PC Automation User Manual
Contents
1. 17 54 18 03 18 12 18 21 18 30 18 39 18 47 18 56 19 05 19 14 19 23 19 32 19 40 19 49 19 58 time Batch no 5 Customer name Page 16 of 20 BCS v21 UserManual 060710 doc BCS user manual Appendix 3 Printout examples Page 17 of 20 BCS v21 UserManual 060710 doc Cry BCS user manual IeTELLIGENT Bunkrnine Solutions Appendix 4 Software installation Recommended Windows2000 XP Minimum 128Mb ram PII or equivalent The desktop video settings must be set to small fonts and computer including hard disk must not be allowed to go to stand by which typically will cause the serial port to close The user interface fits a screen resolution of 1024 768 but higher resolutions is also ok if wanted It is all right to let the screen go to pause after certain minutes Copy the folder BCS and BCS Documentation to a hard disk drive The file BCS gdb is the database file The file BCS exe is the system executable The file settings ini is the initialisation file in which especially the com port number to use can be preset If anything else than com1 is used the file should be edited Make a shortcut to BCS exe and place it on the desktop Select properties for the shortcut just made and set the run value to Maximized Continue with database installation Database installation The BCS program is dependent of a database The database has to be installed before the BCS program is activated for the first2. Viscosity setpoint and press Exit and save Set points are transferred to the controller Volume setpoint The amount of oil wanted in the load The batch size must be between 0 0 and 9999 9 m3 If setpoint 1 is O Zero volume2 is the controlling parameter and the blender will not be activated Viscosity setpoint The viscosity at 50dgC used to adjust the blender so that the blend will be correct The viscosity must be between 20 and 999 cSt Initial Valve position The position from right stop position to which the blender will be moved at blender start if the left stop is active when the start button is pressed If not active the parameter is inactive Note It is a good idea to check actual controller time before leaving the window By pressing PC time transfer the controller time will be synchronized to the PC watch Page 4 of 20 BCS v21 UserManual 060710 doc BCS user manual IeTELLIGENT Bunkrnine Solutions In order to get an accurate blending right from the start it is very important to calculate the relationship between the heavy fuel oil and the light fuel oil to be able to adjust the fuel blender before blending start This will minimise time of equipment to find the right blend and give a much better result on the first delivered bunker cubic meters e Ensure that both valves on inlet are open and valve on outlet is closed e Start the pumps for the fuel blending e Please observe that the
3. graphs are missing data for the period where no PC were connected 2 The database is empty Then the display has no customer and therefore graph data are not logged but at batch end the report is still correct for the whole batch and can be printed as long as a new batch is not started If the PC is connected after finishing the batch the report is still available as in situation 2 above Page 11 of 20 BCS v21 UserManual 060710 doc BCS user manual INTELLIGENT Bunkgnine SOLUTIONS Flexblender V2 1 process flowchart Svstem idle Select batch iu Insert batch narameters View and or print View and or print i unliima 9 lt a gt Start delay EOR A Ge gt lt Blender left Actual T D Pepot i graph report data Start count 1 Volume start point pump Blender right Pause is stopping Alarm detect regu lator average Sum up average calculation alarm and setting STOP Cantinii a Select Pause or Cancel Stop average Stop volume countins and Move to left Stop fan Blender Generating Actual report NI Al Page 12 of 20 BCS v21 UserManual 060710 doc BCS user manual i i lmeeen Bunxemne Sot Appendix 1 Settings This menu contains settings which only have to be selected when the system is initiated or when a unit in the system is changed to another type The menu point is password secured to prevent users from changing thi
4. m3 h Temperature C Viscosity cSt 24 5 148 Setpoint Viscosity cSt Setpoint Volume 1 m3 Setpoint Volume 2 m3 Batch no 0 New batch Customer no Customer name Page 3 of 20 BCS v21 UserManual 060710 doc Cry BCS user manual IurrLLiGENT Bunkrnine Solutions Preparations before the 1 blend Usually a CBI technician carries out the preparation for actual bunker container During the installation the Supplier Ship name text will be edited and different system parameters are set to fit the actual installation See contents of menu Edit in appendix 1 Preparing to start a blend Press new batch Select the customer name from the drop down list or press the button Add new to register a new customer in the database Customer name and number can be any text number which fits into respective field The Edit function is used if specification in the database has to be changed la F Li lox mre Pals ES Customer name Ausrian shipping E dit Add Customer name Customer number Customer number 32641645 Add Add and exit Exit Volume setpoint 1 200 0 m3 Volume setpoint 2 0 0 m3 Viscosity setpoint 120 cSt Initial Valve position 930 Actual controller time jul 07 2006 12 35 45 PC ime transfer Cancel Exit and save When Customer name and customer number is correct key in Volume setpoint
5. selecting Graph in the View menu or by pressing the button Graph on the user interface The Batch select window will open when the Batch button is pressed From here individual batches can be selected by choosing customer and then double clicking on the batch number represented by Batch number and date Immediately when clicking the no all graph pages and the report will be updated ready to inspect and or print out remene Jod t File Edit View Help Star Trek U S S Enterprise ZB Graph E i x Volume 1 m3 Star Trek U S S Enterprise CBI Flex Blender Viscosity at 50 dat Viscosity Temperature Flow 1 Flow 2 Flowrate 1 m3 h Customer name lt Ausrian shipping Customer mmber 32641645 Ani xj i Batch mmber Setpoint volume 1 m3 Actual volume 1 28 8 m3 Setpomt volume 2 0 0 m Actual volume 2 1 2006 07 07 Setpoint viscosity Average viscosity 118 Average temperature IFO 45 6 Average density Batch start 2006 07 07 12 54 Batch stop 2006 07 07 13 06 Batch was cancelled Exit Batch no 1 0 Dutiaermo 32641645 13 119 13 27 9 13 42 13 49 13 57 14 04 Customer name Ausrian shipping Batch rj astj usrian shipping Print Print All Exit Page 10 of 20 BCS v21 UserManual 060710 doc BCS user manual FLEX BLENDER Manual operation GI INTELLIGENT Bunnemne SOLUTIONS The motor
6. 003812213443 Setpoint viscosity 140 Average viscosity 139 Average temperature IFO 34 0 Average density Batch start 2006 02 08 17 37 Batch stop 2006 02 08 19 58 The following 2 pages are showing 4 graphs generated by batch 15 Page 14 of 20 BCS v21 UserManual 060710 doc BCS user manual INTELLIGENT Bunkrnine Solutions Appendix 2 1 Graph examples Graph O x LotsOfOil Arabian distributer Viscosity at 50 Viscosity Temperature Flow Viscosity at 50 cSt 17 54 18 03 18 12 18 21 18 30 18 39 18 47 18 56 19 05 19 14 19 23 19 32 19 40 19 49 19 58 time Batch no 15 Customer name pas Graph o LotsOfOil Arabian distributer Viscosity at 50 Viscosity Temperature Flow Viscosity cSt 0 17 37 17 45 17 54 18 03 18 12 18 21 18 30 18 39 18 47 18 56 19 05 19 14 19 23 19 32 19 40 19 49 19 58 time Batch no 15 Customer name Visco Qi Page 15 of 20 BCS v21 UserManual 060710 doc BCS user manual a INTELLIGENT Bunkrnine Solutions Appendix 2 2 Graph examples Eas Graph 0 x LotsOfOil Arabian distributer Viscosity at 50 Viscosity Temperature Flow Temperature dgC 17 54 18 03 18 12 18 21 18 30 18 39 18 47 18 56 19 05 19 14 19 23 19 32 19 40 19 49 19 58 time Batch no 15 Customer name Eas Graph lolx LotsOfOil Arabian distributer Viscosity at 50 Viscosity Temperature Flow Flowrate m3 h
7. 54 13 Batch start Bm Oui 12 53 55 Positioning E 12 21 09 Inactive m Out4 It is now possible to select either cancel done by pressing Stop again or restart 13 06 42 Inactive To restart the batch just press Start whereby the stop 13 06 29 Moving to left stop signal is removed and regulator alarm detection average 13 05 55 Waiting for flow to stop calculation all are reactivated 13 04 22 Regulator on 12 57 47 Batch pause The batch status window shown left is the course of 12 54 50 Regulator on events for a process where both pause restart and cancel 12 54 48 Blender start were introduced 2 54 13 Batch start Page 8 of 20 BCS v21 UserManual 060710 doc BCS user manual al InTELLGENT Bunnemne Sot As can be seen the initial reaction on a stop either caused by volume setpoint reached or cancel is pressed is that the regulator awaits flow stop When flow 1 is off the volume registration is saved for reporting and the blender is positioning to be ready for a new batch At the moment where inactive is written in the batch status window the report is ready and in the report it will be noted if that the batch was cancelled Actual BCS values when batch is cancelled Note Flow1 is showing O0 not necessarily flow2 and the volume is actual stop value Viscosity at 50C cSt Volume 1 m3 Volume 2 m3 26 8 14 4 Flowrate 1 m3 h Flowrate 2 m3 h Tempe
8. B Database name the BCS program is referring to password default Not used Note Interval 20 is default and should only be changed if batches are very small or very big Page 13 of 20 BCS v21 UserManual 060710 doc Cry BCS user manual IurrLLiGENT Bunkrnine Solutions Appendix 2 Test batch example Obs example without flow2 The following report and graph example is a test batch running on following conditions Settings Pulses per m 100 Regulator delay 30 sec Regulator start delay 300 sec and Pump start delay 1 0 m Set points Volume 1 150 0 Volume 2 O Viscosity 140cSt Flow approx 90m3 h Batch started 17 37 Batch paused 17 48 Flow stopped and adjustment made to equipment Batch restarted 18 21 Batch started and flow re established Batch waiting for flow to stop 19 50 Set point 150m3 reached Flow stop 19 57 Regulator stop and moving to stop position report ready 19 58 Batch end and report ready Batch status window On screen report Batch status a Report Ux 19 58 53 Inactive CBI Flex Blender 19 57 43 Moving to left stop 19 50 54 Waiting for flove to stop 18 21 03 Reaulator on 17 48 08 Batch pause Batch mumber 15 17 4220 Regulator on 17 37 37 Blender start sin cara VOR ay 1500 apes is x Actual volume 1 159 8 17 31 85 Batch start Setpoint volume 2 0 0 17 37 05 Positioning Actual volume 2 14 4 17 38 08 Inactive Customer name Visco Oil Customer mumber
9. BCS v21 UserManual 060710 doc BCS user manual GIA eTELLGENT Bunuemne Sorum PC Controlled Blending Automation 9 c V v SOR pp oO Page 1 of 20 BCS v21 UserManual 060710 doc BCS user manual Table of Contents PC CONTROLLED BLENDING AUTOMATION TABLE OF CONTENTS FLEX BLENDER OPERATION Basics Starting the program Preparations before the 1 blend Preparing to start a blend Starting stopping canceling Examples I O status display Display after start Actual BCS values when batch is cancelled Report contents Showing and printing report Show print reports and graphs FLEX BLENDER Manual operation Running a batch on flow2 only Changing the PC during a batch Flexblender V2 1 process flowchart Appendix 1 Settings Settings ini Description and contents Test batch example Appendix 2 1 Graph examples Appendix 2 2 Graph examples Appendix 3 Printout examples Appendix 4 Software installation Database installation Database inspection Database backup Cr INTELLIGENT Bunnemne SOLUTIONS O 0 O WON DW A BP W WH W N be N RP RP RP KH RP hka RP RR RP ka RP RP RP RP kh kk kl k ka O O O N nN DD Q WH OH BP W WwW WwW WwW HO FP KR kl CQ Page 2 of 20 BCS v21 UserManual 060710 doc BCS user manual INTELLIGENT Bunwemine Sorum FLEX BLENDER operation Basics The following description is for the PC based control system consisting of two
10. abase Locate the file BCS gdb and register with sameUsername and password as for the Server 5 IBConsole Database backup i Register Database and Connect DACBIABCS adb E BCS gdb Iv v Base sensitive role tame To backup the database just copy save the file BCS gdb in a safe place To use a backup copy just overwrite or rename the present file remember to make a backup copy before overwriting The IBConsole can be used for inspection of data saved to the database Page 20 of 20
11. e Observe the viscosity for 2 3 minutes e The blender will automatically adjust in small steps if necessary Page 6 of 20 BCS v21 UserManual 060710 doc BCS user manual Examples I O status display Controller inactive Normal blender batch a iol x LILLIE E imme TTT TTT Tie W W mF m os W A MH F E F W ME W i W Page 7 of 20 BCS v21 UserManual 060710 doc BCS user manual INTELLIGENT Bunkrnine SOLUTIONS Display after start Following display is showing process values just after the regulator has been activated Note Volume and Flow rate are always active When Start is pressed the Volume is set to 0 Viscosity at 50C cSt Volume 1 m3 Volume 2 m3 tte es 3 2 Flowrate 1 m3 h Flowrate 2 m3 h Temperature C Viscosity cSt 359 5 179 7 45 6 148 setpoint Viscosity cSt Setpoint Volume 1 m3 Setpoint Volume 2 m3 120 200 0 0 0 You can stop the batch by pressing the Stop key which will activate a menu where either Pause or Cancel can be selected Selecting Pause causes the controller to activate the stop signal at the output and at the same time stopping regulation average calculation and alarm registration The actual output setting can be observed in the I O status window I O Status when paused Output status Blender left balia Batch status B Fan B Stop hides 12 54 50 Regulator on HM Flow2 stop 12 54 48 Blender start E 12
12. operated blender can be set manually Remember to turn of motor supply before start operating Running a batch on flow2 only Setting Setpoint Volume 1 to 0 activates batch where flow2 only is running Setpoint Volume 2 is set to wanted amount Start the batch by pressing start and the typical status for the process will be as shown The batch can be paused and cancelled exactly like a blender batch and the report is generated like the blender batch Batch status 13 06 42 Inactive 13 05 55 Waiting for flow to stop 12 54 13 Batch start 12 21 08 Inactive Changing the PC during a batch FITTRENMS nput status Blender left Blender right Flow 1 pulse Flow 2 pulse Ind Al A2 15 x eb utput status Blender left Blender right Pump Fan Stop Alarm blink Alarm on Flow 2 stop Flow 2 on Dut1 Dut1 Dut12 Dut13 Outl4 I O status when waiting for flow 2 to stop If the PC of some reason is changed during a batch PC or parts of it has broken down it is still possible to finish the running batch while the controller contains the batch number and all necessary information s to finish it If the batch is running and a new PC is connected where BSC is installed the user interface will be updated and if 1 The database is a copy of the database which were active at PC stop time logging will continue and all is working normally after the stop only the
13. ow installed on your his n computer For a description of new features and changes in InterBase 5 use Acrobat Reader to view the ReleaseNotes pdf file in the InterBase home directory If you do not have Adobe Acrobat Reader 3 With Search installed on your system choose Install Adobe Acrobat Reader from the InterBase setup launcher Copyright c 1999 Inprise Corp All rights reserved When you press finish the BCS program is ready to run Database inspection If you want to be able to inspect and edit the database the database file has to be registered as follows Prog rams i Documentation Under START Programs locate the folder Interbase j Administration IBConsole InterBase M i InterBase Server Manager E License Agreement r Release Notes Click on IBConsole right click Interbase Server and Register InterBase Servers 4 Hegister Server and Connect 21x ue Register Server Information 3 iY Un Register Local Server C Remote Server MC Login Server Name Network Protocol vr vel Logout Ba Alias Name gt User SECUTI cs Jew age Description Diagnose Connection v Save Alias Information Properties Login Information User Name SYSDBA Password pem teca Page 19 of 20 BCS v21 UserManual 060710 doc BCS user manual Key in User Name SYSDBA Password master key Then right click Dat
14. pressure inputs on the blender are equal 0 5 bar and not less than 3 4 bar otherwise the blender will not work correctly Page 5 of 20 BCS v21 UserManual 060710 doc BCS user manual InTELLIGENT Bunwemine Sortim Starting stopping canceling When all data have been inserted and all selections have been made check the BCS main screen to ensure everything is ready for start The only incorrect parameter should be the batch number 10 x File Edit View Help Star Trek U S S Enterprise Viscosity at 50C cSt Volume 1 m3 Volume 2 m3 Flowrate 1 m3 h Flowrate 2 m3 h Temperature C Viscosity cSt Setpoint Viscosity cSt Setpoint Volume 1 m3 Setpoint Volume 2 m3 Batch no 0 Customer no 32641645 Customer name Ausrian shipping The batch operation is started by pressing Start The Batch number is then updated and within few minutes the Batch status will be as shown below indicating that the batch is running Batch no E Batch status Customer no 32641645 12 54 48 Blender start 12 54 13 Batch start 12 54 50 Regulator on Customer name Austrian shipping 12 53 55 Positioning 12 21 09 Inactive The operator now needs to do the following e After positioning start bunkering by opening the outlet valve slowly e Mind the input pressures on the blender Observe the pressures mentioned earlier e Now read the viscosity at 50 C on the BCS display
15. rature C Viscosity cSt 0 0 45 6 148 setpoint Viscosity cSt Setpoint Volume 1 m3 setpoint Volume 2 m3 Report contents Report showing specifications for the test batch iol x When the blending delivery is finished stop the blending pumps CBI Flex Blender e Fill the small tank underneath the viscosity unit ok ike sheoncee with clean gas oil Customer mmber 32641645 e Flush the viscosity unit by closing valves V103 Batch mmber l V104 and opening the valves V105 V106 and PERIE NC TEE starting the viscosity pump Actual volume 1 28 8 Setpoint volume 2 0 0 e After flushing close all the valves f ENES volumes 7 144 Setpomt viscosity 120 i Average viscosity 118 Showing and printing report ris tere HO 5 Now you can choose either to printout the report or Average density just forgetting it for the moment As long as the E e Batch start 2006 07 07 12 54 database is intact it will be possible to recall it and Batch stop 2006 07 07 13 06 print as many copies as wanted Batch was cancelled Page 9 of 20 BCS v21 UserManual 060710 doc BCS user manual InTELLIGENT Bunnemine Sot Show print reports and graphs Usually the report for the actual batch will pop up at the moment when the batch is stopped and the status window tells inactive Reselection of batch report is done by selecting Report from the top menu View In the same way the graph can be called recalled by
16. s by mistake The password is 6 digits as 050908 In the process Pump start delay is the first step after starting a batch registering that flow is on Second step is Regulator start delay which ensures sufficient time for the viscosity registration to be relevant Regulator delay is a permanent delay per regulator pulse which is necessary while the viscosity registration has to be stable after an adjustment Pulses per m3 is the setting for actually installed volume pulse transmitter Supplier name and Name is the header text for the user interface sees OOOO GI Enter password ojx Password Flow Pulses per m3 C 1000 C 100 amp 50 C 20 Flow2 Pulses per m3 C 1000 amp 100 C 50 20 Exit Enter Regulator delay sec 30 C40 C50 C 60 Regulator start delay sec 300 C 600 Pump start delay m3 ORES MI 5 x S2ER Supplier name Star Trek Name JUSS Enterprise Cancel Exit and save Settings ini The settings ini file located in the BCS folder is where the BCS specific parameters are set Description and contents supplier Star Trek Supplier name as editable in the Settings menu shipname U S S Enterprice Name as editable in the Settings menu Serial port 3 Port number used for BCS communication Serial baud 9600 Port baud rate refers to controller baud rate interval 20 Time between loggings to DB Can be 10 20 30 sec database BCS GD
17. time To install the database follow these steps 1 Unpack the ZIP file InterBase WI V6 0 1 server to a folder with the same name as the file 2 Go to the folder generated locate the file Setup exe and double click it 3 Press Next twice Yes once and deselect 3 components as shown below Then press Install Press OK to the information window and Finish to the complete window Now the database server is ready and BCS can be started as long as the database file is present in the BCS folder InterBase component selection Select the components you wish to install lin n v InterBase Client iv Command line tools W Graphical tool Software development support L Example programs Description personnel management and sales database used with the example programs 5 C Programmer B orland InterB ase Browse Available 875032 K Required 7808 K IB r Destination Page 18 of 20 BCS v21 UserManual 060710 doc BCS user manual InteLuicent Bunnemne SOLUTIONS Information x 1 A N Setup is unable to update one or more files because they are in use These files will be updated the next time you reboot your computer Note The InterBase Guardian and the InterBase Server will NOT run until your computer is rebooted Choose OK to continue The InterBase Server and Client are n
18. units Unit1 is the controller box It is located inside the rack containing all electrical equipment Unit2 is the PC based program BCS It is located where convenient near the blender or optional in a control room The purpose of unit1 is to convert and scale analog source data convert and scale digital input and output data control blender valve and generate average values time stamps batch numbers and more When a batch is started all process relevant information is updated and controlled by unit1 Unit2 is the user interface showing all process relevant data in individual windows on the screen Each step in the process is specified with timestamp in the right side of the user inter face Furthermore the user interface has connection to a database The database contains all collected report data e g viscosity temperature data together with customer names and batch numbers for generating of reports and graphs Starting the program Click the BCS Icon on the desktop E The user interface will open even without connection to the controller and the first time it is started following will show up on the screen Note During blending the interface must always be open If not open data will not be logged to the database It is OK to minimize the window Frrffrfrra4 aa File Edit Yiew Help Star Trek U S S Enterprise Batch status Viscosity at 50C cSt Volume 1 m3 Volume 2 m3 Flowrate 1 m3 h Flowrate 2
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