Automation

System Investigations

Contents
Introduction to Process....................................................................................2
Specification of Problem...............................................................................3
Proposal for solution.....................................................................................3
System Design Specification.........................................................................4
Instrumentation and Control Devices...........................................................5
Temperature Device...................................................................................5
PH Device...................................................................................................7
Level Transmitter.......................................................................................8
High and Low Level Switches...................................................................10
Flow Meter...............................................................................................11
Process Control Design...............................................................................13

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Introduction to Process
I work in a pharmaceutical plant manufacturing Flu Vaccines for distribution
globally. Due to the nature of the business and the live egg waste involved it
must be suitably treated. We have classifications of liquid waste and all
liquid waste falls into these two classifications. Contaminated and noncontaminated waste. Contaminated waste currently is treated through our
waste facility on site and this system is fully automated. Non-contaminated
waste can be distributed through the site main water drain. Recently we
have had various complaints from the local water board in regards to
condition of this waste during routine sampling and they have placed
restrictions on the pH and temperature of outgoing waste. Currently our
system Pipes all non-contaminated waste into local storage tank outside the
plant and when it gets full (typically after a days production) it is discharged
throughout the night.

The main cause of the excursion is deemed to be related to the pH. After
each production day every product contact line must be cleaned and
sanitised. This is first done by caustic in the Clean in place process. The
next stage after the chemical mix removes residue left behind by the process
is to clean steam sanitise the pipework ensuring all pathogens are killed at a
very low level. The pH issues arise from this as all chemical waste must be
disposed of and it is very high strength. Initially the discharge tank would
just dilute due to the excess water waste from post clean flushes, however
since these excursions an automated dilution method is required.

The issue we have now is to implement a system that will govern the
discharge of waste to drain in regards to temperature and pH value and a
suitable control system including automatic valves, PLC control (linked to the
site Siemens PCS7 system) and condition monitoring equipment for
temperature, level pH etc.

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Specification of Problem
As discussed earlier the defined issue is with the Environmental monitoring
of the waste water systems to drain. The pH of the waste water can be too
far below pH 7 and is drifting out of our agreed limits. The limits are set by
local regulations and United Utilities and our limits are as follows

Limit Type
pH
Temperature
Flow Rate

Low Limit
6.0
n/a
n/a

High Limit
10.0
43.3C
12l/s

These are the control limits that the instrumentation I will choose will have to
operate within and the control system in place to be robust enough to enable
these tolerances to be controlled within and to block any discharge that it
outside these limits. Also ensuring maintenance of the equipment in line
with our requirements to the Food and Drug Administration (FDA).

The issue in hand has become far more prominent due to the increase in
production waste chemicals from the cleaning. Previously the chemical
would just mix within the tank and dilute after the flush had completed
however this is not currently the case and the pH has been rising and
without manual addition of water to dilute there is no control on this par of
the process.

Proposal for solution

My proposal for a solution to this issue is to have an automatic dosing of
clean water from site to bring down both temperature and pH. The project
must conform to these basic standards;

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Not allow discharge if process conditions are not met.

Dose water to meet process conditions for temperature and pH
Circulate/agitate liquid to ensure consistency.
Automatically discharge after a hold time at defined process
conditions.

For the control system to stop discharge we must have interlock systems in
place that will not allow the discharge valve to open until the temperature is
< 43 degrees and the pH >6 and <10. As the whole site uses Siemens step
7 so any solution would have to be created to work with this system. Cards
occupy both digital inputs/outputs and analogue inputs/outputs so either
methods of feedback, inputs and outputs would be adequate.

A stand-alone system could be possible however there would be no visibility

to the site monitoring system and if there was an issue nobody would be
informed, if we cannot get rid of waste then production will grind to a halt.
Therefore the System would need a minimum of;

Temperature probe and transmitter

pH probe and transmitter
level transmitter
In line flow meter
2 level switches (high and low for overspill and pump protection)
Control valve
Free slots on S7 Rack for IO cards.
Agitator
Dilution water pipework
All instrumentation graphed and recorded for environmental
monitoring

System Design Specification

1. The tank would be modified to add a pocketed temperature probe and
transmitter, wired back into the Siemens AI terminal on the rack

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configured to feed 24v to the transmitter and receive a current readout

of range 4-20 mA to 0 to 100 degrees C.
2. Suitable pH probe and transmitter would need to be selected and
installed within tank taking note of orientation as some probes are not
suitable for mounting upside down etc. This would then also be wired
back to an input card and supplied with 24v power. There is also a
possibility that this one probe could also do temperature so a decision
could be made to try to reduce cost of the project by combining these
into one probe.
3.
Active level transmitter sourced for reading a live level reading
graphed back to the control system to give indication of usage and
levels over time
4. Level switched for protection of pump and secondary high high level
valve shut off.
5. Circulation pump to recirculate tanked liquid to aid with mixing and
keeping liquid of uniform pH/temp.
6. Control valve for limiting flow rate of discharge
7. An agitator and motor would also help with the missing to ensure no
pockets of high temperature or pH.

Instrumentation and Control Devices

Temperature Device
PT100 Endress TH13
Temperature probes often used are PT100 or thermocouples, as
thermocouples are often used for high temperature applications I would
choose to opt for the PT100. It is accurate, repeatable and readily available.
A requirement would be to have it enclosed within a pocket, for calibration
purposes this is a must as there is no requirement to drain the tank to
calibrate (also known as a thermowell). A company we use often is Endress
and Hauser. They supply a TH13 temperature transmitter housing with
thermowell for enclosing the PT100 probe.

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Fig (1)
In figure 1 I propose we use this housing with a socket weld for enhanced
leak protection, the probe will then sit inside spring loaded onto the metal
edge ensuring good contact and eat transfer (this can be enhanced with
thermal Paste).
The probe is a PT100 and connects directly to the transmitter head mounted
directly to the top. This will then be powered by a 24v supply direct from a
local instrument junction box connected to a 2 wire Siemens analogue input
card.
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For calibration purposes temperature transmitters on site are HART

compatible as the programming software we have available in both a laptop
and a remote handheld device. This is used to make adjustments to range
and calibration offsets. There are sometimes alarm set points settable within
the transmitter software however as a site rule the Siemens PCS 7 does all
the control and alarm points the only piece of information we receive on the
input card is a 4-20 mA signal that is converted into a range on the PCS 7
Client.

Working Principal
The working principal of the PT100 Resistance Temperature Device is the use
of a metal coiled wire typically platinum with a predictable resistance value
for the temperature range. The PT100 is most common and its resistance
value is 100 at 0 degrees C. The RTD is useful because it has low drift and
is very accurate; it produces a graph that is almost a straight line, whereas
say a nickel graph will have a curve associated with it.
An RTD is not commonly used above 600 degrees C and in these instances a
thermocouple will be used. This is due to the higher temperature causing
impurities to contaminate the element and cause it to become unusable.
This is purely an application issue and at the design stage it is imperative
that you asses the working range of the probe and determine which type to
select for this application. In general anything below 500 degrees is an RTD
PT100 and above its a range of thermocouple materials that can be selected
depending on the top end on the temperature scale.

PH Device
pH used to be a particularly difficult process measurement to take, it
required multiple probes into one line and was very prone to misreadings
and failures. Newer methods have come into the forefront now and
reliability and calibration methods have really improved. Currently on our
site we use a single probe method that proves with regular calibration to be
reliable. The probe is connected into a local display and transmitter box that
is modular. You can buy different modules for whatever application you
require. Relays can be activated to trigger alarm points back to the control
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system or to local valves to enable one small sub system to complete some
steps of control.

Endress and Hauser Liquiline CM442

The selection I would choose to use is the CM442; it features a modular
design so you can specify the way it is to be configured by modules insert
able into the casing. They can be configured during ordering as to what
modules you would like to be installed and these can be
changed at any time. I would suggest for this project that
we use an analogue output module to supply a 4-20mA
signal to the control software but also a 2 relay module to
provide the outputs to signal for alarm points back to the
control system so that it will react when the item goes out
of specification. Although this will also be done in software
to provide the control for dosing it is also handy to have the
hard wired outputs for safety so we can ensure that the
valves in question will not open regardless of the software.
As discussed earlier it is also possible to receive the
temperature from these devices, in this application the
temperature is used for compensation of the pH in relation
for temperature and could also be used as a reading back
to remove the need for a PT100. I have chosen not to use
this as within the industry my company operates calibration
is mandatory and calibration of the temperature section of
this probe is not possible, for temperature we must use a 3
point check and we would only be able to use a one point
spot check.

Measuring principal
The pH analysis equipment used in this equipment uses the potentiometric
measurement principle. The type of probe used is called a glass electrode,
it has a buffer solution internally and a pH sensitive glass membrane. A gel
layer develops on the inside of the membrane which is in contact with the
buffer. Positive hydrogen ions either diffuse out or into the gel layer
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depending on the pH value of the measured solution. The internal buffer

generates a potential differential between the gel layer and the buffer this is
then compared to a reference sensor (now in newer probed inside the single
unit) and it is proportional to the pH measured in the fluid. Figure 2 shows
the two part probe.
Fig 2

Level Transmitter
The level transmitter will be used to give constant reading of levels in the
tank and will be graphed to show dropping level along with all other system
parameters to ensure when dumping water it is at the correct temperature
and pH.

Radar Micropilot FMR245

The Micropilot radar level system will be a good choice for this system; it is
fairly maintenance free and has no parts that will need replacing as there is
no product contact. All items that need replacing will be on the tank
externals with the possibility of a clean of the radar face every so often to
reduce erroneous readings. It is this reason I would choose a radar system
for this application. We will have contact with a wide range of temperatures
and pH values that could corrode and wear out other methods that use
contact as a means of measurement. Capacitance would be out of the
situation due to changes in the process medium and floats would degrade
too often.
Measurement Principle

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The Micropilot is a downward facing level measurement device that uses the
time of flight method of measurement. Time of flight uses a known distance
to empty value that is measured beforehand and uses radar impulses to
reflect off the measured level and to be received by the measuring device.
This time taken given the measured to empty distance gives a distance to
level which can then be worked out to a live level as measured on the field
as shown in figure 3 below.

Fig 3
High and Low Level Switches
This part of my design is all about safety of both equipment and people.
These switches offer another level of protection other than the radar level.
The radar level will be used for control however the switches are used purely
for safety.

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Liquiphant M Tuning Fork Level

The FEL 52 (3 wire DC) Switched tuning fork level by Endress and Hauser is
designed for this purpose, it connects into the process vessel and detects for
liquid on the tip, on detection the transistor is switched giving a signal back
to the control system. This signal will then be used for the protection of the
pumps, when the level drops below this probe the level will be dangerously
low and could cause pump cavitation so this signal will stop the pumps and
enforce interlock conditions until the level in the vessel is higher. The pump
will be stopped but the discharge valve will still be able to be opened as long
as the discharge conditions are met. The unit is very versatile and can be
mounted anywhere in practically any fluid or solid material see figure 4
below.

Fig 4
Measurement Principle
The level switch operated by using a tuning fork vibrating at their resonant
frequency when the liquid touches the tip of the probe the frequency
changes and this will then activate a limit and cause the switch to operate.
This also provides a self-monitoring function, as corrosion builds up or fouling
the frequency will also change generating an error and the probe will need to
be replaced.

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Flow Meter
The flow meter will be in line with discharge pipe to control the flow rate to
keep it within specification of discharge amount per day. This flowmeter will
enable the control system to throttle a control valve to keep the flow rate to
the set point and our discharge within agreed limits.

Proline Promag E100

This flowmeter is on the cheaper end of the scale, it is low cost but as this is
waste water an electromagnetic flowmeter is ideal. It does not inhibit flow
and allows for a full bore application straight to drain. It will also allow
control of the flow from a local control valve. As we only need a reference
reading and it is not a process parameter that we require to be accurate due
to the process recipe or a metered service.

Measuring Principle
The electromagnetic flowmeter measuring principle is based on theory of
voltage induction, the process medium is the moving conductor and the
voltage induced through a magnetic field caused by this conductor is
proportional to the flow velocity of the liquid. Figure 5 shows a graphical
representation of this process with a full explanation and formulae
Fig 5

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Control Valve
The process flow will be governed by a control valve made by GEMU valves.
Its electronically positioned with feedback for current position. They are
very accurate for rate control and provide very fine tuning for this type of
application. The operate by controlling a diaphragm to modulate the valve,
the input for this would come from the control system via an output signal of
4-20 mA 4 being closed and 20 fully open. This would effectively ensure no
high flowrates on the outlet.

Process Control Design

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This section we will cover the design of the system and layout drawing. The
design has been chosen to meet a specification that will solve the initial
problem. We do not want water to be discharged to drain until it is within
specification set by the local water board.

The specification I devised is as follows each step will be broken down to see
if the chosen solution would be effective.

1. The tank would be modified to add a pocketed temperature probe and

transmitter, wired back into the Siemens AI terminal on the rack
configured to feed 24v to the transmitter and receive a current readout
of range 4-20 mA to 0 to 100 degrees C.
The transmitter has been added to drawing at a location that would read the
temperature and talk with the PCS7 control system to regulate the
temperature if it is too high using the analogue input cards the software
would then provide the conditions.
2. Suitable pH probe and transmitter would need to be selected and
installed within tank taking note of orientation as some probes are not
suitable for mounting upside down etc. This would then also be wired
back to an input card and supplied with 24v power. There is also a
possibility that this one probe could also do temperature so a decision
could be made to try to reduce cost of the project by combining these
into one probe.
PH probe and transmitter has been inserted into the vessel drawing
(QT330004) this will also communicate with the control system and allow the
system to take control using the pre-defined parameters for discharge
interlocking bottom valve when out of specification.
3. Active level transmitter sourced for reading a live level reading
graphed back to the control system to give indication of usage and
levels over time
Lever transmitter has been placed into the top that would provide an active
reading showing current level of the tank. The control system would then be
able to provide a graph.
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4. Level switched for protection of pump and secondary high high level
valve shut off.
Two level switches have been placed onto drawing that would dictate
interlock conditions for inlet and outlet valves and pump for protection of
overspill and pump.

5. Control valve for limiting flow rate of discharge

Control valve has been inserted into drawing to regulate the flow of the
discharge keeping us within tolerance.
6. An agitator and motor would also help with the missing to ensure no
pockets of high temperature or pH.
Agitator placed into drawing to allow mixing of the process waste medium
keeping a constant process condition.
7. Flowmeter installed to allow control of flow
Flowmeter was added to drawing to allow control valve to control flow as to
not breech conditions

As we can see there are no limitations on the implementation of this new

automation system and it would meet all specifications I defined earlier. This
system would work and would benefit the site as a whole in keeping within
our environmental constraints
The outlines of these changes are that the process control system would be
configured to allow the inlet of water/acid from internal process tanks up to
60% of the level of the tank. The pH (QT330004) would be monitored as well
as the temperature (TT330005) and if there are any deviations from this it
would dose water into the tank until pH and temperature are within
tolerance.
This would then allow the discharge control valve (CV330007) to open and
control depending on the measured flowrate (FT330006) to keep it below 12
liters/second. Then that would run until low level alarm is triggered from the
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level switch (LS330002), this will protect the pump from running dry. The
same is true for high level (LS330003) if the transmitter for level is defective
the there is some safety systems in place where the valve will fill only up to
the high level point and interlock conditions would be initiated and the valve
locked out.
Agitation will only be operational when low level is not initiated and level is
measured above 30%.
This system will fulfill the design and the problem and enable us to operate
safely and within our agreed discharge parameters. Figure 6 shows a mock
up drawing showing locations of instrumentation and a graphical display
using on site PCS7 Graphics (readings would be underneath Tag Names).

Fig 6

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Bibliography
Promag Flowmeter Manual TI01159DEN_0114.pdf
http://www.omega.com/prodinfo/magmeter.html Omega Measuring principle
electromagnetic
http://www.endress.com/ PH Analysis Sensor
Temperature sensor TI13 manual TI00110ren_1312.pdf
Level Switch Manual ftl50.pdf
Beamex Ultimate Calibration on site book

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