SSM InfoTech Solution Pvt. Ltd.

Project No: 1000515

Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

FUNCTIONAL DESIGN SPECIFICATION

X-force Recipe and SCADA System for Pramod paint
(Asian Paints)

Version Description of Change Prepared By Reviewed By Date

P0 Initial draft Nirav Mistry 7th Jan 2022
A1 Approved by customer

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

Index
1. INTRODUCTION.................................................................................................................................... 3
2. PURPOSE.............................................................................................................................................. 4
3. SCOPE.................................................................................................................................................. 4
3.1 SCADA SYSTEM................................................................................................................................. 4
3.2 BATCH SYSTEM................................................................................................................................. 4
3.3 CONTROL SYSTEM............................................................................................................................ 4
4. ASSUMPTIONS...................................................................................................................................... 4
5. ABBREVIATIONS................................................................................................................................... 5
6. FUNCTIONAL REQUIREMENT................................................................................................................ 6
6.1 EXISTING SYSTEM ARCHITECTURE..................................................................................................... 6
6.2 PROPOSED SYSTEM ARCHITECTURE.................................................................................................. 7
6.3 PROCESS DATA FLOW....................................................................................................................... 8
7 USER REQUIREMENTS........................................................................................................................... 9
8 PLANT OPERATION............................................................................................................................. 10
8.2 PROCESS OVERVIEW....................................................................................................................... 11
8.2.1 SFG PRODUCTION (BLACK BOX)........................................................................................................ 12
8.2.1.1 WEIGH CAPTURE............................................................................................................................. 13
8.2.2 FG PRODUCTION............................................................................................................................... 14
8.2.2.1 RM WEIGHT CAPTURE..................................................................................................................... 16
8.2.2.2 BB WEIGHT CAPTURE....................................................................................................................... 17
8.2.2.3 MIXING........................................................................................................................................... 17
8.2.2.4 PACKING......................................................................................................................................... 18
8.2.3 QC LAB............................................................................................................................................. 19
9 REPORT.................................................................................................................................................... 20
9.1 BATCH REPORT...................................................................................................................................... 20
9.2 PACKING REPORT.................................................................................................................................. 20
9.3 QC REPORT.......................................................................................................................................... 21

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

1. INTRODUCTION
The Pramod paints is located at Piduguralla, Guntur, and Andhra Pradesh. There is only one type of
product is being manufactured and 5 type of packing at plant.

For manufacturing Plant is equipped with Weigh hopper, Blender (mixer), weigh scale, packing
machine etc. On daily basis, operator receives work order on printed paper containing batch
information, control instructions, and quality checks etc. Operator prepare material required for the
batch and uses HMI panels to control the equipment such as mixer, valve etc. Supervisor make
entry in register of batch information which collected during manufacturing process.

SCADA and BMS system to be implemented to automate/digitize manufacturing process and reduce
paper based operations.

Manufacturing order/Batch information will be entered by operator in to BMS system. Batch

information will be displayed in to the SCADA system. Operator can select, and start respective batch
on the equipment. Information related to the phase wise material addition and other control
instruction will be visible while operation/phase is in progress. Control instructions such as mixer
speed in RPM, Mixing time will be passed to the control system (PLC). Inputs from operators will be
collected for physical checks. At the end, Batch report will be facilitated to view batch information
containing all the phases and material addition along with control instructions and data collected
during manufacturing.

This document further describes functional design detail for the SCADA and BMS system to be
designed/implemented for Pramod paints (Asian Paint) plant.

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

2. Purpose
The purpose of the document is to define overall all system components and its functions such
as SCADA system, Batch system and process control system.

3. Scope
The scope of the document is to define functionalities for system component

3.1 SCADA System

The Wonder ware ITME based SCADA system will help operator to visualize Batch information,
Operator can select and start the batch on the equipment. SCADA system will help operator to
prepare and weigh material for the batch. Operator can start phase for adding and mixing
material to the mixer. Operator would be able to visualize status of valve, mixer motor,
parameters such as weight, tolerance (min – max range), blender speed in process quality
checks.Tablet will be utilized to view, interact with SCADA application and perform
manufacturing operations.

3.2 Batch System

Batch system will help to configure equipment, connection, transfers, Recipe, Procedures,
Operations and phases. Recipes will be defined for the each product in the Batch system with
BOM (Bill of Materials). Batch system will be tightly integrated with control system and will run
in synchronization with each other.

3.3 Control System

Control system will have logic to control phase for the recipes. Phase logic will be defined and
owned in PLC. PLC will be interfaced with field equipment such as Blender, weigh scale, valve,
VFD, PLC logic will control the field equipment plus operator has facility to run equipment from
the HMI as well.

4. Assumptions
Following are the assumptions for the project;

• Operation will be kept manual and operator driven, System will provide guidance but
supervisor may decide to run mixer for more time than the prescribed by the recipe and
control parameters.
• All process parameter will be provided to SCADA through PLC
• Required logics and interlock are programmed in PLC.
• There are recipes will be configured in the SCADA or Batch system. Recipes will have fixed
phases however material quantity, and control instruction such as mixing time can be
dynamic. Phases cannot be dynamically added/removed in recipe. If such requirement rarely
exists, then automation, batch system side development will be required.
• All mixer and valve control done through PLC and HMI

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

5. Abbreviations

Abbreviations Description

BOM Bill of Material

RM Raw Materials

RPM Revolution per minute (RPM) is a Unit of Measure

SCADA Supervisory Control and Data Acquisition

HMI Human Machine Interface

XBMS X-force Batch Management System

PLC Programmable logic controller

FG Finish goods

BB BalckBox

WS Weigh scale

RAL Rotary Air lock

Table 1 - Abbreviation

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

6. Functional Requirement

6.1 Existing System Architecture

6 packing
machine
2 table top
weigh scale

Figure 1 - Existing System Architecture

- Plant is equipped with 3 weigh hopper, 3Blender system, 3packing hopper, 6 packing
machine, and control valve.
- All mention field equipment controlled by PLC AB micro 850 system individually
- HMI is used to operate machine via PLC
- Packing system is control and monitored by VT corp controller it works separately from PLC
- Weigh scale used for weighment of RM separately not integrated with any control system.

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

6.2 Proposed system Architecture

Figure 2 - Proposed System Architecture

Above figure shows proposed system architecture in which 3 individual PM system, Weigh scale,
packing machine system integrated with one application.

- To achieve integration with existing HMI and PLC connected to Port switch and port switch
further connected with HUB switch.
- Weigh scale are facilitate with TCPIP and can communicate with PLC through HUB switch
connection
- VT Corp controller has RS485 provision which can converted to ModbusTCP using converter
VT Corp packing system controller communicate with PLC through HUB switch connection.

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

6.3 Process data Flow

Feild equipment PLC Thin client & Mobile client

weigh scale Allen bradly MIcro850 SCADA

weighhopper XBMS
Blendermotor
valve
packing system VT corp

• Allen-Bradley Micro850 series PLC is used to interface with field devices such as mixer,
RAL valve, Weigh scales, and VFDs. Batch management phase’s logic will be
implemented to control recipe phases.
• Thin client & Mobile clients are the device where operator visualize and interface with
SCADA application. Operator can view and enter Batch information, select Batch/recipe
for the equipment, start batch, view material information for weighment, start recipe
phases, supply in process quality parameter, provide phase completion confirmation,
record parameter etc. For Operator, client is the front end to interact with the SCADA
system
• Application Aveva Edge 2020: SCADA client application for operator visualization and
communication with the control system will be developed on this platform.
• Batch Management System: This is a software to meet all batch management
requirements. From configuration of the master data such as units, phases, operations,
recipes, and control parameters etc.

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

SN SFG Source for source for PLC

(Black box preparation) SCADA
       
1 Weight of DOLOMITE (Kg) PLC BB1 WS

2 Weight of Tylose (Kg) PLC BB1 WS

3    Weight of sodium gluconate (Kg) PLC BB1 WS
4 Weight of Vae,DA1100, PLC BB1 WS
ELOTEX(vinapas) (Kg)
5 Mixing time (min) PLC logic in PLC
6 SFG bags weight (kg) PLC BB1 WS

SN FG Source for Source for PLC

SCADA
1 Weight of DOLOMITE (Kg) PLC weigh hopper RM
2 Weight of White cement (Kg) PLC weigh hopper RM
3 Weight of SFG (black box) (Kg) PLC weigh hopper BB
4 RM1 discharge time PLC logic in plc
(weigh hopper to blender) (min)
5   BB discharge time PLC logic in plc
(BB weigh hopper to blender) (min)
6 Mixing time (min) PLC logic in plc
7 FG discharge time PLC logic in plc
(blender to packing hopper) (min)
8 FG bags weight (Kg) PLC or VT corp controller
Direct VT corp controller
9 FG bags count (Nos.) PLC or VT corp controller
Direct VT corp controller
10 QC parameter Entered by operator

7 User Requirements

User requirements for SCADA and Automation systems are as below;

• Batch Management system to control and run recipe through automation system
• Visualization tool for Operator/supervisor interaction with Automation and Batch
Management system
• Record process parameter (Mixing time, material transfer time, Weigh of RM and FG,
counts of FG bags
• Batch report including batch information such as materials, weights, control parameters,
and quality parameters

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

8 Plant operation

8.1 Process Flow legends

The process flow depicts user interaction, process flow, and user actions/activity. To read the
process flow in the respective sections Following legends are used.

Symbol Description

User action in system interface

User action

User physical actions

User physical
action

Process or sub process

Process/
sub
process
Non digital process or paper based operation
Manual
operation

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

8.2 Process overview

 Production involve with multiple process flow like Semi finish goods batching
process,
Finish goods batching process, SFG packing process, FG packing process, QC process,
All this process concluded with overall process flow.
 As per production planning and scheduling No. of batch/ day decided, as per recipe
RM
Are decided for produce finish goods (FG). In process of FG production various
process of weighing, mixing and transfer of material will held.
 To support proper mixing process semi finish good (SFG) batching process is held, as
per
Recipe RM are decided for produce SFG, SFG production contains process of RM
weighing, mixing, and packing. SFG will further involve in FG production.
 On completing production FG packing process starts, FG packing involve with
bag/container Filling, bag/container counting, and weighing process.
 QC lab process support to derive Quality parameters of produced FG, QC sample
Taken while packing in progress, once QC test is passed overall batch is finished.

8.2.1 SFG production (Black box)

Figure 3 – Process overview

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

START

Production
planning
/scheduling

Production Personal:

Create PO Production personal enter PO details as per planning

Production Personal:
Start batch
Select batch and start

Weighment of
RM
Production Personal:

1. Supervisor guide workman to pick RM as defined in Recipe

Record RM 2. Workmen place Raw materials on weigh scale as per
Supervisor guidance
Weight 3. Supervisor gives confirmation on Tab once suitable weight is
displayed

More RM
to weigh?
YES

NO

RM charging
in Blender

Mixing
proces
s Production personal
Fill SFG In bags and put on weigh scale
SFG filling
& weighing

Weight Production personal

capture 1. Supervisor gives confirmation on Tab once suitable
weight is displayed

END
BB PO creation

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

Black Box Select and start Batch

Black Box Weighment of RM

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

Black Box Packing and weighing

8.2.2 FG production

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

START

Production Personal:
Production
Plan work orders on monthly, weekly, daily basis
planning Launch work orders on Daily and Daily+1 basis
/scheduling

Production Personal task in BMS

Create PO
1. Add work order details in BMS
2. Release work order
3. Selects product code, work order and starts the
Batch
Start batch

Production personnel

Weighment of Weighment of 1. Supervisor guide workman to pick RM as

RM defined in Recipe
SFG (black box) 2. Supervisor guide other workman to Pick
specific batch of BB
3. Supervisor enter specific BB batch no. in BMS
4. Workman charge BB in BB weigh hopper
Record RM Record BB 5. Workmen charge RM in Weigh hopper
Weight Weight

Production personnel task in BMS

More RM Ensure correctness of RM & BB weight as

to weigh? per recipe and record the weight in tab

YES Production personnel task in BMS

Add multiple RM as define in recipe

Start RM Start BB
discharge in Discharge in
Blender Blender
NO

Production personnel task with existing HMI

Post RM charging in weigh hopper

Mixing Start discharge hopper in blender

On completing of 50% RM, BB discharge start

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

Production personnel

Transfer FG On completing mixing time blender valve will be

open by supervisor to transfer material from blender
to packing hopper, on completing transfer blender
valve will be closed

Packing

END

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

Create PO

Batch control pahse

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

8.2.2.1 RM Weight capture

RM weight capture is PLC auto process.

Step1: work man charge RM through gyro shaker

Step2: Bucket conveyor conveying RM to weigh hopper
Step3: weight value displayed in BMS through PLC
Step4: supervisor confirms weight value as per recipe and capture in BMS
Step5: while charged RM weigh value reached to target value gyro shaker and bucket
conveyor stop
Step6: For next RM charging production personnel give command from BMS or HMI
Step7: For Multiple RM charge step1 to 6 is repeated

8.2.2.2 BB Weight capture

RM weight capture is PLC auto process.

Step1: work man charge BB in BB weigh hopper

Step2: weight value displayed in BMS through PLC
Step3: supervisor confirms weight value as per recipe and capture in BMS

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

8.2.2.3 Mixing
Mixing is PLC auto process as below

- Post discharging of all RM in blender RM weigh hopper and BB weigh hopper valve
closed.
- After closing of all valve mixing timer start in plc and same value displayed in BMS
- Timer stopped while mixing timer = preset mixing time
- Mixing time capture in to BMS through PLC.

8.2.2.4 Packing

Packing is semi auto process perform by VT corp controller system.

Step1: work man put nonwoven sack to packing outlet
Step2: work man press button to fill bags
Step3: VT corp controller get command to fill bag
Step4: packaged bag weight and no. of bags captured by BMS system through VTcorp
system

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

8.2.3 QC LAB

QC is sample analysing process done by lab personnel

Step 1: QC personnel take sample during packing

Step2: select batch no: in system

Step 3: perform test as required

Step 4: Enter QC parameter Value in system

Step 5: if QC parameter Actual value meets LSL and USL criteria system displayed pass or fail status
in final remarks

Step 6: on completing QC LAB personnel press completed button

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

9 Report
Production personnel will able to generate report and will be in following format

9.1 Batch Report

Batch Report
Batch Mixing Dolomite Black Box Start End Duratio
NO. time Qty. White cement Qty. Qty. time Time n
               
               
               
               

               
               
               
               
               

9.2 Packing Report

Packing Report
PO No. FG Name Total Qty. Packing Qty. Pack Size Pack Duration
           
           
           
           
           
           
           
           
           

PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Version: X-force Recipe and SCADA System for Pramod paint (Asian Paints)

9.3 QC Report

QC Report
Batch Whitenes Pass
Residue on Sieve Chalk Resistance Consistence on Penetrometer Loss on Ignition
Number s fail
             
             
             
             
             
             
             
             
             

PRAMOD PAINTS LLP