Intelligent Batch Solutionsdesigned for you - KROHNE...

Intelligent Batch Solutions.........designed for you

Presentation Batching Master © 2005 IBS BatchControl GmbH

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Presentation Batch Controller and Batch Systems:



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mbH - Field housing IP 65

- Installation local tothe loading station

- Backlight optional

Batching Master 110i (intrinsically safe)

Batching Master 110 (Non-Ex unit)



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- Panel mount

- Front IP 65

- Backlight optional

Batching Master 210i (intrinsically safe)

Batching Master 210 (Non-Ex unit)



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Loading system for tankers or railway tank wagons

Batch system for basic products into a reactor in

the pharmaceutical industries

The Batching Master controls your batching process



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Indication in the field:

- pre-set, batched quantity

- flow rate, grand total

- back-light optional

Safe batch in the fieldThe operator has all the information that he needs for a safe batching process local to the plant.

If there is a failure in the system, the batch can be stopped immediately.



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Precise Batch

The Batching Master opens the valve with a 4 – 20 mA output signal. Because of the start ramp and the 5 shut down steps it is possible to fill small quantities with the highest accuracy.

No pressure ”hammer” in high flow rate systemsThis is eliminated because of the start ramp and the shut down ramp of the 4 - 20 mA signal.

4

20I [mA]

Start Batchedquantity [kg]

Batch completed

0510152025

4

20I [mA]

Start Batchedquantity [kg]

Batch completed!

051015

Output ramp for high quantities:

Output ramp for small quantities:

Flow meters:All types of flow meters can be connected to the Batching Master



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Error messages in clear textThe reasons for the failure messages can be due to incorrect operation or one of the safety functions of the Batching Master.

After resetting the message, the batch can be continued via the start button.

Emergency Stop Switch- It works on the 4/20 mA output and digital output 1-3

- One digital input for a second emergency stop signal

- One digital output for the message “emergency stop pressed”



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Low flow rate monitoringIf the flow rate during the batch is to low, the Batching Masterstops the batch after a programmed time.

Sensor break monitoring The Batching Master monitors the 4/20 mA input and the NAMUR contact input circuit.

Error at the flow meterThe error output of the flow meter can be connected to a digitalinput of the Batching Master so any failure of the meter will stop the batch.



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Two customer specific error messages can be programmed via the Modbus interface. They are used for interlocks via digital inputs. 16 characters can be used for each message.

This messages have to be specified on order placement

Examples:



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PID Controller function (Option)

The Batching Master has 2 separate controllers which can work parallel during the batch.

1. A flow controller that makes it possible to dose a product with a pre-programmable flow rate

2. An override controller can keeping a second physical value during the batch. E.g. the temperature or the pressure .



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Purge function via F1 or a digital input:For the emptying, cleaning or filling of the pipe system it could be necessary to open the batching valve. When the purge function is activated, the output signal to the valve opens to 20mA, a digital output could indicate the active function and the message “Purge” is be shown in the display.



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Product way selection via the function keys F1 - F3before the start of the batch, it is possible to chose a product way via the function keys.

Therefore it's possible to pre-program one question text and three texts that are dedicated to the function keys.

One digital output is dedicated to each function key.

Via this digital outputs it's possible so activate valves, pumps or product ways.



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Terminal function

The terminal function is controlled by the serial interface. The host system can send text messages to the display of the Batching Master. Operator acknowledgements such as confirming plant status, entry of order numbers or selection of a product can be carried out using the keyboard.



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Average density during the batchSometimes the density of the product is an important quality characteristic which has to be reported after the filling process. The density signal from the mass flow meter can be connected to analoge input 2 of the Batching Master. The density information are shown in the display after pushing the “RC-key”.

- The first line of the LCD shows the average density of the last or of the actual batch

- The second line shows the actual density value at analog input 2

These information‘s are also available at the Modbus interface so it can be printed in delivery papers



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Technical Data for the Batching Master 110i

Approval: BVS 04 ATEX E 172, EEx ib IIC T4

Housing: Field housing IP 65

Weight: 4,4 kg

Dimensions: 240 mm x 240 mm x 120 mm

Power supply: via PSC 300i card

Analogue inputs: 3 x 4/20 mA, passive

Pulse inputs: 2 x for the connection of passive pulses

Digital inputs: 4 x for the connection of passive contacts

Digital input: 1 x for the connection of a second emergency stop contact

Analogue output: 1 x 4/20 mA, active to the batching valve

Digital outputs: 5 x, passive, voltage free

Digital output: 1 x , passive for the alarm “emergency stop pressed”

Interface: MODBUS, TTY, intrinsically safe



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Connection plan for a typical application



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IBS BatchControl offers complete batch systems, consisting of flow meters, batch controller, valves, Exi-interfaces, Exd-housings, printers, loading software and documentation.

The documentation includes:

Installation drawings, circuit diagrams, operating instructions and test certificates.

Calibration:

It’s possible to calibrate the whole system in a calibration area with water. The proven accuracy will be certified in a calibration protocol.

Due to our calibration procedure, the start- up costs of the system will be reduced. This is very important, if the products are toxic or expensive.

Batch systems:



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Replacement of mechanical flow meters with pre-select and batch function.

Advantages:- electronic flow meters are

maintenance-free

- the accuracy is much better

- mechanical flow meters are not as

reliable

- calibration and repair of mechanical

meters is expensive



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1. Start the batch

2. Back flow valve closes

3. A waiting time begins

4. The flow stops

5. The batch valve opens and the real batch begins

6. Batch is finished

7. The back flow valve opens

8. Printout of the batch information

Batching system for ultra pure water using a circulatory systemIn the pharmaceutical, cosmetics and toiletry industry, as well as often in the food industry, ultra pure water is used as a basic material for the production of creams lotions and syrups. A standard plant design requires the water to flow continuously to prevent the formation of germs. The supply of the whole plant with ultra pure water is done via a circulatory system.



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Loading and Batching of Liquefied GasLiquefied Petroleum Gas demonstrates out-gassing effects as soon as the pressure falls below the vaporization pressure of the LPG.

As shown in the vaporization curve of propane below, the temperature dependency of the pressure is non-linear.

As a consequence, pressure control is required, the preset value of which is determined by the actual vaporization pressure.



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Loading and Batching of Liquefied Gas Realisation with the Batching Master:

The batching master provides three functions operating in parallel. Based on a minimal selection procedure, the lowest value is transferred to the output of the Batching Master and thus to the control element.



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Power supply for the Batching Master

PSC 300i - one channel:DIN – rail housing, power supply: 24 V DC

Output 1: Power supply for the Batching Master 110i / 210i

Certificate: ATEX [EEx ib] IIC

KL 13/14

KL 15/16

KL1 +

KL2 -

KL8 +

KL6 -

24V DCPower supply 1

Power supply 2

Hazardous Area Safe Area

PSC 300i - two channel:DIN – rail housing, power supply: 24 V DC

Output 1:Power supply for the Batching Master 110i / 210i

Output 2:Power supply for the backlight of the LCD




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Power supply and MODBUS interface The IPC 300i interface card DIN – rail housing, Power supply: 24 V DC

Exi supply output: Power supply for the Batching Master 110i/210i

Interfaces:

Exi : TTY to the Batching Master 110i/210i

Safe area: RS 485 (MODBUS)


Hazardous Area Safe Area

KL10 GND

Power supply

KL1 +

KL2 -

KL5 TXDKL6 GND

KL7 RXD

TTY Interface to the Batching Master RS485- Interface

24V AC/DCKL13/14

KL15/16

KL9 A

KL11 B



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Management Loading Stations

Disposition

Control roomLocal

Network

Software system for visualisation of the batching process and loading order management

Standard Edition

Power Edition



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Order managementCustomer Delivery address

AssignedProduct

Orders Spec. order quantity

PlanningVehicleLoading order

One or more orders are grouped into a single loading order.•The forwarding agency and vehicles are planned and assigned to the loading order.•The specified order quantities are distributed among the vehicle's chambers.•Loading information is provided.

Forwarding agency

LoadingLoading control with facility and loading informationRelease of the loading order.•Execution and control of the loading process (start, stop, cancellation).•Display of current statuses and actual quantities.•Printout of delivery notes.

Dosage system

Delivery note printout

Document administrationDocument(s)

A document is prepared for each order.•Each document contains data on the related order, forwarding agency and vehicle, as well as the loaded quantities (actual values).

StatisticsCustomer, forwarding agency and product statistics.•System throughput.



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Loading Software - Databases:

Vehicle Database

Database, Forwarding Agencies

Customer Database

Product Database



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Loading Software - Order Administration:



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Loading control and visualisation:



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Functionality of the loading software:- Customer database

- Carrier database

- Vehicle database

- Product database

- Order administration

- Creation of loading orders

- Batch control function

- Batch supervision

- Printing of delivery papers

- Product and customer statistics

- Direct loading without an order



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Optional functions of the loading software:- Data exchange with SAP R/3 databases

- OPC-Server for the connection to supervising

systems

- System security via card readers

- Additional languages

- User database and log files

- Multi-user system in client- / server function



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Order Code for the Batching Master 110i/210i:Batching Master 110iEx-i, field housing IP65Batching Master 110Non-Ex, field housing IP65Batching Master 210iEx-i, panel mountBatching Master 210 Non-Ex, panel mountBacklight for the LCDThis option require the two channel power supply for Exi units.Modbus interfaceTTY for intrinsically safe units, RS485 for non Ex units Terminal functionIncluding the Modbus interface

Filling /EmptyingSpecial software function

120-0110

120-0120

120-0130

120-0140

120-0145

120-0150

120-0160

120-0170

120-0180

PID Controller function

120-0175 Density correction of the volume flow signal

120-0176 Calculation of the average density during the batch



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Function keys F1-F3120-0191 3 product ways120-0192 3 fixed pre-selections120-0193 3 fixed controller set points

Emergency stop as a key switchonly for the field housing

Exi power supply, one channelPSC 300i, one channel, DIN-rail housing, supply 24 VExi power supply, two channelPSC 300i, two channel, DIN-rail housing, supply 24 V necessary for the back light version.Interface and power supply cardIPC 300i DIN-rail housing, power supply 24 V. TTY intrinsically safe to RS485 non Ex and one Exi power supplyOptocoupler module, 2 channelType 07-7311-93QH/C5NO, DIN rail housing. For the connection of non Exi pulses or non Exi digital signals to the Batching Master

A-120-0220

A-120-240

120-0200

Accessories / Interface Cards

A-120-0215

A-120-0210

Order Code for the Batching Master 110i/210i:



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3M, France/GermanyAbbot, GermanyAir Liquide, GermanyAker Kvaerner, The NetherlandsAkzo Nobel, China, The Netherlands Astra Zeneca, EnglandAventis, GermanyBASF, Belgium, Mexico, China, Germany Bayer, Spain, GermanyBritish American TobaccoButagaz, FranceClariant, Greece/Switzerland/GermanyCiba, Italy/Switzerland/GermanyCoca Cola, GermanyCognis, GermanyDegussa; Belgium/GermanyDupont, GermanyDSM The Netherlands/Austria/GermanyExxon, France/The Netherlands

GlaxoSmithKline, EnglandJohnson & Johnson, GermanyKrohne Messtechnik, WorldwideKANEX, RussiaLinde, GermanyLurgi, GermanyMerck, GermanyNovartis, Switzerland/GermanyPfizer, GermanyRhodia, France/Germany Roche, Switzerland/GermanySanofi, FranceShell, GermanyTecnicas Reunidas, SpainTotal, FranceToyo Engineering, JapanVopak Banyan Terminals, SingaporeWacker Chemie, Germany

We solved their batching problems:



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IBS BatchControl GmbH, Marie-Curie-Str. 8, 50170 KerpenTel.: +49 22 73 / 60 37 - 0, [email protected], www.ibs-batchcontrol.de

When can we solve your

batching problems?

Intelligent Batch Solutionsdesigned for you - KROHNE...

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