Operator Manual - Level 1
Operator Manual - Level 1
Revision
GP0CUL GP0CUL-XB12-E9000-AB150 00
BUTIA I ranian Steel Co.
Title
MAKE UP WATER TREATMENT PLANT
Operator manual
Level 1
Approvals
Remarks
Table of contents
1 OVERVIEW
This manual describes the automation of the Water Treatment Plant (WTP) Area.
The manual is divided in two main sections:
Section 1 is oriented to the “Main control station” operators
Section 2 is oriented to the “Local control stations” operators
Section 1 describes:
Main Control Desk commands
Operator Assistant screens
HMI screens
Section 2 describes:
Local Control Stations commands
Operator Panels screens
The main control desk is located directly in front of the operator and contains all the controls necessary
to manage the machine and process.
The operator assigned to the Main Control Desk performs the following activities:
The desk consists of a central section with direct hardwired buttons and Operator Assistant for
immediate action commands and of HMI for supervision and for slow reaction commands.
The Main Control Desk commands are always enabled.
2.1 HMI
The HMI (Human Machine Interface) is an interface for the operator to control and supervise the
machine.
For installation refer to the document “HMI Installation General Steps” that is provided in the
Documentation folder of HMI:
TOP BAR
MIDDLE BAR
MENU
BAR
MAIN BAR
The Top Bar acts as a header for the application and has no other special functions attached to it.
It contains the logo of DanieliGREENTECH on the left, the title of the active page on the center and the
logo of BUTIA on the right.
The Middle Bar is located just belowthe top bar contains some general diagnostic tools
• One or more semaphores that show the general status of the related plant area
• Text and priority of the last not yet acknowledged alarm
• Button to acknowledge the shown alarm
• Navigation icon to access the Alarms Summary page, with counter of the total alarms (in gray)
and of the not yet acknowledged ones (in red)
• Navigation icon to access the Messages and Events Summary page
• Navigation icon to access the Plant Network Diagnostics, with counter that shows the total
number of PLCs currently not communicating with HMI
• Time and data
On the navigation icons to access alarms, events and network pages the following counters are shown:
Unacknowledged alarms: placed on the upper left corner of alarms icon, red background, it
displays the number of still unacknowledged alarms active. It disappears if all alarms are
acknowledged.
Total alarms: placed on the lower right corner of alarms icon, white background, it displays the
number of total alarms active. It disappears if no alarms are present.
Active notifications: placed on the upper right corner of messages icon, yellow background, it
displays the number of messages in notification window. It disappears if no notification is
active.
Off –line PLCs: placed in the upper right corner of network icon, red background, it displays the
number of PLCs that are not communicating. It disappears if all PLCs are active.
The Main Bar area is located on the lower of the screen. Here are placed the most important icons for
page navigation.
The configuration of icons dependson the area currently activated: the pages opened by the visualized
icons are all related to this active area.
The icons on the left are usually intended for “horizontal” navigation, i.e. clicking these icons the pages
that will be open doesn’t change the active area.
The Menu Bar is a vertical menu containing additional icons: it is opened by some icons on the Main
Bar.
Some icons can appear in dark gray font in certain occasions: this means that the user is not allowed to perform
the operation, usually when the permission level required is higher than the one of the logged-on user.
The Overlay Area is the wider portion of the screen and is deputed to host the overlay pages: it extends
vertically from just below the Main Bar to just over the Bottom Bar and laterally from side to side of the screen.
It is possible to have only one Overlay page opened at any time: as soon as a new one is showed, the
previous one is replaced.
Each area is a group of pages related between them by plant control (in this case areas are named with
the plant name) or by function criteria (these are named special areas).
Among all the plant areas there is a main area, which is the area that is firstly opened at system startup,
while the other plant areas are called just plant (auxiliary) areas.
Each area has usually one or more “overview” pages: the overview is a page that contains a summary
of the most important information from the other same area pages.
Also associated to each area there is a specific set of icons that will be shown on the Main Bar:
Figure 7 HMI Navigation: main overview with its relative main bar
Each time a new area is accessed, the overview page of the area appears and in the Main Bar the
previous set of icons is replaced with the set of icons of the new area.
The “Main” button is provided on the each main bar to move back from an area to a previous one.
There are THREE ways to navigate between the HMI overlay pages and Pop-up windows:
Icons on Main Bar, Menu, Bottom bar
Textual links on Sub Bar
Icons inside pages
Figure 9 HMI Navigation: the links available on page
The Active Halo is a dashed gray line that surrounds the image of a device. Clicking it a detail pop
pop-up
window will open:
Figure 10 HMI Navigation: Active halo
The fields can be both input-output (ex. to change a set-point). Some input-output fields, depending
on the process/system conditions, can temporarily inhibit the input feature (ex. when a basic operator
is not permitted to change a set-point): in this case the field changes the background color.
MIDLLE BLUE
Labels are the texts used to describe the state of devices, usually on details
Next table is used on drawings of animated motorized machines such as pumps, fans and so on. The
priority is intended that in case of more states simultaneously active the one with the highest priority is
shown:
In certain cases the valves use the blinking effect to identify the effect of movement towards a steady
position.
The color of pipelines depends on the fluid flowing inside. The pipeline never changes color to show presence or
movement of fluid
The alarms in textual format appear on the Middle Bar and on Alarms Summary/Historical pages.
The font color depends only on the priority and on the status of the alarm.
When a not active alarm is acknowledged it will disappear from Bottom Bar and Alarms Summary lists,
while in the Historical Alarms list it will be reported in three distinct rows: one with the original color to
identify the appearance event, one in gray color lor to identify the acknowledge operation and one in blue
color to identify the disappearance event.
The elements here explained are the most common graphic objects used on the HMI to control the
process (active elements) or to show the status of it (passive elements).
Navigation icons are placed mainly on the navigation bars but they can also be found on overlay pages
and pop-up windows.
The only purpose of icons is to open a page or a window. They are not used to control the process or
the change the status of the system.
In certain cases the icon can be highlighted to attract attention or in a disabl
disabled graphic when the action
is not permitted.
Push-Buttons
Buttons are usually found in overlay pages and pop-up
pop windows.
The purpose of push-buttons is to initiate an action that can affect the process or the system. They are
not used for simple navigation purposes.
In some cases it is useful to convey information (ex. device enabled) directly within the button: this is
obtained by changing the push-button border color.
The button action can in some cases be disabled for interaction: in this case they appear with flat
background style and grayed text.
A combination box (combo-box) is a text entry field combined with a drop-down list. They can be found
in overlay pages and pop-up windows.
A permissive button is used to open a permissive window. They are usually found in overlay pages and
pop-up windows.
The symbol on the button shows the cumulative status of the permissive itself:
SYMBAL MEANING
THE ACTION IS PERMITTED
The permissive window lists all the conditions that have taken to the cumulative result shown on the button:
SYMBAL MEANING
THE CONDITON IS READY
The permissive window usually offers some more details and tools:
• Subdivision between “Start conditions” and “Run conditions”
• Access to detail for some cumulative conditions
• Expand/Compress conditions to only not ready or failed
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Water treatment plant - Operator manual - Level
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• Conditions list scrolling buttons
Transducers are used on P&ID pages to show an instrument analog measured value (temperatures,
flows, pressures, levels, etc.).
The transducer provides the value, the unit and whenever necessary the tag of the instrument. The field
with the value changes the color according to the alarm status.
The switches are used on P&ID pages to show instruments that detect when a value (such as flows,
pressures or levels) is above or below a certain threshold.
The switch provides the status and whenever possible the tag of the instrument. The field with the
status changes the color according to the alarm status.
The bar-graphs have a flat aspect and just show the value of the measure. The bars are recognized
by the color gradient.
The motor status can be show in different ways, depending on the device where they are installed, and
on the picture requirements. Anyway usually the basic symbol for a motor is the following:
MOTOR
PUMP FAN (SMALL) MOTOR
Figure 26 HMI Graphic elements: motors
In the case of motorized valve, as shown in the picture the animation of the motor is independent of the animation of
the valve itself.
EXAMPLES
Here are present some of the most common or important pages used in HMIs.
The Start-up page is the first page that is shown when the HMI software is started. This page can be
reached also selecting HMI Log-off from the System menu.
Besides the usual elements on Top Bar (Danieli Automation logo, application title, customer logo) on
this page can be found:
• Log-in area
• Copyright text
About Log-in section it is important to notice that each time this page is entered the reset of the
previous logged-in account is performed and to enter the application internal pages it is always
necessary to log-in.
After user name and password have been inserted, pressing the “Enter HMI” button the credentials are
checked and in case they are correct the main overview page will be opened:
The menu presents a list of all the plant areas involved on the project. Clicking any item it is opened the
overview page of the relative area.
The System menu is used to access some special functions related to the application intended as a
system, not to the process.
It can be accessed from the first icon on the Left of the Main Bar:
Clicking any item various actions are possible, such as opening an overlay page or a pop-up window or
just launch an action:
• Calculator: launches the Calculator application of Windows O.S.
• System Log-Off: resets the logged-on account and returns to Start-up page
• Shut Down: opens the Shut Down window pop-up that will ask a confirmation before exiting the
HMI application
The Historical Trends is a page that shows the graphs of some recorded values during time.
It can be accessed from the Main Bar icon on the left.
After clicked the icon the first trends menu page will be opened:
Notice that also the Main bar changes in order to host the icons to navigate between various trend
menu pages.
From here it is possible to access a specific graph. On each graph a number of pens is shown and can
be analyzed with the available tools:
The network diagnostics is a page that shows the status of communication with PLCs and field devices.
It can be accessed from the Bottom Bar icon on the right.
After clicked the icon the initial page is opened:
Notice that also the Main bar changes in order to host the icons related to diagnostic functions
pages.
Notice that also the Main bar changes in order to host the icons related to diagnostic function pages. The last alarm is
shown on bottom of the list. The alarm list presents this information for each alarm:
• Date and time the alarm was generated
• Value of the alarm (active or not active). This information is conveyed also by the blue text color
• Acknowledgement status
• Alarm priority
• Group: the area or PLC from which the alarm comes
• Device: the device alarm that generated the alarm
• Text description of the alarm
This page besides the alarms list offers some tools in order to manage it:
• Filter by PLC area, device, alarms status and priority
• Acknowledge of alarms by selection, by page or by whole
• Alarms counters
• Scrolling of the list when this is longer than the available space
This page is a part of the more general Alarms Management System, whose goals are:
1. detect alarm conditions reported by the external devices (e.g. basic automation PLCs)
2. notify new alarm conditions to operators
3. track the changes of alarms status over time
4. present to the operator the status of alarms on his request
5. always show to users the latest most important alarm
6. allow the operator to recognize (acknowledge) the new alarms
The alarms changes in status are continuously tracked and logged on the disk: these data can be accessed through
the Historical Alarms page and from here some tools are provided in order to export and/or print it. Depending on the
WINCC product used to develop the application an external application can be necessary to perform this operation.
For the complete list of the alarm colors refer to the color table (Tab. 6) on this document.
The P&ID pages usually follow the same layout of the drawings even if this can be slightly changed for
better representations of the information:
In this section the description of all the screens for the WATER TREATMENT PLANT is provided.
Description It contains the icons to access the more important pages of this
area.
Path Areas menu > Overview WTP
UF=ULTRA FILTRATION
RO=REVERS OSMOSIS
MB=MIXED BED SLUDGE DEWATERING SYSTEM
Description It contains the icons to access the more important pages of this
area.
Path MAIN PAGE>MBBR
Description It contains the icons to access the more important pages of this
area.
Path MAIN PAGE>MBBR>alarm SUMMARY
Description It contains the icons to access the more important pages of this
area
Path MAIN PAGE>MBBR>MOTOR
Description It contains the icons to access the more important pages of this
area
Path MIAN PAGE>MBBT>VALVE
Description It contains the icons to access the more important pages of this
area.
Path MAIN PAGE>MBBR >SEDIMENTATION SYSTEM