Application 5
Application 5
Application No.5 - Multi Mixing Plant
Application No.5 - Multi Mixing Plant
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This application deals with the control of three PVC mixing plants.
The project involved panel design, plc and SCADA application software, and on site commissioning.
Key components:- Mitsubishi AnS series PLCs, Mitsubishi MX4 SCADA software
Please scroll down to see more detail of the application
The central part of the system is a number of Mitsubishi AnS series plcs, communicating over ethernet with a number of Mitsubishi MX4 SCADA systems..
The manufacture of the panels, in this instance, was in house
What the plant does
This application deals with the control of three PVC mixing plants.
Mixers 1 & 2 were originally controlled by another company's control system. In 1995, PJC Systems removed the existing control system, and replaced it with a new suite of control panels, and two control desks. The plcs used were Mitsubishi AnS series (and they are still running today), and the graphics were Mitsubishi AMING, running under DOS.
Mixer 3 was installed in 1995, and controlled by a PJC Systems control system. Initially the plc was a Mitsubishi AnS series (and still is), and the graphics was Mitsubishi AMING, running under DOS.
In 2000, PJC Systems upgraded the graphics to Mitsubishi MX32 running under Windows NT, but left the rest of the control the same.
In 2008, PJC Systems upgraded the front end to Mitsubishi MX4 SCADA, running under Windows XP. All three Mixing Plants can be monitored from a number of stations, and each mixer can be controlled from two nodes. This is so that each mixer has a second point of control in case of hardware failure.
The operators in the main control cabin can monitor all three mixers, but can only control Mixer 3, as it is the only one they can see.
The operators in the mixer 1/2 cabin can control both mixers 1 & 2 from two different computer systems, and can monitor mixer 3
The factory manager can monitor all three mixers, but cannot control any of them.
Batch data is logged to the factory manager's computer, and onward to the factory server.
(PJC Systems do not carry out any work beyond the SCADA system we install. All access to the factory network is to be carried out by the customer)
The slideshow above shows photographs of the plant that PJC Systems controlled. The plant comprises 3 x PVC Mixing Plants, producing a variety of pipes, and guttering. PVC, and a few other additives are accurately weighed and loaded into the high-speed mixer, and mixed vigorously until the batch reaches the required discharge temperature (approx 120 deg C), when it is discharged into the cooler, and cooled to a temperature at which it will convey easily (approx 40deg C). The material is then conveyed to storage silos
The slideshow above shows the SCADA screens that PJC Systems designed for this project. They depict the status of all aspects of the plant, logging all weights and temperatures to the hard drive, enabling historic trends to be retrieved and viewed. Each mixer had two points of control, to ensure that a single computer failure did not render a plant inoperable, but all three mixers could be monitored at at least four points.
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