AQUAT FOOD INDUSTRIES CO.

LTD

User Operators Manual

Level – Flow Monitoring and Reporting System Project

Client: Aquat Food Industries Co. Ltd

Project / System: Level – Flow Monitoring and Reporting System Project
Document No.: UOM_AQFIABM_ESS_0.00
Document Version : 1.01
Version Date: 03.15.2017

Management of this Document

Role Name Signature Date

Author Engr. Mark Spicer
Automated Business Machines Est.
Reviewed by Engr. Hatem Khalil
Technical Aspects Automated Business Machines Est.

This document specifies the performance of the intended system and defines the necessary functions of the equipment. The objective
of the UOM is to show the system structure of the intended system and not the design of single components.
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Document History

Version Description Author Date

0.00 Issued for Reference MMS 3.21.2017

0.01 Issued for Reference MMS 8.19.2017

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1. Introduction
This document describes the Software / Machines developed to operate the Level – Flow
Monitoring and Reporting System Project of Aquat Food Industries Co. Ltd in order to deliver and
maintain a good quality product for the customer's satisfaction.

2. Project Overview Section

2.1. Purpose of this Project

The purpose of this project is to develop an optimize control system in compliance with
the process design and operational procedures of the customer.

2.2. Benefits of the New Control System

1. To operate and monitor the process in an effective and simple manner via HMI/SCADA.
2. Analyze data through automatic reporting.
3. Improve control system accuracy and reliability.

2.3. Scope of this Project

This document covers the software design specifications of the Level – Flow Monitoring and
Reporting System Project of Aquat Food Industries Co. Ltd. Software to be developed includes
programs for both the PLC and HMI/SCADA.

The new system shall provide the following controls:

1. Visual representations of Tanks and Flows.

2. Automatic reporting - .CSV File.
3. Trending and Alarms via Runtime PC, Email.

3. Design Specification
This section describes the structure of the system. (E.g. stand-alone or embedded
system). It explains the modular structure of the system. In case of system failures, the
operation for maintenance purposes should be still possible.

3.1. Hardware Design

This section describes the system hardware components. The major hardware components
are:

 Mitsubishi FX3U PLC

 Desktop for SCADA/HMI

Software for component Software name Version

PLC Melsoft GX Works 2 V1.5
SIMATIC WinCC
SCADA/ HMI V2008 SP3
Flexible Advanced
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3.2. System Architecture

In the Figure 1, the system connection beginning from the Field Devices are
connected in a conventional wiring going to the RS485 Analog Module. From the RS485 Analog
Module, it is now connected via Modbus RS485 going to the PLC. After that, the PLC is connected via
RS232 going to the HMI PC in Pump Room Control Panel for monitoring purposes.

Pump Room
Control Panel

MODBUS RS485

USB RS232

Conventional Wiring

Node 1

Conventional Wiring Conventional Wiring Conventional Wiring

Generator Boiler JB - Back Area JB

JB - Node 4 Node 3 - Node 2

Figure 1

4. Supervisory Control and Data Acquisition / Human Machine Interface

This section describes the Supervisory Control and Data Acquisition / Human Machine Interface
and further interfaces that are used in the project. It contains information about all visualization
aspects of the system like displays and trends, the operation concept, the event and message
concept.

4.1. Screen Structure

The SCADA is use to navigate screens to facilitate operation of the Glue Preparation Batch.

a) Start Up Screen (Aquat Food Industries Co. Ltd Logo)

b) Main Screen
c) Settings Screen
d) Trend Screen
e) Alarm Screen
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f) Report Screen

4.1.1. Event Types

Each message should be assigned to a message class. Message classes can be e.g.:

 Alarm – Red Color

 Warning – Yellow Color

4.1.2. SCADA/HMI Screens

Figure 2: Start Up Screen

Figure 3: Main Screen

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Figure 4: Trend Screen

Figure 5: Alarm Screen

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Figure 6: Settings Screen

Figure 7: Alarm Maintenance under Settings Screen

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Figure 8: Report Screen

5. Control Operation
This section explains how to operate, navigate and monitor the process via HMI/SCADA.

a. Header
○
2 ○
4 ○
6 ○
9 ○
10

○
1 ○
3 ○
5 ○
7 ○
8 ○
11

ICON NO. DESCRIPTIONS

○
1 This button will redirect you to the Start page which shows you the Company Logo and Project Title.
○
2 This button will redirect you to the Main page.
○
3 This button will redirect you to the Alarm page which includes Current Alarms and Historical Alarms.
This button will redirect you to the Settings page and give you access to set limits for the tanks as well
as resetting the total flow for the flowmeters. In addition, you are able navigate to the Alarm
○
4
Maintenance page which you will be able to activate and de-activate alarms for a certain tanks during
maintenance.
This button will redirect you to the Trend page. Analyzing data via trend can give you an idea for the
○
5
situation of a certain process tanks and flows.
This button will redirect you to the Report page. Giving you access to print current alarms and historical
○
6
alarms. Also the directory of the automatic reporting system for the devices includes in this page.
○
7 This button will Log Off current user that is Log In in order to prevent any access on the Settings page.
○
8 This button will redirect you to a pop-up Log In in order to access the Settings page.
○
9 The Alarm View. This is where current alarms shows.
○
10 The Developers Company Logo.
○
11 Date and Time.
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b. Main Screen

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6
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1
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7

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2
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○9
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10

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3

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4

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11

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5 ○
12

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13

ICON NO. DESCRIPTIONS

○
1 Very High Level Limit Alarm occur. Under Error Alarm.
○2 Very Low Level Limit Alarm occur. Under Error Alarm.
○3 High Level Limit Alarm occur. Under Warning Alarm.
○4 Low Level Limit Alarm occur. Under Warning Alarm.
○5 Realtime trend for Flowmeter.
○6 Realtime Level Bar for Process Tanks.
○7 Realtime trend for Process Tanks.
○8 Actual Value for the Process Tanks Level in unit meters(m).
○9 Actual Value for the Process Tanks Level in unit percentage(%).
○
10 Actual Volume Value for the Process Tanks Level in unit cubic meters(m3).
○
11 Status for Tank Maintenance if Alarms are to be Activated( ) or De-Activated( ).
○
12 Actual Flow Rate of the Flowmeter unit in GMP.
○
13 Totalize Flow of the Flowmeter unit in GMP.
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c. Alarms Screen

○
1

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3

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2

ICON NO. DESCRIPTIONS

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1 Alarm view for Current Alarms.
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2 Alarm view for Historical and Log Alarms.
○
3 Acknowledge button for Current Alarms.

d. Settings Screen

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1

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10

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11
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2

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3
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12
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4
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13

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14
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5
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15
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6
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7 ○
8 ○
9

ICON NO. DESCRIPTIONS

○
1 Actual Value for the Process Tanks Level in unit meters(m).
○
2 Realtime trend for Process Tanks.
○
3 Input Field for Very High Level Limit unit in percentage(%). Input desired value and hit "Enter".
○
4 Input Field for High Level Limit unit in percentage(%). Input desired value and hit "Enter".
○
5 Input Field for Low Level Limit unit in percentage(%). Input desired value and hit "Enter".
○
6 Input Field for Very Low Level Limit unit in percentage(%). Input desired value and hit "Enter".
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○
7 Actual Flow Rate of the Flowmeter unit in GMP.
○
8 Totalize Flow of the Flowmeter unit in GMP.
○
9 Reset button for Totalize Flow.
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10 Output Field for Very High Level Limit unit in meters(m).
○
11 Output Field for High Level Limit unit in meters(m).
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12 Output Field for Low Level Limit unit in meters(m).
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13 Output Field for Very Low Level Limit unit in meters(m).
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14 This button will redirect you to the Alarm Maintenance Page under Settings Page.
○
15 This button will Log Off current user that is Log In in order to prevent any access on the Settings page.

e. Alarm Maintenance Screen

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1

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3

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4

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2

ICON NO. DESCRIPTIONS

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1 Indicator Lamp for Alarm on a specific Process Tank. Activated( ), De-Activated( ).
○
2 This button redirect you on the Settings Page.
○
3 Activate Alarm Button.
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4 De-activate Alarm Button.
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f. Trend Screen

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12
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1

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5
○9
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3 ○
11
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4 ○
6 ○
7
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8 ○
10 ○
13

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2

ICON NO. DESCRIPTIONS

○
1 Historical trend view.
○2 Buttons for each devices Trends.
○3 Trend "Start/Stop trend recording" button.
○
4 Trend "Go to Start" button.
○
5 Trend "Backward" button.
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6 Trend "Forward" button.
○
7 Trend "Zoom in" button.
○
8 Trend "Zoom out" button.
○
9 Trend "Ruler visibility" button.
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10 Trend "Ruler backward" button.
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11 Trend "Ruler forward" button.
○
12 Trend Ruler.
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13 Trend value table.
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g. Report Screen
h.

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1 ○
2

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3
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9
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11
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8 ○
12

ICON NO. DESCRIPTIONS

○
1 "Print Recent 30 Alarms" report button.
○2 "Print Full Alarm Log" report button.
○3 Directory details for the Automatic Archiving of Devices/Instruments data per hour.
○
4 Actual output of “Before Delivery” in m3 .
○
5 Input field for “Before Delivery” in meters.
○
6 Actual output of “After Delivery” in m3 .
○
7 Input field for “After Delivery” in meters.
○
8 Calculate button to identify volume difference.
○
9 Input field for “Tanker Volume” in liters.
○
10 Output for the volume difference of Tanker and Diesel tank.
○
11 Drop down list for tank selection.
○
12 Print Report button.
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i. Automatic Data Archiving

Default Directory:

D:\Storage_Data\Year_####\Device
Name\Month_##\Day_##\Press_01_###.c
sv
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○
2 ○
3 ○
4

○
1

ICON NO. DESCRIPTIONS

○
1 "VarName" column indicates the instrument/device name. With "perc" suffix represents percentage.
○
2 "TimeString" column indicates the time during the data has been log.
○
3 "VarValue" column indicates the instrument/device actual value at specified time.
○
4 "Time_ms" column indicates the time during the data has been log in milliseconds.
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i. User Log In Pop-up

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1

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2

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3

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5
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4

ICON NO. DESCRIPTIONS

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1 Close pop-up button.
○
2 Username input field.
○
3 Password input field.
○
4 Cancel button.
○
5 OK button.

Important Note:

For User Log In. Kindly input the following details below in order to have access into
the Settings Page.

User: admin

Password: aquat2017

After filling the information. Click "OK" button in able to activate the User. "Enter"
button from the keyboard will not process the authentication.
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