_C1.lhp. All items

will reference the Accord Model Project Name “CIP Set 1 Tank”.

Screens and Objects may be accessed by usual manner.

Connecting for Configuration

A connection to Accord Server is necessary for both modifications in HMI Design and for

running the HMI application in Runtime.

The following Mimic Screen should be present.

The Status in the bottom Left hand Corner should be Connected before modifications or

deploying to Runtime. Ensure Server is started before refreshing. If Status shows Disconnected

then click on Disconnected and a popup for Configuration appears.

Use the Refresh button in the bottom Right Hand Corner and HMI Design will find the available

Accord Servers and the required one may be selected.




Accord Servers and the required one may be selected.

Then press Save to finish the connection.



Connecting for HMI Runtime

In Tools select Service Manager and use the Refresh Button to find the IP Address of the

Accord Server being used for the installation.


Accord Servers and the required one may be selected. Again Save when required is selected.



4 Customisation

Data should be uploaded from PLC to Builder Model before any modifications. Use the

Sync function in Server Tools for this.

Items in the Model may be changed and the Cross Reference and Consistency Checks will

allow secure modifications.

Accord is an integrated environment so all changes to Model are available in HMI, Recipe,

Reports, as appropriate. Depending on the change, an item may need to be re-assigned using

Project Explorer in Accord HMI.

4.1 Changing the Model Name.

1. In Accord Builder

This is carried out initially in Builder. The Project Model Summary contains the Model Name and

this may be changed to a new name. If required the Model may be saved as a new Model using

‘Save As’. This will provide a new Model when importing.

For Example to change to “Building 2 CIP Set” and from Emulator to PLC,



4.2 Importing Modified Project

If the Model Name, or any item for control purposes is changed, then the modified Model must

be re-imported to Server. For a new Model name a Full Download is required, otherwise for

modifications a Partial Download will be sufficient. Remember to assign reserve space for items

for modifications when doing a Full Download.

For items modifications, -Partial Download- The Model is imported as before and Partial

Download is selected. Server will examine the existing configuration and compare to the new

configuration and make all required adjustments into the Server database and PLC data

configurations.

During Partial Downloads items that have been deleted from the Model are deleted also from

the PLC, and are deactivated before deletion. In this case the deletion means the configuration

data is not used or referenced anymore, and this configuration area will be used for any new

items that are downloaded.

4.3 Changing the Model reference in HMI

If the Model name is changed in Builder then the Devices in HMI will need to be update also;

Then when the modified Model is imported to Server, the items/devices must be updated in the

HMI Project. To do this click on the “Rename Project Bindings” on the top right of the HMI

Design screen, above Properties.

A Remane Project panel allows input of the existing project name and the new project name

Enter the required names and click Save; the HMI will be updated with replacement Project

Name for devices.



4.4 To add an Equipment Item

Equipment Items are: Valve, Motor, Digital In, Digital Out Signal, Instrument or Drive


Drag in the appropriate icon into the unit

Or

Copy an existing item, using right-click copy and paste

Or

Right-click on the Unit and use Add Valve, etc…

Configure the item and give the new item an appropriate I/O address. Use the Edit I/O Table

from the top menu to see all the existing I/O and to modify for the new item if required.

Remember that this table can be copied to excel, modified by auto-fill and copied back, if

required.

When an Analog Output; a Drive or Control Valve, that has a PID Loop controller, is copied then

PID Loop Controller is also copied automatically. The Process Variable for the PID Loop will

have to be changed or confirmed.

2. In Server and Accord HMI or other module

The new device will be available for placing on screen as required. The quickest way is to copy

an existing device and select the new device name using the built-in HMI Explorer.

4.5 To add a Program Item

Program Items are: Program, Step, Operation, Alarm, Condition, Decision, Setpoint,


Drag in the appropriate icon into the unit

Or

Copy an existing item, using right-click copy and paste

Or

Right-click on the container and use Add Operation, etc…

Configure the item and add to Steps etc as required.


The new item will be available for placing on screen as required. The quickest way is to copy an

existing device and select the new device name using the built-in HMI Explorer.



4.6 To rename an Item


Simply right click on the item and use “Rename” function.

The new name will be populated through all the places it is used in the Model.


Server treats a renamed item as a new item.

On import and Partial Download the original Equipment Item will be deleted in PLC and Server,

and the item must be reassigned in HMI. This is done by clicking on the item and selecting

configure…change and using the Project Explorer or Lists to find the new renamed item. All

settings for the item will be imported also.

The renamed item will be available in other modules (Reports, Plan…), and must be inserted

into any configurations. The original named item will not be available any more.

4.7 To modify an Item


Open the item Properties by right-clicking on the item. The texts, times and setpoints associated

with the item can be changed easily. Interlocks and activations can also be seen and changed

here if required.


The modified model is imported to Server and properties changes will be assigned to items in

HMI automatically.

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