PT UNILEVER OLEOCHEMICAL (UNIOLEO)

Sei Mangkei - Indonesia

CONTINUOUS FATTY ACIDS / NEUTRAL OILS SAPONIFICATION

AND
DRYING PLANT
SCTU+C 15000 KG/H
PNEUMATIC TRANSPORT PLANT
TPCP 15000 KG/H

INTERLOCKS AND SEQUENCES LIST

0 18-01-2022 1st issue M.G.Bressan

Rev. Issued on Description Name Signat. Name Signat.
Issued By Checked By
We reserve the ownership under the law of this document with prohibition of even partial reproduction and to make it
known to third persons without written authorization

1
SUMMARY

SUMMARY ......................................................................................................................................... 2
1 CONTROL LOOPS OF PROCESS VARIABLES ................................................................. 4
2 FEED FORWARD CONTROLS............................................................................................. 7
3 MONITORING OF PROCESS VARIABLES ........................................................................ 8
4 OTHER SIGNALS ................................................................................................................ 10
4.1 Motors ................................................................................................................................ 14
5 INTERLOCKS ....................................................................................................................... 16
6 SEQUENCES......................................................................................................................... 32
6.1 Pump P-104.01 start-up...................................................................................................... 32
6.2 Pump P-104.01 shut-down ................................................................................................. 32
6.3 EDTA automatic valves ..................................................................................................... 32
6.4 Glycerine automatic valves ................................................................................................ 33
6.5 Pump P-117.08 start-up...................................................................................................... 33
6.6 Pump P-117.08 shut-down ................................................................................................. 34
6.7 EHDP automatic valves ..................................................................................................... 34
6.8 Pump P-126.02 start-up...................................................................................................... 34
6.9 Pump P-126.02 shut-down ................................................................................................. 35
6.10 Pump P-126.04 start-up...................................................................................................... 35
6.11 Pump P-126.04 shut-down ................................................................................................. 35
6.12 Pump P-126.20 start-up...................................................................................................... 35
6.13 Pump P-126.20 shut-down ................................................................................................. 36
6.14 Turbomixer R-201.01 start-up ........................................................................................... 36
6.15 Turbomixer R-201.01 shut-down ....................................................................................... 36
6.16 Dryer automatic valves ...................................................................................................... 36
6.17 Water dosing to kettles PS-124.03A/B .............................................................................. 37
6.18 Idle for reactor .................................................................................................................... 40
6.19 Saponification stand-by...................................................................................................... 42
6.20 Reactor feeding .................................................................................................................. 47
6.21 Vacuum chamber feeding .................................................................................................. 49
6.22 Additives feeding ............................................................................................................... 51
6.23 Soap pipes cleaning ............................................................................................................ 53
6.24 Pneumatic transport............................................................................................................ 54
6.25 Silo bottom fluidization ..................................................................................................... 68

2
7 APPENDIX ............................................................................................................................ 73

3
 1 CONTROL LOOPS OF PROCESS VARIABLES

All the PID (Proportional–Integral–Derivative) control loops will have the possibility to set an alarm
for
 very high alarm (HH) (without an intervention timer for delay),
 high alarm (H) (with an intervention timer for delay),
 low alarm (L) (with an intervention timer for delay),
 very low alarm (LL) (without an intervention timer for delay).
This feature will be completed with an adjustable intervention timer (only for H and L).
Exception is made for mass flow controls which will be developed as relative deviations (alarms (%)
– see note 28 for details).
The alarms for each loop can be enabled / disabled with a button (ON / OFF).
Every control loop will foresee:
 N.1 AI (Analog Input) or N.1 DI (Digital Input) from process transmitter,
 N.1 AO (Analog Output) for process controlling actuator (inverter or control valve or other
device).
Every control loop can be managed in automatic or in manual1:
 automatic – set point can be modified by operator and automatic control (SP vs PV) is
activated,
 manual – valve stroke (%) or motor speed (%) can be modified by operator and automatic
control (SP vs PV) is disabled.

Set point
Tag Number Description Loop input Output to Functions
input from
EDTA to reactor
Recipe or Deviation alarms (%)
FICQ-104.1 R-126.02 FE/FIT-104.1 FZ-104.101
keyboard Totalizer
mass flow control
Glycerine to dryer Recipe or Deviation alarms (%)
FICQ-117.6 FE/FIT-117.6 FZ-117.106
mass flow control keyboard Totalizer
EHDP to reactor
Recipe or Deviation alarms (%)
FICQ-117.8 R-126.02 FE/FIT-117.8 FZ-117.108
keyboard Totalizer
mass flow control
Soap to reactor FZ-124.103A Deviation alarms (%)
FICQ-124.3 FE/FIT-124.3 Keyboard2
R-126.02 and Totalizer

4
 Set point
Tag Number Description Loop input Output to Functions
input from
mass flow control FZ-124.103B
F.A. / N.O. blend to
Recipe or Deviation alarms (%)
FICQ-126.1A reactor R-126.02 FE/FIT-126.1A FV-126.1A
keyboard Totalizer
mass flow control
Caustic soda
solution to reactor Recipe or Deviation alarms (%)
FICQ-126.2 FE/FIT -126.23 FV-126.2
R-126.02 keyboard Totalizer
mass flow control
Process water to
Recipe or Deviation alarms (%)
FICQ-126.3 reactor R-126.02 FE/FIT -126.3 FV-126.3
keyboard Totalizer
mass flow control
Brine to reactor
Recipe or Deviation alarms (%)
FICQ-126.4 R-126.02 FE/FIT-126.44 FV-126.4
keyboard Totalizer
mass flow control
Caustic soda
solution tank
LIC-126.2 LIT-126.2 Keyboard LV-126.22 Alarms
D-126.02
level control
Process water tank
LIC-126.3 D-126.03 LIT-126.3 Keyboard LV-126.23 Alarms
level control
PIT-206.1A and
Semi-barometric PIT- 206.1B via
LIC-206.1 C-206.03 water software Keyboard LV-206.1 Alarms
level control calculation (∆P
 XT-206.1)
Reactor R-126.02
PIC-126.10 PIT-126.10 Keyboard PV-126.10 Alarms5
pressure control
Soap to atomizer
PIC-204.10 SD-204.01 pressure PIT-204.10 Keyboard PV-204.10 Alarms
control
PIC-206.11 Atomizer PIT-206.11 Keyboard PV-206.11 Alarms

5
 Set point
Tag Number Description Loop input Output to Functions
input from
SD-204.01 residual
pressure control
Glycerine tank
TIC-117.6 D-117.06 TE/TT-117.6 Keyboard TV-117.6 Alarms
temperature control
Kettle PS-124.03A
TIC-124.3A TE/TT-124.3A Keyboard TV-124.3A Alarms
temperature control
Kettle PS-124.03B
TIC-124.3B TE/TT-124.3B Keyboard TV-124.3B Alarms
temperature control
HE E-126.01
TIC-126.5 TE/TT-126.5 Keyboard TV-126.5 Alarms
temperature control
HE E-126.02
TIC-126.6 TE/TT-126.6 Keyboard TV-126.6 Alarms
temperature control
Reactor R-126.02
TIC-126.9 TE/TT-126.9 Keyboard TV-126.9 Alarms6
temperature control

6
2 FEED FORWARD CONTROLS

Every feed forward control manages one AO (Analog Output) for process actuator.

Tag Number Description Input from Output to Functions

Recipe or
EDTA pump P-104.01 motor
HIC-104.101 keyboard or FZ-104.101 Speed variation
speed adjustment
local
Recipe or
Glycerine pump P-117.06
HIC-117.106 keyboard or FZ-117.106 Speed variation
motor speed adjustment
local
Recipe or
EHDP pump P-117.08 motor
HIC-117.108 keyboard or FZ-117.108 Speed variation
speed adjustment
local
Slop soap pump P-124.03A Keyboard or
HIC-124.103A FZ-124.103A Speed variation
motor speed adjustment local
Slop soap pump P-124.03B Keyboard or
HIC-124.103B FZ-124.103B Speed variation
motor speed adjustment local
Slop kettle PS-124.03A motor Keyboard or
HIC-124.104A FZ-124.104A Speed variation
speed adjustment local
Slop kettle PS-124.03B motor Keyboard or
HIC-124.104B FZ-124.104B Speed variation
speed adjustment local
Plodder PL-204.01 preliminary Keyboard or
HIC-204.134 FZ-204.134 Speed variation
motor speed adjustment local
Plodder PL-204.01 final motor Keyboard or
HIC-204.135 FZ-204.135 Speed variation
speed adjustment local
Blower B-250.01 speed Keyboard or
HIC-250.101 FZ-250.101 Speed variation
adjustment local

7
3 MONITORING OF PROCESS VARIABLES

Every process variable transmitter manages one AI (Analog Input) from process transmitter.
All transmitter values can be seen on PC screen.
Transmitters have the following functions:
 indication (I),
 very high alarm (HH) (without any intervention timer for delay),
 high alarm (H) (with an intervention timer for delay),
 low alarm (L) (with an intervention timer for delay),
 very low alarm (LL) (without any intervention timer for delay).
This feature will be completed with an adjustable intervention timer (only for H and L).

Tag number Description Input from

Process water to kettles PS-124.03A/B
FIQ-126.3B FE/FIT-126.3B
flow and totalizer
JI-124.104A Soap kettle PS-124.03A stirrer torque Inverter of PS-124.03A
JI-124.104A Soap kettle PS-124.03B stirrer torque Inverter of PS-124.03B
TI-126.23 Caustic soda solution to reactor R-126.02 temperature TIT-126.2
DI-126.23 Caustic soda solution to reactor R-126.02 density DIT-126.2
TI-126.44 Brine to reactor R-126.02 temperature TIT-126.4
DI-126.44 Brine to reactor R-126.02 density DIT-126.4
SI-126.120 Soap recycle pump P-126.20 speed (RPM) Inverter of P-126.20
II-126.120 Soap recycle pump P-126.20 absorbed current (Ampere) Inverter of P-126.20
TI-126.7 Soap recycle pump P-126.20 outlet temperature TE/TT-126.7
FIQ-120.3A Instrument air flow and totalizer FE/FIT-120.3A
PI-120.3A Instrument air pressure PIT-120.3A
FIQ-120.3B Compressed air flow and totalizer FE/FIT-120.3A
PI-120.3B Compressed air pressure PIT-120.3A
FIQ-120.7 Softened water flow and totalizer FE/FIT-120.7
PI-120.8 Softened water for mechanical seals pressure PIT-120.8
FIQ-249.1 Chilled water flow and totalizer FE/FIT-249.1
TI-249.1 Chilled water temperature TE/TT-249.1
PI-249.1 Chilled water pressure PIT-249.1
PI-120.1 Steam at 15 ÷ 16 barg pressure PIT-120.1

8
Tag number Description Input from
PI-120.2 Steam at 2 barg pressure PIT-120.2
PI-120.4 Steam at 4 barg pressure PIT-120.4
FIQ-120.4 Steam at 4 barg flow and totalizer FE/FIT-120.4
JI-204.101 Vacuum chamber SD-204.01 stirrer torque Inverter of SD-204.01
PI-204.52 Preliminary plodder PL-204.01 pressure PT-204.52
Inverter of PL-204.01
SI-204.134 Preliminary plodder PL-204.01 screws speed (RPM)
(preliminary)
Preliminary plodder PL-204.01 absorbed current Inverter of PL-204.01
II-204.134
(Ampere) (preliminary)
PI-204.51 Final plodder PL-204.01 pressure PT-204.50
Inverter of PL-204.01
SI-204.135 Final plodder PL-204.01 screws speed (RPM)
(final)
Inverter of PL-204.01
II-204.135 Final plodder PL-204.01 absorbed current (Ampere)
(final)
Cooling water from semi-barometric condenser
TI-206.1 TE/TT-206.1
C-206.03 temperature
Cooling water to semi-barometric condenser C-206.03
TI-206.2 TE/TT-206.2
temperature
TI-206.3 Chilled water from vacuum pump P-206.01 temperature TE/TT-206.3
TI-250.1 Conveying air refrigerator E-250.01 outlet air temperature TE/TT-250.1
TI-250.1A Soap noodles silo D-250.01A temperature TE/TT-250.1A
LI-250.1A Soap noodles silo D-250.01A level LIT-250.1A
TI-250.1B Soap noodles silo D-250.01B temperature TE/TT-250.1B
LI-250.1B Soap noodles silo D-250.01B level LIT-250.1B
TI-250.1C Soap noodles silo D-250.01C temperature TE/TT-250.1C
LI-250.1C Soap noodles silo D-250.01C level LIT-250.1C
PDI-250.9A Exhaust air filter F-250.05 differential pressure PDIT-250.9A
PDI-250.9B Exhaust air filter F-250.06 differential pressure PDIT-250.9B

9
4 OTHER SIGNALS

Every process variable manages one / two DI (Digital Inputs) from field device.
Note: Delay “time”, the alarm will appear only when a predetermined delay time expires (delay can
be modified in dedicated video page).

Tag Description
XA-126.200 Plant emergency stop
XA-126.201 Plant emergency stop
ZSL-104.4 EDTA solution to feed tank D-104.01 automatic valve AV-104.4 closed
ZSH-104.4 EDTA solution to feed tank D-104.01 automatic valve AV-104.4 open
LAL-104.1 EDTA solution feed tank D-104.01 low level alarm
LAH-104.1 EDTA solution feed tank D-104.01 high level alarm
ZSL-104.3 EDTA solution feed tank D-104.01 discharge automatic valve AV-104.3 closed
ZSH-104.3 EDTA solution feed tank D-104.01 discharge automatic valve AV-104.3 open
PDAH-104.1 EDTA solution filters F-104.01A/B high differential pressure alarm
FAL-104.11 EDTA solution to feed pump P-104.01 low flow alarm
FAL-104.101 Seal water to EDTA solution feed pump P-104.01 low flow alarm
ZSL-104.5 EDTA solution delivery automatic valve AV-104.5 closed
ZSH-104.5 EDTA solution delivery automatic valve AV-104.5 open
ZSL-104.6 EDTA solution recycle automatic valve AV-104.6 closed
ZSH-104.6 EDTA solution recycle automatic valve AV-104.6 open
ZSL-117.4A Glycerine to feed tank D-117.06 automatic valve AV-117.4A closed
ZSH-117.4A Glycerine to feed tank D-117.06 automatic valve AV-117.4A open
LAL-117.6 Glycerine feed tank D-117.06 low level alarm
LAH-117.6 Glycerine feed tank D-117.06 high level alarm
ZSL-117.3A Glycerine feed tank D-117.06 discharge automatic valve AV-117.3A closed
ZSH-117.3A Glycerine feed tank D-117.06 discharge automatic valve AV-117.3A open
PDAH-117.6 Glycerine filters F-117.06A/B high differential pressure alarm
FAL-117.16 Glycerine to feed pump P-117.06 low flow alarm
ZSL-117.5A Glycerine delivery automatic valve AV-117.5A closed
ZSH-117.5A Glycerine delivery automatic valve AV-117.5A open
ZSL-117.6A Glycerine recycle automatic valve AV-117.6A closed

10
 Tag Description
ZSH-117.6A Glycerine recycle automatic valve AV-117.6A open
ZSL-117.4B EHDP solution to feed tank D-117.08 automatic valve AV-117.4B closed
ZSH-117.4B EHDP solution to feed tank D-117.08 automatic valve AV-117.4B open
LAL-117.8 EHDP solution feed tank D-117.08 low level alarm
LAH-117.8 EHDP solution feed tank D-117.08 high level alarm
ZSL-117.3B EHDP solution feed tank D-117.08 discharge automatic valve AV-117.3B closed
ZSH-117.3B EHDP solution feed tank D-117.08 discharge automatic valve AV-117.3B open
PDAH-117.8 EHDP solution filters F-117.08A/B high differential pressure alarm
FAL-117.18 EHDP solution to feed pump P-117.08 low flow alarm
FAL-117.108 Seal water to EHDP solution feed pump P-117.08 low flow alarm
ZSL-117.5B EHDP solution delivery automatic valve AV-117.5B closed
ZSH-117.5B EDTA solution delivery automatic valve AV-117.5B open
ZSL-117.6B EDTA solution recycle automatic valve AV-117.6B closed
ZSH-117.6B EDTA solution recycle automatic valve AV-117.6B open
ZSL-126.3B Process water to kettles PS-124.03A/B automatic valve AV-126.3B closed
ZSH-126.3B Process water to kettles PS-124.03A/B automatic valve AV-126.3B open
ZSL-124.2A Soap from kettle PS-124.03A automatic valve AV-124.2A closed
ZSH-124.2A Soap from kettle PS-124.03A automatic valve AV-124.2A open
ZSL-124.2B Soap from kettle PS-124.03B automatic valve AV-124.2B closed
ZSH-124.2B Soap from kettle PS-124.03B automatic valve AV-124.2B open
PAH-124.3A Soap from kettles PS-124.03A/B transfer pump P-124.03A high pressure alarm
PAH-124.3B Soap from kettles PS-124.03A/B transfer pump P-124.03B high pressure alarm
ZSL-126.11A F.A. / N.O. blend storage tank T-15A outlet automatic valve AV-126.11A closed
ZSH-126.11A F.A. / N.O. blend storage tank T-15A outlet automatic valve AV-126.11A open
PDAH-126.1A F.A. / N.O. blend filters F-126.01A/B high differential pressure alarm
LAH-126.2 Caustic soda feed tank D-126.02 high level alarm
ZSL-126.12 Caustic soda feed tank D-126.02 discharge automatic valve AV-126.12 closed
ZSH-126.12 Caustic soda feed tank D-126.02 discharge automatic valve AV-126.12 open
PDAH-126.2 Caustic soda filters F-126.02A/B high differential pressure alarm
FAL-126.102A Seal water to caustic soda solution feed pump P-126.02 low flow alarm
FAL-126.102B Seal water to caustic soda solution feed pump P-126.02 low flow alarm
LAH-126.3 Process water feed tank D-126.03 high level alarm

11
 Tag Description
ZSL-126.13 Process water feed tank D-126.03 discharge automatic valve AV-126.13 closed
ZSH-126.13 Process water feed tank D-126.03 discharge automatic valve AV-126.13 open
PDAH-126.3 Process water filters F-126.03A/B high differential pressure alarm
ZSL-126.24 Brine to feed tank D-126.04 automatic valve AV-126.24 closed
ZSH-126.24 Brine to feed tank D-126.04 automatic valve AV-126.24 open
LAL-126.4 Brine feed tank D-126.04 low level alarm
LAH-126.4 Brine feed tank D-126.04 high level alarm
ZSL-126.14 Brine feed tank D-126.04 discharge automatic valve AV-126.14 closed
ZSH-126.14 Brine feed tank D-126.04 discharge automatic valve AV-126.14 open
PDAH-126.4 Brine filters F-126.04A/B high differential pressure alarm
FAL-126.104A Seal water to brine feed pump P-126.04 low flow alarm
FAL-126.104B Seal water to brine feed pump P-126.04 low flow alarm
PAH-126.6 F.A. / N.O. blend to reactor R-126.02 high pressure alarm
PAH-126.7 Lye to reactor R-126.02 high pressure alarm
ZSL-126.31 Lye to reactor R-126.02 automatic valve AV-126.31 closed
ZSH-126.31 Lye to reactor R-126.02 automatic valve AV-126.31 open
Soap from pumps P-124.03A/B to reactor R-126.02 automatic valve AV-126.32
ZSL-126.32
closed
Soap from pumps P-124.03A/B to reactor R-126.02 automatic valve AV-126.32
ZSH-126.32
open
ZSL-126.33 F.A. / N.O. blend to reactor R-126.02 automatic valve AV-126.33 closed
ZSH-126.33 F.A. / N.O. blend to reactor R-126.02 automatic valve AV-126.33 open
FAL-126.120 Seal water to soap recycle pump P-126.20 low flow alarm
ZSL-126.7 Reactor R-126.02 recycle inlet automatic valve AV-126.7 closed
ZSH-126.7 Reactor R-126.02 recycle inlet automatic valve AV-126.7 open
ZSL-126.8 Reactor R-126.02 recycle outlet automatic valve AV-126.8 closed
ZSH-126.8 Reactor R-126.02 recycle outlet automatic valve AV-126.8 open
PAH-126.12 Reactor R-126.02 high pressure alarm
ZSL-126.11 Reactor R-126.02 outlet automatic valve AV-126.11 closed
ZSH-126.11 Reactor R-126.02 outlet automatic valve AV-126.11 open
ZSL-126.90 Steam to reactor R-126.02 outlet automatic valve AV-126.90 closed
ZSH-126.90 Steam to reactor R-126.02 outlet automatic valve AV-126.90 open

12
 Tag Description
ZSL-201.1 Soap to turbomixer R-201.01 hand valve HV-201.1 closed
ZSH-201.1 Soap to turbomixer R-201.01 hand valve HV-201.1 open
ZSL-201.2 Soap from turbomixer R-201.01 hand valve HV-201.2 closed
ZSH-201.2 Soap from turbomixer R-201.01 hand valve HV-201.2 open
ZSL-201.3 Turbomixer R-201.01 by-pass hand valve HV-201.3 closed
ZSH-201.3 Turbomixer R-201.01 by-pass hand valve HV-201.3 open
FAL-201.101 Seal water to turbomixer R-201.01 low flow alarm
ZSL-204.1 Soap to vacuum chamber SD-204.01 automatic valve AV-204.1 closed
ZSH-204.1 Soap to vacuum chamber SD-204.01 automatic valve AV-204.1 open
ZSL-204.2 Soap recycle to kettles PS-124.03A/B automatic valve AV-204.2 closed
ZSH-204.2 Soap recycle to kettles PS-124.03A/B automatic valve AV-204.2 open
ZSL-204.3 Steam to vacuum chamber SD-204.01 automatic valve AV-204.3 closed
ZSH-204.3 Steam to vacuum chamber SD-204.01 automatic valve AV-204.3 open
ZSL-204.4 Steam to soap recycle line automatic valve AV-204.4 closed
ZSH-204.4 Steam to soap recycle line automatic valve AV-204.4 open
LAH-204.137 Vacuum chamber SD-204.01 high level alarm
ZI-204.14 Vacuum chamber SD-204.01 manhole open
ZI-205.1 First fines separator DC-205.01 manhole open
LAH-205.1 First fines separator DC-205.01 high level alarm
ZI-205.2 Second fines separator DC-205.02 manhole open
LAH-205.2 Second fines separator DC-205.01 high level alarm
LALL-206.3 Semi-barometric condenser C-206.03 very low level alarm
LAHH-206.38 Semi-barometric condenser C-206.03 very high level alarm
FAL-206.2 Water from semi-barometric condenser C-206.03 low flow alarm
ZI-204.29 /
Preliminary plodder PL-204.01 chamber OR final plodder PL-204.01 head open
ZI-204.30
LAH-204.29 Preliminary plodder PL-204.01 chamber high level alarm
PAH-250.1 Blower B-250.01 high pressure alarm
LAH-250.1 Mixing chamber CM-250.01 high level alarm
ZLL-250.11 Diverting valve DV-250.0A to soap noodles storage silo D-250.01A
ZLH-250.11 Diverting valve DV-250.01A to soap noodles storage silos D-250.01B/C
ZLL-250.12 Diverting valve DV-250.0B to soap noodles storage silo D-250.01B

13
 Tag Description
ZLH-250.12 Diverting valve DV-250.01B to soap noodles storage silo D-250.01C
LAL-250.1A Soap noodles storage silo D-250.01A low level alarm
LAH-250.1A Soap noodles storage silo D-250.01A high level alarm
ZLL-250.15 Exhaust air throttle automatic valve VF-250.01A closed
ZLH-250.15 Exhaust air throttle automatic valve VF-250.01A open
LAL-250.1B Soap noodles storage silo D-250.01B low level alarm
LAH-250.1B Soap noodles storage silo D-250.01B high level alarm
ZLL-250.16 Exhaust air throttle automatic valve VF-250.01B closed
ZLH-250.16 Exhaust air throttle automatic valve VF-250.01B open
LAL-250.1C Soap noodles storage silo D-250.01C low level alarm
LAH-250.1C Soap noodles storage silo D-250.01C high level alarm
ZLL-250.17 Exhaust air throttle automatic valve VF-250.01C closed
ZLH-250.17 Exhaust air throttle automatic valve VF-250.01C open
LAH-250.10A Soap fines collecting bin of exhaust air filter F-250.05 high level alarm
LAH-250.10B Soap fines collecting bin of exhaust air filter F-250.06 high level alarm

4.1 Motors

Tag Description
ZI-104.101/201/301 EDTA solution feed pump P-104.01 motor status
ZI-117.106/206/306 Glycerine feed pump P-117.06 motor status
ZI-117.108/208/308 EHDP solution feed pump P-117.08 motor status
ZI-124.104A/204A/304A Kettle PS-124.03A stirrer AG-124.03A motor status
ZI-124.104B/204B/304B Kettle PS-124.03B stirrer AG-124.03B motor status
Soap from kettle PS-124.03A transfer pump P-124.03A motor
ZI-124.103A/203A/303A
status
ZI-124.103B/203B/303B Soap from kettle PS-124.03B transfer pump P-124.03B motor status
ZI-126.101A/201A/301A F.A. / N.O. blend feed pump P-126.01A motor status
ZI-126.101B/201B/301B F.A. / N.O. blend feed pump P-126.01B motor status
ZI-126.102/202/302 Caustic soda feed pump P-126.02 motor status
ZI-126.103/203/303 Process water feed pump P-126.03 motor status
ZI-126.104/204/304 Brine feed pump P-126.04 motor status
ZI-126.120/220/320 Soap recycle pump P-126.20 motor status

14
 Tag Description
ZI-201.101/201/301 Turbomixer R-201.01 motor status
ZI-204.101/201/301 Vacuum chamber SD-204.01 stirrer motor status
ZI-205.101/201/301 Soap fines reversible extruder / conveyor PL-205.03 motor status
Bridge breaker of soap fines reversible extruder / conveyor PL-
ZI-205.101A/301A
205.03 motor status
ZI-205.102/202/302 Soap fines worm conveyor T-205.02 motor status
ZI-205.102A/302A Bridge breaker of soap fines worm conveyor T-205.02 motor status
ZI-206.101/201/301 Vacuum pump P-206.01 motor status
ZI-206.102/202/302 Semi-barometric ICS water recycle pump P-206.02 motor status
ZI-204.134/234/334 Preliminary plodder PL-204.01 motor status
ZI-204.135/235/335 Final plodder PL-204.01 motor status
ZI-204.136/236/336 Plodder PL-204.01 vacuum pump motor status
ZI-250.101/201/301 Blower B-250.01 motor status
ZI-250.101A/301A Soundproof cabin PX-250.01 of blower B-250.01 fan motor status
ZI-250.115A/215A/315A Exhaust air filter F-250.05 fan motor status
ZI-250.115B/215B/315B Exhaust air filter F-250.06 fan motor status

15
 5 INTERLOCKS

Interlocks can be enabled or disabled by means of a software button: this operation is allowed only
under password.
When an interlock is active, a padlock has to be shown on the video page next to the interlocked
item: by clicking on the padlock icon a pop-up will show all the causes which have activated the
relevant interlock (HELP PAGE).
The interlocks managed by the PLC of the saponification are the following:

N. CONDITION (IF) ACTIONS (THEN)

Stopped if running (one-shot
1. LSH-104.1 On9 EDTA transfer pump10
command)
Locked to close OR closed if
2. LSH-104.1 On9 Valve AV-104.410
open
3. LSL-104.1 On9 EDTA transfer pump10 Started (one-shot command)
4. LSL-104.1 On9 Valve AV-104.410 Set to open (one-shot command)
LAL-104.1 AND On, at the Locked on stop OR stopped if
5. EDTA transfer pump10
LAH-104.1 same time running
LAL-104.1 AND On, at the Locked to close OR closed if
6. Valve AV-104.410
LAH-104.1 same time open
On for more
Locked on stop OR stopped if
7. LAL-104.1 than a pre- Pump P-104.01
running
set time11
Locked on stop OR stopped if
8. Valve AV-104.3 Not open Pump P-104.01
running
Locked on stop OR stopped if
9. FAL-104.11 On Pump P-104.01
running
On for more
Locked on stop OR stopped if
10. FAL-104.101 than a pre- Pump P-104.01
running
set time11
Solenoid valve
11. Pump P-104.01 Running Cannot be closed (locked)
XY-104.101
Valves AV-104.5 AND Locked on stop OR stopped if
12. Not open12 Pump P-104.01
AV-104.6 running

16
N. CONDITION (IF) ACTIONS (THEN)
Glycerine transfer Stopped if running (one-shot
13. LSH-117.6 On9
pump13 command)
Locked to close OR closed if
14. LSH-117.6 On9 Valve AV-117.4A13
open
Glycerine transfer
15. LSL-117.6 On9 Started (one-shot command)
pump13
16. LSL-117.6 On9 Valve AV-117.4A13 Set to open (one-shot command)
LAL-117.6 AND On, at the Glycerine transfer Locked on stop OR stopped if
17.
LAH-117.6 same time pump13 running
LAL-117.6 AND On, at the Locked to close OR closed if
18. Valve AV-117.4A13
LAH-117.6 same time open
On for more
Locked on stop OR stopped if
19. LAL-117.6 than a pre- Pump P-117.06
running
set time11
Locked on stop OR stopped if
20. Valve AV-117.3A Not open Pump P-117.06
running
Locked on stop OR stopped if
21. FAL-117.16 On Pump P-117.06
running
Valves AV-117.5A AND Locked on stop OR stopped if
22. Not open12 Pump P-117.06
AV-117.6A running
Stopped if running (one-shot
23. LSH-117.8 On9 EHDP transfer pump14
command)
Locked to close OR closed if
24. LSH-117.8 On9 Valve AV-117.4B14
open
25. LSL-117.8 On9 EHDP transfer pump14 Started (one-shot command)
26. LSL-117.8 On9 Valve AV-117.4B14 Set to open (one-shot command)
LAL-117.8 AND On, at the Locked on stop OR stopped if
27. EHDP transfer pump14
LAH-117.8 same time running
LAL-117.8 AND On, at the Locked to close OR closed if
28. Valve AV-117.4B14
LAH-117.8 same time open
On for more
Locked on stop OR stopped if
29. LAL-117.8 than a pre- Pump P-117.08
running
set time11

17
N. CONDITION (IF) ACTIONS (THEN)
Locked on stop OR stopped if
30. Valve AV-117.3B Not open Pump P-117.08
running
Locked on stop OR stopped if
31. FAL-117.18 On Pump P-117.08
running
On for more
Locked on stop OR stopped if
32. FAL-117.108 than a pre- Pump P-117.08
running
set time11
Solenoid valve
33. Pump P-117.08 Running Cannot be closed (locked)
XY-117.108
Valves AV-117.5B AND Locked on stop OR stopped if
34. Not open12 Pump P-117.08
AV-117.6B running
Kettle PS-124.03A Locked on stop OR stopped if
35. JAHH-124.104A15 On
motor running
Kettle PS-124.03B Locked on stop OR stopped if
36. JAHH-124.104B16 On
motor running
Valves AV-124.2A AND Locked on stop OR stopped if
37. Not open Pump P-124.03A
AV-124.2B running
Valves AV-124.2A AND Locked on stop OR stopped if
38. Not open Pump P-124.03B
AV-124.2B running
39. Pump P-124.03A Running Pump P-124.03B Locked on stop
40. Pump P-124.03A Running Pump P-124.03B Cannot be started (locked)
41. Pump P-124.03B Running Pump P-124.03A Locked on stop
42. Pump P-124.03B Running Pump P-124.03A Cannot be started (locked)
Locked on stop OR stopped if
43. PAH-124.3A On Pump P-124.03A
running
Locked on stop OR stopped if
44. PAH-124.3B On Pump P-124.03B
running
Locked on stop OR stopped if
45. Valve AV-126.11A Not open Pump P-126.01A
running
Locked on stop OR stopped if
46. Valve AV-126.11A Not open Pump P-126.01B
running
47. Pump P-126.01A Running Pump P-126.01B Locked on stop
48. Pump P-126.01A Running Pump P-126.01B Cannot be started (locked)

18
N. CONDITION (IF) ACTIONS (THEN)
49. Pump P-126.01B Running Pump P-126.01A Locked on stop
50. Pump P-126.01B Running Pump P-126.01A Cannot be started (locked)
Caustic soda transfer Locked on stop OR stopped if
51. LAH-126.2 (DI) On
pump running
Locked to close OR closed if
Control valve open (LIC-126.2 on manual,
52. LAH-126.2 (DI) On
LV-126.22 opening 0% and relevant XY
solenoid valve locked to close)
Caustic soda transfer Locked on stop OR stopped if
53. LAHH-126.2 (AI) On
pump running
Locked to close OR closed if
Control valve open (LIC-126.2 on manual,
54. LAHH-126.2 (AI) On
LV-126.22 opening 0% and relevant XY
solenoid valve locked to close)
On for more
Locked on stop OR stopped if
55. LALL-126.2 (AI) than a pre- Pump P-126.02
running
set time11
Locked on stop OR stopped if
56. Valve AV-126.12 Not open Pump P-126.02
running
On for more Locked on stop OR stopped if
57. FAL-126.102A Pump P-126.02
than 5”11 running
On for more Locked on stop OR stopped if
58. FAL-126.102B Pump P-126.02
than 5”11 running
Solenoid valve
59. Pump P-126.02 Running Cannot be closed (locked)
XY-126.102
Process water transfer Locked on stop OR stopped if
60. LAH-126.3 (DI) On
pump running
Locked to close OR closed if
Control valve open (LIC-126.3 on manual,
61. LAH-126.3 (DI) On
LV-126.23 opening 0% and relevant XY
solenoid valve locked to close)
Process water transfer Locked on stop OR stopped if
62. LAHH-126.3 (AI) On
pump running

19
N. CONDITION (IF) ACTIONS (THEN)
Locked to close OR closed if
Control valve open (LIC-126.3 on manual,
63. LAHH-126.3 (AI) On
LV-126.23 opening 0% and relevant XY
solenoid valve locked to close)
On for more
Locked on stop OR stopped if
64. LALL-126.3 (AI) than a pre- Pump P-126.03
running
set time11
Locked on stop OR stopped if
65. Valve AV-126.13 Not open Pump P-126.03
running
Stopped if running (one-shot
66. LSH-126.4 On9 Brine transfer pump17
command)
Locked to close OR closed if
67. LSH-126.4 On9 Valve AV-126.2417
open
68. LSL-126.4 On9 Brine transfer pump17 Started (one-shot command)
69. LSL-126.4 On9 Valve AV-126.2417 Set to open (one-shot command)
LAL-126.4 AND On, at the Locked on stop OR stopped if
70. Brine transfer pump17
LAH-126.4 same time running
LAL-126.4 AND On, at the Locked to close OR closed if
71. Valve AV-126.2417
LAH-126.4 same time open
On for more
Locked on stop OR stopped if
72. LAL-126.4 than a pre- Pump P-126.04
running
set time11
Locked on stop OR stopped if
73. Valve AV-126.14 Not open Pump P-126.04
running
On for more
Locked on stop OR stopped if
74. FAL-126.104A than a pre- Pump P-126.04
running
set time11
On for more
Locked on stop OR stopped if
75. FAL-126.104B than a pre- Pump P-126.04
running
set time11
Solenoid valve
76. Pump P-126.04 Running Cannot be closed (locked)
XY-126.104

20
N. CONDITION (IF) ACTIONS (THEN)
From open
77. Valve AV-126.32 Pump P-124.03A Stopped (one-shot command)
to closed
From open
78. Valve AV-126.32 Pump P-124.03B Stopped (one-shot command)
to closed
If valve AV-126.32 is closed and operator attempt to start pump P-124.03A (or pump P-124.03B), a
pop-up with written “Valve AV-126.32 is closed, confirm the start command of P-124.03A/B (check
79. that manual recycle valves to PS-124.03A or PS-124.03B are open)” is shown.
If operator selects “Yes”, the pump P-124.03A (or P-124.03B) is started and pop-up is closed.
If operator selects “No”, the pop-up is closed without starting pumps P-124.03A/B.
On for more
Locked on stop OR stopped if
80. FAL-126.120 than a pre- Pump P-126.20
running
set time11
Solenoid valve
81. Pump P-126.20 Running Cannot be closed (locked)
XY-126.120
Locked on stop OR stopped if
82. Valve AV-126.7 Not open Pump P-126.20
running
Locked on stop OR stopped if
83. Valve AV-126.8 Not open Pump P-126.20
running
84. Pump P-126.20 Running Valve AV-126.7 Cannot be closed (locked)
85. Pump P-126.20 Running Valve AV-126.8 Cannot be closed (locked)
Valves Locked to close OR closed if
86. PAHH-126.10 On
AV-126.31/32/33 open
Locked to close OR closed if
Control valve open (TIC-126.9 on manual,
87. PAHH-126.10 On
TV-126.9 opening 0% and relevant XY
solenoid valve locked to close)
Locked on stop OR stopped if
88. PAHH-126.10 On Pump P-126.20
running
Valves Locked to close OR closed if
89. PAH-126.12 On
AV-126.31/32/33 open
Control valve Locked to close OR closed if
90. PAH-126.12 On
TV-126.9 open (TIC-126.9 on manual,

21
N. CONDITION (IF) ACTIONS (THEN)
opening 0% and relevant XY
solenoid valve locked to close)
Locked on stop OR stopped if
91. PAH-126.12 On Pump P-126.20
running
Locked to close OR closed if
92. Valve AV-126.11 Not closed Valve AV-126.90
open
Blocked open 100% (PIC-126.10
Control valve on manual, opening 100% and
93. Valve AV-126.90 Open
PV-126.10 relevant XY solenoid valve locked
to open)
Set to close (PIC-126.10 on
From open Control valve manual, opening 0% and relevant
94. Valve AV-126.90
to closed PV-126.10 XY solenoid valve set to close)
(one-shot command)
Control valve Locked to close OR closed if
95. Not open18 Valve AV-117.5A
PV-126.10 open19
Locked to close OR closed if
96. Valve AV-126.11 Not open Valve AV-117.5A
open19
Valves HV-201.1 AND Locked to close OR closed if
97. Not open Valve AV-126.90
HV-201.3 open
Automatic valves AV-126.31/32/33 and AV-126.11 are not locked to close only if hand valves ((HV-
98. 201.1 and HV-201.2) are open and hand valve HV-201.3 is not open) or (hand valves (HV-201.1 and
HV-201.2) are closed and hand valve HV-201.3 is open)
Automatic valve AV-117.5A is not locked to close only if hand valves ((HV-201.1 and HV-201.2) are
99. open and hand valve HV-201.3 is not open) or (hand valves (HV-201.1 and HV-201.2) are closed and
hand valve HV-201.3 is open)
Solenoid valve
100. Turbomixer R-201.01 Running Cannot be closed (locked)
XY-201.101
On for more
Locked on stop OR stopped if
101. FAL-201.101 than a pre- Turbomixer R-201.01
running
set time11
Locked on stop OR stopped if
102. Valve HV-201.1 Not open Turbomixer R-201.01
running

22
N. CONDITION (IF) ACTIONS (THEN)
Locked on stop OR stopped if
103. Valve HV-201.2 Not open Turbomixer R-201.01
running
Locked on stop OR stopped if
104. Valve HV-201.3 Open Turbomixer R-201.01
running
Control valve Locked on stop OR stopped if
105. Not open18 Turbomixer R-201.01
PV-126.10 running
Locked on stop OR stopped if
106. Valve AV-126.11 Not open Turbomixer R-201.01
running
Locked to close OR closed if
107. Valve AV-204.1 Not open Valve AV-117.5A
open19
From open
108. Valve AV-204.1 Valve AV-204.3 Set to open20
to closed
Blocked open 100% (PIC-204.10
Control valve on manual, opening 100% and
109. Valve AV-204.3 Open
PV-204.10 relevant XY solenoid valve locked
to open)
Set to close (PIC-204.10 on
From open Control valve manual, opening 0% and relevant
110. Valve AV-204.3
to closed PV-204.10 XY solenoid valve set to close)
(one-shot command)
From open
111. Valve AV-204.2 Valve AV-204.4 Set to open21
to closed
Locked to close OR closed if
112. Valve AV-204.1 Not closed Valve AV-204.3
open
Locked to close OR closed if
113. Valve AV-204.2 Not closed Valve AV-204.4
open
Locked to close (PIC-126.10 on
Valves AV-204.1 AND Control valve
114. Not open12 manual, opening 0% and relevant
AV-204.2 PV-126.10
XY solenoid valve locked to close)
Valves
Valves AV-204.1 AND Locked to close OR closed if
115. Not open12 AV-126.31/32/33
AV-204.2 open
AND AV-126.11

23
N. CONDITION (IF) ACTIONS (THEN)
Valves AV-204.1 AND Locked on stop OR stopped if
116. Not open12 Turbomixer R-201.01
AV-204.2 running
Vacuum chamber Locked on stop OR stopped if
117. JAHH-204.10122 On
SD-204.01 motor running
Plodder PL-204.01
Locked on stop OR stopped if
118. JAHH-204.10122 On motors (preliminary
running
and final)
Soap fines reversible
Locked on stop OR stopped if
119. JAHH-204.10122 On extruder / conveyor
running
PL-205.03 motor
Locked to close OR closed if
120. PAHH-206.11 On Valve AV-204.1
open
Locked to close OR closed if
121. PAHH-206.11 On Valve AV-204.3
open
Vacuum chamber
Not closed Vacuum chamber Locked on stop OR stopped if
122. SD-204.01 inspection door
(not off) SD-204.01 motor running
(ZI-204.14)
Vacuum chamber Plodder PL-204.01
Not closed Locked on stop OR stopped if
123. SD-204.01 inspection door motors (preliminary
(not off) running
(ZI-204.14) and final)
Vacuum chamber Soap fines reversible
Not closed Locked on stop OR stopped if
124. SD-204.01 inspection door extruder / conveyor
(not off) running
(ZI-204.14) PL-205.03 motor
Vacuum chamber
Not closed Locked to close OR closed if
125. SD-204.01 inspection door Valve AV-204.1
(not off) open
(ZI-204.14)
Vacuum chamber
Not closed Control valve Locked to close OR closed if
126. SD-204.01 inspection door
(not off) PV-204.10 open
(ZI-204.14)
Vacuum chamber
Not closed Locked to close OR closed if
127. SD-204.01 inspection door Valve AV-204.3
(not off) open
(ZI-204.14)

24
N. CONDITION (IF) ACTIONS (THEN)
First fines separator Soap fines reversible
Not closed Locked on stop OR stopped if
128. DC-205.01 inspection door extruder / conveyor
(not off) running
(ZI-205.1) PL-205.03 motor
First fines separator
Not closed Soap fines conveyor Locked on stop OR stopped if
129. DC-205.01 inspection door
(not off) T-205.02 motor running
(ZI-205.1)
Second fines separator
Not closed Soap fines conveyor Locked on stop OR stopped if
130. DC-205.02 inspection door
(not off) T-205.02 motor running
(ZI-205.2)
Set to open (LIC-206.1 on
automatic, opening according to
pre-set value that can be defined
Control valve
131. LAH-206.1 On for each single valve in a
LV-206.123
dedicated video page and relevant
XY solenoid valve set to open)
(one-shot command)
Set to close (LIC-206.1 on
Control valve manual, opening 0% and relevant
132. LAL-206.1 On
LV-206.123 XY solenoid valve set to close)
(one-shot command)
Set to close (LIC-206.1 on
Control valve manual, opening 0% and relevant
133. LALL-206.1 On
LV-206.1 XY solenoid valve set to close)
(one-shot command)
Set to close (LIC-206.1 on
Control valve manual, opening 0% and relevant
134. LALL-206.3 On
LV-206.1 XY solenoid valve set to close)
(one-shot command)
On for more
135. FAL-206.2 than a pre- Pump P-206.02 Stopped (one-shot command)
set time11
Pump P-206.02 stopped if running AND, after 15”11, pump
136. TAHH-206.3 On
P-206.01 locked on stop OR stopped if running

25
N. CONDITION (IF) ACTIONS (THEN)
Preliminary plodder
PL-204.01 chamber Plodder PL-204.01
Not closed Locked on stop OR stopped if
137. (ZI-204.29) OR final motors (preliminary
(not off) running
plodder PL-204.01 head and final)
(ZI-204.30)
Preliminary plodder Locked on stop OR stopped if
138. PAHH-204.52 On24
PL-204.01 motor running
Stopped (pop-up “stand-by”
Preliminary plodder
139. LSH-204.29 On9 appears next to the motor
PL-204.01 motor
(blinking))25
From on to Preliminary plodder Started again, if it was running,
140. LSH-204.29
off9 PL-204.01 motor (pop-up “stand-by” disappears)25
On for more Locked on stop OR stopped if
Preliminary plodder
141. LAH-204.29 than a pre- running (pop-up “stand-by”
PL-204.01 motor
set time”11 disappears)
Final plodder Locked on stop OR stopped if
142. PAHH-204.51 On24
PL-204.01 motor running
Final plodder Not on Locked on stop OR stopped if
143. Blower B-250.01
PL-204.01 motor automatic running
“Silo #A” or “Silo #B” or Locked on stop OR stopped if
144. Not green Blower B-250.01
Silo #C pushbuttons running
Solenoid valve Locked on stop OR stopped if
145. Not open Blower B-250.01
XY-250.11B running
Solenoid valve
146. Blower B-250.01 Running Cannot be closed (locked)
XY-250.11B
Solenoid valve XY-250.12B not open
Locked on stop OR stopped if
147. AND valve DV-250.01A open to D- Blower B-250.01
running
250.01B/C
Blower B-250.01 running AND valve Solenoid valve
148. Cannot be closed (locked)
DV-250.01A open to D-250.01B/C XY-250.12B
On for more
Locked on stop OR stopped if
149. PAH-250.1 than a pre- Blower B-250.01
running
set time”11

26
N. CONDITION (IF) ACTIONS (THEN)
Final plodder Locked on stop OR stopped if
150. Blower B-250.01 Not running
PL-204.01 motor running
Final plodder Locked on stop OR stopped if
151. LAH-250.1 On
PL-204.01 motor running
Valve DV-250.01A open to D-250.01A Final plodder
152. Stopped (one-shot command)
AND LAH-250.1A (DI) on PL-204.01 motor
Valve DV-250.01A open to D-250.01A Final plodder
153. Stopped (one-shot command)
AND LLAH-250.1A (AI) on PL-204.01 motor
Valve DV-250.01A open to D-250.01B/C
Final plodder
154. AND valve DV-250.01B open to D- Stopped (one-shot command)
PL-204.01 motor
250.01B AND LAH-250.1B (DI) on
Valve DV-250.01A open to D-250.01B/C
Final plodder
155. AND valve DV-250.01B open to D- Stopped (one-shot command)
PL-204.01 motor
250.01B AND LAHH-250.1B (AI) on
Valve DV-250.01A open to D-250.01B/C
Final plodder
156. AND valve DV-250.01B open to D- Stopped (one-shot command)
PL-204.01 motor
250.01C AND LAH-250.1C (DI) on
Valve DV-250.01A open to D-250.01B/C
Final plodder
157. AND valve DV-250.01B open to D- Stopped (one-shot command)
PL-204.01 motor
250.01C AND LAHH-250.1C (AI) on
LAH-250.1A (DI) (OR
LAHH-250.01A (AI))
AND LAH-250.1B (DI) Final plodder Locked on stop OR stopped if
158. On
(OR LAHH-250.01B (AI)) PL-204.01 motor running
AND LAH-250.01C (DI)
(OR LAHH-250.01C (AI))
Open to
159. Valve DV-250.01A Valve VF-250.01A Locked to open OR open if close
D-250.01A
Valve DV-250.01A open to D-250.01B/C
160. AND valve DV-250.01B open to D- Valve VF-250.01B Locked to open OR open if close
250.01B

27
N. CONDITION (IF) ACTIONS (THEN)
Valve DV-250.01A open to D-250.01B/C
161. AND valve DV-250.01B open to D- Valve VF-250.01C Locked to open OR open if close
250.01C
Valve DV-250.01A open to D-250.01A Locked on stop OR stopped if
162. Blower B-250.01
AND valve VF-250.01A not open running
Valve DV-250.01A open to D-250.01B/C
Locked on stop OR stopped if
163. AND valve DV-250.01B open to D- Blower B-250.01
running
250.01B AND VF-250.01B not open
Valve DV-250.01A open to D-250.01B/C
AND valve DV-250.01B open to D- Locked on stop OR stopped if
164. Blower B-250.01
250.01C AND valve VF-250.01C not running
open
Valve DV-250.01A (not open to D-
Locked on stop OR stopped if
165. 250.01A AND not open to D-250.01B/C) Blower B-250.01
running
for more than 10”11
Valve DV-250.01A open to D-250.01B/C
AND valve DV-250.01B (not open to D- Locked on stop OR stopped if
166. Blower B-250.01
250.01B AND not open to D-250.01C) running
for more than 10”11
Valves VF-250.01A AND
Locked on stop OR stopped if
167. VF-250.01B AND VF- Not open12 Blower B-250.01A
running
250.01C
Exhaust air filter F-250.05 fan running Can be started by operator, but
168. AND Exhaust air filter F-250.06 fan not Blower B-250.01 with selectable maximum speed
running limited to 80%26
Pop-up “B-250.01
Exhaust air filter F-250.05 fan running maximum speed is
169. AND Exhaust air filter F-250.06 fan not limited to 80%26 to Shown
running optimize powder
recovery of filters”
Exhaust air filter F-250.06 fan running Can be started by operator, but
170. AND Exhaust air filter F-250.05 fan not Blower B-250.01 with selectable maximum speed
running limited to 80%26

28
N. CONDITION (IF) ACTIONS (THEN)
Pop-up “B-250.01
Exhaust air filter F-250.06 fan running maximum speed is
171. AND Exhaust air filter F-250.05 fan not limited to 80%26 to Shown
running optimize powder
recovery of filters”
Can be started by operator,
Exhaust air filters F-250.05
172. Running Blower B-250.01 without limit on selectable
AND F-250.06 fans
maximum speed (100%)26
Pop-up “B-250.01
maximum speed is
Exhaust air filters F-250.05
173. Running limited to 80%26 to Hidden
AND F-250.06 fans
optimize powder
recovery of filters”
Exhaust air filters F-250.05 Locked on stop OR stopped if
174. Not running Blower B-250.01
AND F-250.06 fans running
Pop-up “B-250.01
maximum speed is
Exhaust air filters F-250.05
175. Running limited to 80%26 to Hidden
AND F-250.06 fans
optimize powder
recovery of filters”
Solenoid valve
176. Open Valve VF-250.01A Locked to open OR open if close
XY-250.101A
Solenoid valve XY-250.101A open AND
Solenoid valve XY-
177. valve VF-250.01A not open for more than Set to close (one-shot command)
250.101A
a pre-set time”11
Solenoid valve From open
178. Valve VF-250.01A Set to close (one-shot command)
XY-250.101A to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
179. Not running
OR F-250.06 fans 250.101A open
Solenoid valve Pop-up “D-250.01A
180. Open Shown
XY-250.101A fluidization ON)
Solenoid valve Pop-up “D-250.01A
181. Closed Hidden
XY-250.101A fluidization ON)

29
N. CONDITION (IF) ACTIONS (THEN)
Solenoid valve
182. Open Valve VF-250.01A Locked to open OR open if close
XY-250.201A
Solenoid valve XY-250.201A open AND
Solenoid valve XY-
183. valve VF-250.01A not open for more than Set to close (one-shot command)
250.101A
a pre-set time”11
Solenoid valve From open
184. Valve VF-250.01A Set to close (one-shot command)
XY-250.201A to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
185. Not running
OR F-250.06 fans 250.201A open
Solenoid valve
186. Open Valve VF-250.01B Locked to open OR open if close
XY-250.101B
Solenoid valve XY-250.101B open AND
Solenoid valve XY-
187. valve VF-250.01B not open for more than Set to close (one-shot command)
250.101B
a pre-set time”11
Solenoid valve From open
188. Valve VF-250.01B Set to close (one-shot command)
XY-250.101B to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
189. Not running
OR F-250.06 fans 250.101B open
Solenoid valve Pop-up “D-250.01B
190. Open Shown
XY-250.101B fluidization ON)
Solenoid valve Pop-up “D-250.01B
191. Closed Hidden
XY-250.101B fluidization ON)
Solenoid valve
192. Open Valve VF-250.01B Locked to open OR open if close
XY-250.201B
Solenoid valve XY-250.201B open AND
Solenoid valve XY-
193. valve VF-250.01B not open for more than Set to close (one-shot command)
250.101B
a pre-set time”11
Solenoid valve From open
194. Valve VF-250.01B Set to close (one-shot command)
XY-250.201B to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
195. Not running
OR F-250.06 fans 250.201B open
Solenoid valve
196. Open Valve VF-250.01C Locked to open OR open if close
XY-250.101C

30
N. CONDITION (IF) ACTIONS (THEN)
Solenoid valve XY-250.101C open AND
Solenoid valve XY-
197. valve VF-250.01C not open for more than Set to close (one-shot command)
250.101C
a pre-set time”11
Solenoid valve From open
198. Valve VF-250.01C Set to close (one-shot command)
XY-250.101C to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
199. Not running
OR F-250.06 fans 250.101C open
Solenoid valve Pop-up “D-250.01C
200. Open Shown
XY-250.101C fluidization ON)
Solenoid valve Pop-up “D-250.01C
201. Closed Hidden
XY-250.101C fluidization ON)
Solenoid valve
202. Open Valve VF-250.01C Locked to open OR open if close
XY-250.201C
Solenoid valve XY-250.201C open AND
Solenoid valve XY-
203. valve VF-250.01C not open for more than Set to close (one-shot command)
250.101C
a pre-set time”11
Solenoid valve From open
204. Valve VF-250.01C Set to close (one-shot command)
XY-250.201B to closed
Exhaust air filters F-250.05 Solenoid valve XY- Locked to close OR closed if
205. Not running
OR F-250.06 fans 250.201C open

Legend:
HV: hand valve
AV: automatic valve
XY: solenoid valve
“Set to …” means a one-shot command
“Locked to …” always prevails over “Set to …”

31
6 SEQUENCES

6.1 Pump P-104.01 start-up

The start command of pump P-104.01:

 opens solenoid valve XY-104.101,
 checks FAL-104.101  if, after 10”11, it is off proceed, otherwise stop the sequence and give
alarm,
 starts the motor of pump P-104.01.
If it’s started from LOCAL, when ZI-104.101 goes from OFF to ON  open solenoid valve XY-
104.101.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

6.2 Pump P-104.01 shut-down

The stop command of pump P-104.01 (given by operator or through an interlock):

 stops pump P-104.01,
 after 10”11, solenoid valve XY-104.101 is closed.
If it’s stopped from LOCAL, when ZI-104.101 goes from ON to OFF  close solenoid valve XY-
104.101.

6.3 EDTA automatic valves

The open command for automatic valve AV-104.5 will:

 open automatic valve AV-104.5,
 then, when ZSH-104.5 is ON, automatic valve AV-104.6 will be closed.
The close command for automatic valve AV-104.5 will:
 open automatic valve AV-104.6,
 then, when ZSH-104.6 is ON, automatic valve AV-104.5 will be closed.
The open command for automatic valve AV-104.6 will:
 open automatic valve AV-104.6,
 then, when ZSH-104.6 is ON, automatic valve AV-104.5 will be closed.
The close command for automatic valve AV-104.6 will:
 open automatic valve AV-104.5,
 then, when ZSH-104.5 is ON, automatic valve AV-104.6 will be closed.

32
Automatic valves AV-104.5 and AV-104.6 can’t be both “not open” at the same time, otherwise
alarm is given.
Sequence is functioning, either if the open / close commands are given by operator or if they are given
by interlocks or other sequences.

6.4 Glycerine automatic valves

The open command for automatic valve AV-117.5A will:

 open automatic valve AV-117.5A,
 then, when ZSH-117.5A is ON, automatic valve AV-117.6A will be closed.
The close command for automatic valve AV-117.5A will:
 open automatic valve AV-117.6A,
 then, when ZSH-117.6A is ON, automatic valve AV-117.5A will be closed.
The open command for automatic valve AV-117.6A will:
 open automatic valve AV-117.6A,
 then, when ZSH-117.6A is ON, automatic valve AV-117.5A will be closed.
The close command for automatic valve AV-117.6A will:
 open automatic valve AV-117.5A,
 then, when ZSH-117.5A is ON, automatic valve AV-117.6A will be closed.
Automatic valves AV-117.5A and AV-117.6A can’t be both “not open” at the same time, otherwise
alarm is given.
Sequence is functioning, either if the open / close commands are given by operator or if they are given
by interlocks or other sequences.

6.5 Pump P-117.08 start-up

The start command of pump P-117.08:

 opens solenoid valve XY-117.108,
 checks FAL-117.108  if, after 10”11, it is off proceed, otherwise stop the sequence and give
alarm,
 starts the motor of pump P-117.08.
If it’s started from LOCAL, when ZI-117.108 goes from OFF to ON  open solenoid valve XY-
117.108.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

33
6.6 Pump P-117.08 shut-down

The stop command of pump P-117.08 (given by operator or through an interlock):

 stops pump P-117.08,
 after 10”11, solenoid valve XY-117.108 is closed.
If it’s stopped from LOCAL, when ZI-117.108 goes from ON to OFF  close solenoid valve XY-
117.108.

6.7 EHDP automatic valves

The open command for automatic valve AV-117.5B will:

 open automatic valve AV-117.5B,
 then, when ZSH-117.5B is ON, automatic valve AV-117.6B will be closed.
The close command for automatic valve AV-117.5B will:
 open automatic valve AV-117.6B,
 then, when ZSH-117.6B is ON, automatic valve AV-117.5B will be closed.
The open command for automatic valve AV-117.6B will:
 open automatic valve AV-117.6B,
 then, when ZSH-117.6B is ON, automatic valve AV-117.5B will be closed.
The close command for automatic valve AV-117.6B will:
 open automatic valve AV-117.5B,
 then, when ZSH-117.5B is ON, automatic valve AV-117.6B will be closed.
Automatic valves AV-117.5B and AV-117.6B can’t be both “not open” at the same time, otherwise
alarm is given.
Sequence is functioning, either if the open / close commands are given by operator or if they are given
by interlocks or other sequences.

6.8 Pump P-126.02 start-up

The start command of pump P-126.02:

 opens solenoid valve XY-126.102,
 checks FAL-126.102A and FAL-126.102B  if, after 10”11, both are off proceed, otherwise
stop the sequence and give alarm,
 starts the motor of pump P-126.02.
If it’s started from LOCAL, when ZI-126.102 goes from OFF to ON  open solenoid valve XY-
126.102.

34
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

6.9 Pump P-126.02 shut-down

The stop command of pump P-126.02 (given by operator or through an interlock):

 stops pump P-126.02,
 after 10”11, solenoid valve XY-126.102 is closed.
If it’s stopped from LOCAL, when ZI-126.102 goes from ON to OFF  close solenoid valve XY-
126.102.

6.10 Pump P-126.04 start-up

The start command of pump P-126.04:

 opens solenoid valve XY-126.104,
 checks FAL-126.104A and FAL-126.104B  if, after 10”11, both are off proceed, otherwise
stop the sequence and give alarm,
 starts the motor of pump P-126.04.
If it’s started from LOCAL, when ZI-126.104 goes from OFF to ON  open solenoid valve XY-
126.104.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

6.11 Pump P-126.04 shut-down

The stop command of pump P-126.04 (given by operator or through an interlock):

 stops pump P-126.04,
 after 10”11, solenoid valve XY-126.104 is closed.
If it’s stopped from LOCAL, when ZI-126.104 goes from ON to OFF  close solenoid valve XY-
126.104.

6.12 Pump P-126.20 start-up

The start command of pump P-126.20:

 opens solenoid valve XY-126.120,
 checks FAL-126.120  if, after 10”11, it is off proceed, otherwise stop the sequence and give
alarm,
 starts the motor of pump P-126.20.

35
If it’s started from LOCAL, when ZI-126.120 goes from OFF to ON  open solenoid valve XY-
126.120.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

6.13 Pump P-126.20 shut-down

The stop command of pump P-126.20 (given by operator or through an interlock):

 stops pump P-126.20,
 after 10”11, solenoid valve XY-126.120 is closed.
If it’s stopped from LOCAL, when ZI-126.120 goes from ON to OFF  close solenoid valve XY-
126.120.

6.14 Turbomixer R-201.01 start-up

The start command of turbomixer R-201.01:

 opens solenoid valve XY-201.101,
 checks FAL-201.101  if, after 10”11, it is off proceed, otherwise stop the sequence and give
alarm,
 starts the motor of turbomixer R-201.01.
If it’s started from LOCAL, when ZI-201.101 goes from OFF to ON  open solenoid valve XY-
201.101.
Note: while solenoid valve is closed, FSL control will be disabled (FAL will not turn on, also if the
signal is given).

6.15 Turbomixer R-201.01 shut-down

The stop command of turbomixer R-201.01 (given by operator or through an interlock):

 stops turbomixer R-201.01,
 after 10”11, solenoid valve XY-201.101 is closed.
If it’s stopped from LOCAL, when ZI-201.101 goes from ON to OFF  close solenoid valve XY-
201.101.

6.16 Dryer automatic valves

The open command for automatic valve AV-204.1 will:

 open automatic valve AV-204.1,
 then, when ZSH-204.1 is ON, automatic valve AV-204.2 will be closed.
The close command for automatic valve AV-204.1 will:

36
  open automatic valve AV-204.2,
 then, when ZSH-204.2 is ON, automatic valve AV-204.1 will be closed.
The open command for automatic valve AV-204.2 will:
 open automatic valve AV-204.2,
 then, when ZSH-204.2 is ON, automatic valve AV-204.1 will be closed.
The close command for automatic valve AV-204.2 will:
 open automatic valve AV-204.1,
 then, when ZSH-204.1 is ON, automatic valve AV-204.2 will be closed.
Automatic valves AV-204.1 and AV-204.2 can’t be both not open at the same time, otherwise alarm
is given.
Sequence is functioning, either if the open / close commands are given by operator or if they are given
by interlocks or other sequences.

6.17 Water dosing to kettles PS-124.03A/B

The purpose of the “Water dosing to kettles” sequence is to carry on the feeding of the requested
quantity of process water to kettles PS-124.03A/B, by decision of the operator hitting the relevant
keys below described.
Water dosing to kettles PS-124.03A/B can be done batch wise manually or by means of an automatic
sequence.
On the video page of kettles PS-124.03A/B,
• a table with the following values:
 water feeding set point A [kg]: editable value, input from keyboard,
 water feeding actual value B [kg]: output from the totalizer of mass flow meter FE/FIT-
126.3B (FIQ-126.3B),
 flight time for water C [kg]: editable value, input from keyboard,
 water flow rate D [kg/h]: output from the mass flow meter FE/FIT-126.3B,
 control timer for water charge step X (s): editable value, input from keyboard.
• the following graphic pushbuttons:
 start button,
 stop button,
 reset button.
have to be shown.

37
 Control
PS-124.03A/B Set [kg] Actual [kg] Flight time [kg] Water flow rate [kg/h]
timer [s]
PROCESS WATER A (input) B (output) C (input) D (input) X (input)

Note: all input data must be bigger than or equal to 0.

• Water dosing to kettles automatic sequence.

Conditions for “water dosing to kettles automatic” sequence to be effective are:
 interlocks activated,
 process water feed pump P-126.03 running,
 process water to kettles PS-124.03A/B automatic valve AV-126.3B closed (this only as
starting condition).
If one or more of the above conditions is not matched, the dosing sequence can't be activated or
it is interrupted if running (the system will be set in the same conditions as if the “Stop” button is
pushed and an alarm is given); restart has to be given by operator.
If all the conditions which allow the activation of the sequence are effective, the “Start” button
will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
(blinking - impossibility of activating the sequence).
A dedicated help video page has to be foreseen in order to show all the conditions that are
necessary to activate the “Water dosing to kettles” sequence and which ones are currently
activated or missing.
Function of timer:
o total timer of the sequence t1 [s]: it is the timer which shows the duration of the complete
sequence.
Functions of the pushbuttons:
o “Start” button: once the “Start” button is pushed, the operations described in the list below
will be done.
At this point, the “Start” button will become green to show that the feeding sequence is
active.

38
 Conditions to be
Starting Conditions to be verified
Duration Actions verified during the
condition at the end of the step
duration of the step

1. t1 is reset and started

Sequence ends (when B 2. AV-126.3B is set to open
“Start” button • AV-126.3B open
≥ A – C) or (if t1, 3. FE/FIT-126.3B starts to read the flow and to • ZSL-126.3B ON
pushed by (ZSH-126.3B ON)
started from X11, totalize it (D and B) • B = A ± C27
operator • B<A+C
expires and B < A – C) 4. When B ≥ A – C, then AV-126.3B will be
locked to close and value B is locked until reset

39
 o “Stop” button: its colour is grey; once the “Stop” button is pushed, automatic valves AV-
126.3B will be closed and timer t1 will be stopped; if “Stop” is pushed before reaching
one of the set points, “actual value” B will remain as it is without being reset; when “Start”
is pushed again, the automatic sequence will continue from where it was stopped and FIQ-
126.3B will continue to increase actual value B from the previous one.
When the “Stop” button is pushed before the automatic feeding has been completed, the
“Start” button will return grey to show that the feeding sequence is not active.
o “Reset” button: once the “Reset” button is pushed, a pop-up “Water dosing to kettles
sequence will be reset: YES / NO” will be shown. If “NO” is selected, the pop-up will be
closed, if “YES” is pushed, the following operation will be done:
 “actual value” B is reset,
 timers t1 is reset,
“Reset” button can be pushed only if the sequence is not running and automatic valve AV-
126.3B is closed. In this case, the button will be grey, otherwise it is yellow (blinking -
impossibility of activating the sequence).

Additional notes:
 set point for the water to be charged can’t be modified if the sequence is running,
 if the sequence is stopped by an interlock, the system will be set in the same conditions as
if the “Stop” button is pushed,
 when the interlock that previously blocked the sequence is removed (and the alarm
recognized), the automatic sequence has to be started / restarted by operator.

• Water dosing to kettles manual use.

Safety will be done by interlocks only (see details in section 5).
All the locks due to the “Water dosing to kettles” automatic sequence on valve AV-126.3B will
be removed.
All the operations have to be done manually by operators (opening / closing of valve).

6.18 Idle for reactor

The purpose of the “Reactor idle” sequence for reactor R-126.02 is to recirculate the soap in the
reactor loop, by decision of the operator hitting the “Reactor idle” key.
On the video page of reactor R-126.02, next to the soap recycle pump P-126.20, a table with the
following values:

40
  timer trun11 [min],
 timer tstop11 [min]
has to be shown. Both timers work as countdown.

Conditions for “Reactor idle” sequence to be effective are:

 interlocks activated,
 “Reactor feeding” sequence not active,
 reactor R-126.02 feeding automatic valves AV-126.31/32/33 closed,
 soap from reactor R-126.02 automatic valve AV-126.11 closed,
 reactor R-126.02 recycle inlet automatic valve AV-126.7 open,
 reactor R-126.02 recycle outlet automatic valve AV-126.8 open,
 reactor R-126.02 high pressure PISH-126.12 alarm (PAH-126.12) off,
 reactor R-126.02 high pressure PIT-126.10 alarm (PAH-126.10) off,
 reactor R-126.02 very high pressure PIT-126.10 alarm (PAHH-126.10) off,
 reactor R-126.02 high temperature TE/TT-126.9 alarm (TAH-126.9) off,
 reactor R-126.02 very high temperature TE/TT-126.9 alarm (TAHH-126.9) off.

The activation of the “Reactor idle” sequence, through the relevant pushbutton, will have the
following effects (sequential actions):
1. soap recycle pump P-126.20 is started for an interval of time trun (countdown is shown on the
video page of P-126.20),
2. when timer trun expires, the soap recycle pump P-126.20 is stopped and the timer trun is reset,
3. When the soap recycle pump P-126.20 is stopped, timer tstop is started (countdown is shown
on the video page of P-126.20),
4. When timer tstop expires, the “Reactor idle” sequence is restarted and the timer tstop is reset.

Conditions for “Reactor idle” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched (exception PAH-126.10
and TAH-126.9 on – see below),
 activation of an interlock on soap recycle pump P-126.20,
 fault on soap recycle pump P-126.20,
 decision of the operator of stopping the sequence by pushing the “Reactor idle” key while the
sequence is running.
When the sequence is stopped, soap recycle pump P-126.20 is stopped and the timers trun and tstop are
reset.

41
Additional notes:
 if reactor R-126.02 high pressure PIT-126.10 alarm (PAH-126.10) goes from off to on5 while
the sequence is running, the sequence is suspended:
o timers trun and tstop are stopped and reset,
o soap recycle pump P-126.20 is stopped,
o alarm is given and the “Reactor idle” pushbutton becomes blue,
o pop-up ““Reactor idle” sequence suspended” is shown,
 if reactor R-126.02 high pressure PIT-126.10 alarm (PAH-126.10) goes from on to off5 while
the sequence is suspended, the sequence is restarted from the step number 1 previously
described,
 if reactor R-126.02 high temperature TE/TT-126.9 alarm (TAH-126.9) goes from off to on6
while the sequence is running, the sequence is suspended:
o timers trun and tstop are stopped and reset,
o soap recycle pump P-126.20 is stopped,
o alarm is given and the “Reactor idle” pushbutton becomes blue,
o pop-up ““Reactor idle” sequence suspended” is shown,
 if reactor R-126.02 high temperature TE/TT-126.9 alarm (TAH-126.9) goes from on to off6
while the sequence is suspended, the sequence is restarted from the step number 1 previously
described.

If all the conditions which allow the activation of the sequence are effective, the “Reactor idle” button
becomes grey to indicate the possibility to activate the sequence, otherwise it is yellow (blinking -
impossibility of activating the sequence).
When “Reactor idle” sequence is active, the key will be green.
When “Reactor idle” sequence is active, but suspended, the key will be blue.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Reactor idle” sequence and which ones are currently activated or missing.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.

6.19 Saponification stand-by

The purpose of the “Saponification stand-by” sequence is to bring the plant to a safe situation in one
of the following events:
 general power / utilities failure,

42
  steam 15 ÷ 16 barg very low pressure alarm PIT-120.1 (PALL-120.1 ON),
 steam 4 barg very low pressure alarm PIT-120.4 (PALL-120.4 ON),
 steam 2 barg very low pressure alarm PIT-120.2 (PALL-120.2 ON),
 instrument air very low pressure alarm PIT-120.3A (PALL-120.3A ON),
 decision of the operator by hitting the software “Saponification stand-by” key,
 decision of the operator by hitting the field emergency buttons (HS-126.200 or HV-126.201),
 anomalous conditions during steady plant operation as indicated in the following paragraphs.
Any of the above events can be by-passed (password required) to allow easier operation during
start-up and shutdown (one ON / OFF button for each alarm).
Above very low pressure alarms activate after a delay time11 (one timer for all the switches).
Start-up, shutdown, pipe draining and steam blowing operation had to be done manually by operators
(combined operation from PC and “on-field”).

The anomalous conditions during steady plant operation that must be taken in account to activate
“Saponification stand-by” sequence are the following:
1. Deviation of actual flow rate versus set point of the mass dosing loops (FICQ-104.1, FICQ-
117.8, FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4) feeding the reactor28 (only
if relevant set point is different from 0 kg/h29),
2. Generic failure on reactor R-126.02 dosing pumps:
 EDTA solution feed tank D-104.01 discharge automatic valve AV-104.3 fault or change
of status (i.e. from open to not open) (only if AV-104.5 is open and set point of FICQ-
104.1 is different from 0 kg/h),
 EDTA feed pump P-104.01 fault or change of status (i.e. from running to stopped) (only
if AV-104.5 is open and set point of FICQ-104.1 is different from 0 kg/h29),
 EDTA to reactor R-126.02 automatic valve AV-104.5 fault or change of status (i.e. from
open to not open) (only if set point of FICQ-104.1 is different from 0 kg/h29),
 EDTA recycle automatic valve AV-104.6 fault or change of status (i.e. from closed to not
closed) (only if set point of FICQ-104.1 is different from 0 kg/h29),
 EHDP solution feed tank D-117.08 discharge automatic valve AV-117.3B fault or change
of status (i.e. from open to not open) (only if AV-117.5B is open and set point of FICQ-
117.8 is different from 0 kg/h29),
 EHDP feed pump P-117.08 fault or change of status (i.e. from running to stopped) (only
if AV-117.5B is open and set point of FICQ-117.8 is different from 0 kg/h29),
 EHDP to reactor R-126.02 automatic valve AV-117.5B fault or change of status (i.e. from
open to not open) (only if set point of FICQ-117.8 is different from 0 kg/h29),

43
  EHDP recycle automatic valve AV-117.6B fault or change of status (i.e. from closed to
not closed) (only if set point of FICQ-117.8 is different from 0 kg/h29),
 F.A. / N.O. blend storage tank T-15A outlet automatic valve AV-126.11A fault or change
of status (i.e. from open to not open) (only if set point of FICQ-126.1A is different from
0 kg/h29),
 neutral oil / fatty acid feed pump P-126.01A fault or change of status (i.e. from running to
stopped) (only if P-126.01B is not running);
 neutral oil / fatty acid feed pump P-126.01B fault or change of status (i.e. from running to
stopped) (only if P-126.01A is not running);
 caustic soda daily tank D-126.02 discharge automatic valve AV-126.12 fault or change of
status (i.e. from open to not open),
 caustic soda feed pump P-126.02 fault or change of status (i.e. from running to stopped);
 process water daily tank D-126.03 discharge automatic valve AV-126.13 fault or change
of status (i.e. from open to not open),
 process water feed pump P-126.03 fault or change of status (i.e. from running to stopped);
 brine daily tank D-126.04 discharge automatic valve AV-126.14 fault or change of status
(i.e. from open to not open) (only if set point of FICQ-126.4 is different from 0 kg/h29),
 brine feed pump P-126.04 fault or change of status (i.e. from running to stopped) (only if
set point of FICQ-126.4 is different from 0 kg/h29),
3. Generic failure on reactor R-126.02:
 recycle pump P-126.20 fault or change of status (i.e. from running to stopped),
 raw materials feeding automatic valves (AV-126.31 or AV-126.33) fault or change of
status (i.e. from open to not open),
 reactor R-126.02 recycle inlet automatic valve AV-126.7 or reactor R-126.02 recycle
outlet automatic valve AV-126.8 fault or change of status (i.e. from open to not open),
 reactor R-126.02 very high pressure PIT-126.10 alarm (PAHH-126.10 ON),
 reactor R-126.02 high pressure PISH-126.12 alarm (PAH-126.12 ON),
4. Generic failure on reactor R-126.02 outlet:
 reactor R-126.02 outlet automatic valve AV-126.11 fault (valve can be manually closed
by operator if it is required). For “Reactor feeding” activation the position of the valve
(open or closed) is not relevant,
 reactor R-126.02 outlet automatic valve AV-126.11 change of status (i.e. from open to not
open) (only if AV-204.1 is open),
 turbomixer R-201.01 fault or change of status (i.e. from running to stopped) (only if AV-
126.11 is open),

44
  soap to turbomixer R-201.01 hand valve HV-201.1 fault or change of status (i.e. from
open to not open) (only if HV-201.3 is closed),
 soap from turbomixer R-201.01 hand valve HV-201.2 fault or change of status (i.e. from
open to not open) (only if HV-201.3 is closed),
 turbomixer R-201.01 by-pass hand valve HV-201.3 change of status (i.e. from not open
to open) (only if HV-201.1 OR HV-201.2 are open),
 soap to turbomixer R-201.01 hand valve HV-201.1 fault or change of status (i.e. from
closed to not closed) (only if HV-201.3 is open),
 soap from turbomixer R-201.01 hand valve HV-201.2 fault or change of status (i.e. from
closed to not closed) (only if HV-201.3 is open),
 turbomixer R-201.01 by-pass hand valve HV-201.3 fault or change of status (i.e. from
open to not open) (only if HV-201.1 or HV-201.2 are closed),
 automatic valves AV-204.1 and AV-204.2 not open (or one of the valves in reference on
fault),
5. Generic failure on additives section (only if AV-204.1 is open):
 glycerine feed tank D-117.06 discharge automatic valve AV-117.3A fault or change of
status (i.e. from open to not open) (only if AV-117.5A is open and set point of FICQ-
117.6 is different from 0 kg/h29),
 glycerine feed pump P-117.06 fault or change of status (i.e. from running to stopped) (only
if AV-117.5A is open and set point of FICQ-117.6 is different from 0 kg/h29),
 deviation of actual flow rate versus set point of the glycerine mass dosing loop (FICQ-
117.4) feeding the dryer28 (only if AV-117.5A is open and set point of FICQ-117.6 is
different from 0 kg/h29),
 glycerine to dryer automatic valve AV-117.5A fault or change of status (i.e. from open to
not open) (only if set point of FICQ-117.6 is different from 0 kg/h29),
 glycerine recycle automatic valve AV-117.6A fault or change of status (i.e. from closed
to not closed) (only if set point of FICQ-117.6 is different from 0 kg/h29),
6. Generic failure on dryer vacuum chamber SD-204.01 (only if AV-204.1 is open):
 vacuum chamber SD-204.01 motor fault or change of status (i.e. from running to stopped),
 very high torque JI-204.101 alarm (JAHH-204.101 ON) on vacuum chamber SD-204.01
motor22,
 high level LSH-204.13 alarm (LAH-204.13 ON) on vacuum chamber SD-204.01 for more
than 10”7, 11,
7. Generic failure on vacuum pump P-206.01 and condensation system (only if AV-204.1 is
open):

45
  vacuum pump P-206.01 fault or change of status (i.e. from running to stopped),
 very high pressure PIT-206.11 alarm (PAHH-206.11 ON) on vacuum chamber SD-
204.01,
 semi-barometric ICS water recycle pump P-206.02 fault or change of status (i.e. from
running to stopped),
 low flow FSL-206.2 alarm (FAL-206.2 ON) on semi-barometric ICS water recycle pump
P-206.02 suction line for more than a pre-set time11,
 very high level LSHH-206.1 alarm (LAHH-206.1 ON) on semi-barometric condenser C-
206.03 for more than 5”11,
 very high level LSHH-206.3 alarm (LAHH-206.3 ON) on semi-barometric condenser C-
206.03 for more than 5”8, 11,
 very low level LSLL-206.1 alarm (LALL-206.1 ON) on semi-barometric condenser C-
206.03,
 very low level LSLL-206.3 alarm (LALL-206.3 ON) on semi-barometric condenser C-
206.03,
 very high temperature TE/TT-249.1 alarm (TAHH-249.1) for chilled water,
8. Generic failure on feeding sequences activation:
 time-out timer for “Reactor feeding” sequence alarm30,
 time-out timer for “Vacuum chamber feeding” sequence alarm30,
 time-out timer for “Additives feeding” sequence alarm30,
9. Generic failure on recycle sequences activation:
 time-out timer for “Vacuum chamber recycle” sequence alarm30,
 time-out timer for “Additives recycle” sequence alarm30,
10. Generic failure on system:
 interlocks from enabled to disabled.

The activation of the “Saponification stand-by” sequence will have the following effects:
 put on manual loops FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4 with output
0% to control valves and close relevant XY solenoid valves,
 open EDTA recycle automatic valve AV-104.6 and close EDTA to reactor R-126.02
automatic valve AV-104.5 (further info in sequences section 6.3),
 open glycerine recycle automatic valve AV-117.6A and close glycerine to dryer automatic
valve AV-117.6B (further info in sequences section 6.4),
 open EHDP recycle automatic valve AV-117.6B and close EHDP to reactor R-126.02
automatic valve AV-117.5B (further info in sequences section 6.7),

46
  close the reactor R-126.02 feeding automatic valves AV-126.31/32/33,
 put on manual loops TIC-126.5 and TIC-126.6 with output 0% to control valves and close
relevant XY solenoid valves,
 stop soap from kettles PS-124.03A/B transfer pump P-124.03,
 close reactor R-126.02 outlet automatic valve AV-126.11 and put on manual loop PIC-126.10
with output 0% to control valve and close relevant XY solenoid valve. This operation has a
delay time of 5”11 in relation to stand-by sequence activation,
 stop turbomixer R-201.01. This operation has a delay time of 5”11 in relation to stand-by
sequence activation (same timer which delay the closure of AV-126.11 and XY-126.10),
 close soap to vacuum chamber SD-204.01 automatic valve AV-204.1 and open soap recycle
automatic valve AV-204.2 (further info in sequences section 6.16). After 5”, PIC-204.10 is
set on manual mode and control valve PV-204.10 is blocked open 100% (relevant XY
solenoid valve is set to open), then valve AV-204.3 opens for 5” (time can be changed in a
dedicated video page). When the blowing time expires, the automatic steam valve AV-204.3
is closed. At this point, also PV-204.10 is closed (relevant XY solenoid valve is set to close),
 stop preliminary plodder PL-204.01’s motor,
 stop final plodder PL-204.01’s motor,
 time-out timers for feeding sequences stopped and reset30.

If any anomalous condition that has previously caused the stand-by sequence is still active, the
“Saponification stand-by” key becomes yellow (blinking), otherwise it is grey.
A dedicated help video page has to be foreseen in order to show all the conditions that can activate
the “Saponification stand-by” sequence and which ones are currently activated.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.

6.20 Reactor feeding

The purpose of the “Reactor feeding” sequence is to allow to start or restart the plant (i.e. to feed
reactor R-126.02), by decision of the operator hitting the “Reactor feeding” key.
If any anomalous condition that has previously caused the stand-by sequence is still active, the
“Reactor feeding” key cannot have any effect.

Conditions for “Reactor feeding” sequence to be effective are:

 any anomalous condition that can cause the “Saponification stand-by” sequence not active,
 interlocks activated,

47
  “Idle for reactor” sequence not active,
 “Soap pipes cleaning” sequence not active,
 EDTA feed pump P-104.01 running (only if set point of FICQ-104.1 is different from 0
kg/h29),
 EHDP feed pump P-117.08 running (only if set point of FICQ-117.8 is different from 0
kg/h29),
 F.A. / N.O. blend feed pump P-126.01A or F.A. / N.O. blend feed pump P-126.01B running,
 caustic soda feed pump P-126.02 running.
 process water feed pump P-126.03 running.
 brine feed pump P-126.04 running (only if set point of FICQ-126.4 is different from 0
kg/h29),
 reactor R-126.02 recycle inlet automatic valve AV-126.7 open,
 reactor R-126.02 recycle outlet automatic valve AV-126.8 open,
 reactor R-126.02 very high pressure PIT-126.10 alarm (PAHH-126.10) off,
 reactor R-126.02 high pressure PISH-126.12 alarm (PAH-126.12) off,
 ((soap to turbomixer R-201.01 hand valve HV-201.1 and soap from turbomixer R-201.01
hand valve HV-201.2 open) and turbomixer R-201.01 by-pass hand valve HV-201.3 not open)
or ((soap to turbomixer R-201.01 hand valve HV-201.1 and soap from turbomixer R-201.01
hand valve HV-201.2 closed) and turbomixer R-201.01 by-pass hand valve HV-201.3 open),
 soap recycle automatic valve AV-204.2 open and soap to vacuum chamber SD-204.01
automatic valve AV-204.1 closed.

When the operator wants to start the production (soap to reactor R-126.02), the “Reactor feeding”
key has to be pushed. This operation will:
 put all the raw materials feeding the reactor (FICQ-104.1, FICQ-126.1A, FICQ-126.2, FICQ-
126.3, FICQ-126.04 and FICQ-117.8) on auto mode (FICQ settings remain as they are
because we are not giving any shot command here when we go to stand-by) (only if relevant
set point is different from 0 kg/h29),
 open EDTA to reactor R-126.02 automatic valve AV-104.5 and close EDTA recycle
automatic valve AV-104.6 (only if set point of FICQ-104.1 is different from 0 kg/h29)
(further info in sequences section 6.3),
 open EHDP to reactor R-126.02 automatic valve AV-117.5B and close EHDP recycle
automatic valve AV-117.6B (only if set point of FICQ-117.8 is different from 0 kg/h29)
(further info in sequences section 6.76.4),

48
  mass flow control valves FV-126.1A, FV-126.2, FV-126.3 and FV-126.4 start opening from
pre-set values that can be defined for each single valve in a dedicated video page (only if
relevant set point is different from 0 kg/h29),
 put on auto mode loops TIC-126.5 and TIC-126.6 (TIC settings remain as they are because
we are not giving any shot command here when we go to stand-by) and open relevant XY
solenoid valves,
 temperature control valves TV-126.5/6 start opening from pre-set values that can be defined
for each single valve in a dedicated video page,
 open the reactor R-126.02 feeding automatic valves AV-126.31/33,
 open the reactor R-126.02 outlet valve AV-126.11 (automatic valve can be, afterwards,
manually closed by operator, if it is required, without activating the “Saponification stand-
by”, but only if AV-204.1 is closed), open solenoid valve XY-126.10 and put on auto mode
pressure control loop PIC-126.10 (PIC setting remains as it is because we are not giving any
shot command here when we go to stand-by),
 pressure control valve PV-126.10 starts opening from pre-set value that can be defined for
each single valve in a dedicated video page,
 open soap recycle automatic valve AV-204.2 and close soap to vacuum chamber SD-204.01
automatic valve AV-204.1 (further info in sequences section 6.16),
 show a pop-up to start P-126.20, if it’s not running (pump P-126.20 start-up sequence, see
sequence 6.12). The choice to start the item is up to the operator,
 time-out timer for “Reactor feeding” sequence started30.

If all the conditions which allow the activation of the sequence are effective, the “Reactor feeding”
button will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
(blinking - impossibility of activating the sequence).
When “Reactor feeding” sequence is active (i.e. relevant pushbutton pressed and AV-126.31 and AV-
126.33 are open), the colour of the key will be green.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Reactor feeding” sequence and which ones are currently activated or missing.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.

6.21 Vacuum chamber feeding

The purpose of the “Vacuum chamber feeding” sequence is to allow to start the production (soap to
vacuum chamber SD-204.01), by decision of the operator hitting the “Vacuum chamber feeding” key.

49
Conditions for “Vacuum chamber feeding” sequence to be effective are:
 interlocks activated,
 “Reactor feeding” sequence active,
 soap recycle pump P-126.20 running,
 soap from reactor R-126.02 automatic valve AV-126.11 open,
 chilled water very high temperature TE/TT-249.1 alarm (TAHH-249.1) off,
 soap recycle automatic valve AV-204.2 open and soap to vacuum chamber SD-204.01
automatic valve AV-204.1 closed,
 atomizer SD-204.01 motor running,
 vacuum chamber SD-204.01 very high pressure PIT-206.11 alarm (PAHH-206.11) off,
 vacuum chamber SD-204.01 high level LSH-204.13 alarm (LAH-204.13) off7,
 vacuum pump P-206.01 running,
 semi-barometric ICS water recycle pump P-206.02 running,
 semi-barometric ICS water recycle pump P-206.02 suction line low flow FSL-206.2 alarm
(FAL-206.2) off,
 semi-barometric condenser C-206.03 very high level LSHH-206.1 alarm (LAHH-206.1) off,
 semi-barometric condenser C-206.03 very high level LSHH-206.3 alarm (LAHH-206.3) off8,
 semi-barometric condenser C-206.03 very low level LSHH-206.1 alarm (LALL-206.1) off,
 semi-barometric condenser C-206.03 very low level LSLL-206.3 alarm (LALL-206.3) off.

When the operator wants to start the production (soap to vacuum chamber SD-204.01), the “Vacuum
chamber feeding” key has to be pushed. This operation will:
 open soap to vacuum chamber SD-204.01 automatic valve AV-204.1 (further info in
sequences section 6.16),
 close recycle automatic valve AV-204.2 (valve AV-204.4 is set to open for 10”21) (further
info in sequences section 6.16),
 at the same time, open XY-204.10 and put on automatic mode loop PIC-204.10 (PIC setting
remains as it is because we are not giving any shot command here when we go to stand-by),
 pressure control valve PV-204.10 starts opening from pre-set value that can be defined for
each single valve in a dedicated video page,
 pop-ups for direct opening/closing of soap to vacuum chamber SD-204.01 automatic valve
AV-204.1 and soap recycle automatic valve AV-204.2 are disabled (when “Vacuum chamber
feeding” sequence is active, to manually operate on these valves, only the sequences
pushbuttons can be used),

50
  time-out timer for “Vacuum chamber feeding” sequence started30 (time-out timer for this
sequence is given by the timer of interlock n. 111 of AV-204.4 plus 10”).

If all the conditions which permit the activation of the sequence are effective, the “Vacuum chamber
feeding” button will become grey to indicate the possibility to activate the sequence itself, otherwise
it is yellow (blinking - impossibility of activating the sequence).
When “Vacuum chamber feeding” sequence is active (i.e. relevant pushbutton pressed, AV-204.1
open, solenoid valve XY-204.10 open and motor of atomizer SD-204.01 running), the colour of the
key will be green.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Vacuum chamber feeding” sequence and which ones are currently activated or
missing.
Plodder's motors have to be restarted manually by operator at the proper moment.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.

The operator can end the previous sequence, without activating the “Saponification stand-by”
sequence, by pushing the “Recycle” key (when the sequence is already running). This operation will:
 open soap recycle automatic valve AV-204.2 (further info in sequences section 6.16),
 close soap to vacuum chamber SD-204.01 automatic valve AV-204.1 (further info in
sequences section 6.16). After 5”, PIC-204.10 is set on manual mode and control valve PV-
204.10 is blocked open 100% (relevant XY solenoid valve is set to open), then valve AV-
204.3 opens for 5” (time can be changed in a dedicated video page). When the blowing time
expires, the automatic steam valve AV-204.3 is closed. At this point, also PV-204.10 is closed
(relevant XY solenoid valve is set to close),
 open glycerine recycle automatic valve AV-117.6A and close glycerine to dryer automatic
valve AV-117.5A (further info in sequences section 6.4),
 start time-out timer for “Vacuum chamber recycle” sequence30 (time-out timer for this
sequence is given by the timer of interlock n. 108 of AV-204.3 plus 10”).

6.22 Additives feeding

The purpose of the “Additives feeding” sequence is to allow to start the feeding of the additives to
the soap, by decision of the operator hitting the “Additives feeding” key.

Conditions for “Additives feeding” sequence to be effective are:

51
  interlocks activated,
 “Vacuum chamber feeding” sequence activated,
 glycerine feed pump P-117.06 running (only if set point of FICQ-117.6 is different from 0
kg/h29);
 turbomixer R-201.01 running (only if HV-201.1 and HV-201.2 are open).

By pressing the “Additives feeding” key, the following operation will be done:
 all the additives feeding pumps will be put in production, this means:
 put all the additives feeding the dryer (FICQ-117.6) on auto mode (FICQ settings remain
as they are because we are not giving any shot command here when we go to stand-by)
(only if relevant set point is different from 0 kg/h29);
 open glycerine to dryer automatic valve AV-117.5A and close glycerine recycle automatic
valve AV-117.6A (only if set point of FICQ-117.6 is different from 0 kg/h29) (further
info in sequences section 6.4);
 time-out timer for “Additives feeding” sequence started30.

If all the conditions which permit the activation of the sequence are effective, “Additives feeding”
key will become grey to indicate the possibility to activate the sequence, otherwise it is yellow
(blinking - impossibility of activating the sequence). If all the additives are off29, the “Additives
feeding” key will be yellow (blinking - impossibility of activating the sequence).
When “Additives feeding” sequence is active (i.e. relevant pushbutton pressed and AV-117.5A open
- only if set point of FICQ-117.6 is different from 0 kg/h29), the colour of the key will be green.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Additives feeding” sequence and which ones are currently activated or missing.
If a motor is in “local control”, the PLC doesn’t have the control over it and it’ll be ignored by the
sequence / interlock which is carrying out.

The operator can end the previous sequence, without activating the “Saponification stand-by”
sequence, by pushing the “Recycle” key, which involves:
 open glycerine recycle automatic valve AV-117.6A and close glycerine to dryer automatic
valve AV-117.5A (further info in sequences section 6.4),
 start time-out timer for “Additives recycle” sequence30.

52
6.23 Soap pipes cleaning

The purpose of the “Soap pipes cleaning” sequence is to allow the cleaning of the soap recycle pipe
and the soap to vacuum chamber pipe, by decision of the operator hitting the “Soap pipes cleaning”
key.

Conditions for “Soap pipes cleaning” sequence to be effective are:

 interlocks activated,
 “Reactor feeding” sequence not active,
 “Vacuum chamber feeding” sequence not active,
 “Additives feeding” sequence not active,
 “Idle for reactor” sequence not active,
 glycerine to dryer automatic valve AV-117.5A closed,
 soap from reactor R-126.02 automatic valve AV-126.11 closed,
 pressure control valve PV-126.10 closed (relevant XY solenoid valve closed and control on
manual with opening on 0%),
 vacuum chamber SD-204.01 very high pressure PIT-206.11 alarm (PAHH-206.11) off.

When the operator wants to start the sequence, the “Soap pipes cleaning” key has to be pushed. This
operation will:
 open AV-204.1 (AV-204.2 closes - further info in sequences section 6.16) and open valve
AV-204.421;
 at the end of the previous operation, close the atomizer feeding valve AV-204.1 (AV-204.2
opens - further info in sequences section 6.16), valve PV-204.10 is blocked open 100% and
valve AV-204.3 opens20.

If all the conditions which allow the activation of the sequence are effective, the “Soap pipes
cleaning” button becomes grey to indicate the possibility to activate the sequence itself, otherwise the
button is yellow (blinking - impossibility of activating the sequence).
When “Soap pipes cleaning” sequence key is active (i.e. relevant pushbutton pressed), the colour of
the key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Soap pipes cleaning” sequence and which ones are currently activated or missing.

“Soap pipes cleaning” sequence can be stopped by decision of the operator hitting the “Reset” key or
the “Saponification stand-by” button.
53
By pushing the “Reset” key (when the sequence is already running), the system will:
 close soap to vacuum chamber SD-204.01 automatic valve AV-204.1 and open soap recycle
automatic valve AV-204.2 (further info in sequences section 6.16),
 close steam valves AV-204.3 and AV-204.4,
 After 5”, PIC-204.10 is set on manual mode and control valve PV-204.10 is closed (relevant
XY solenoid valve is set to close).
When cleaning sequence is on, if any automatic valve of cleaning, production or recycle goes on fault
or changes position (i.e. operators choice) or “Reset” key is pushed or one (or more) of the sequence
activation conditions is not met, then the cleaning sequence must be terminated by PLC (same
operation done when “Reset” button is pushed).

6.24 Pneumatic transport

The purpose of the “Pneumatic transport” sequence is to allow the fast and safe change of the noodles
storage silo, by decision of the operator hitting the relevant key.
It will be possible to select the desired silo through proper graphic pushbuttons shown on the
pneumatic transport video page (pushbuttons “Silo #A”, “Silo #B” and “Silo #C”).

Conditions for silo D-250.01A to be selected are:

 interlocks activated,
 silo D-250.01A high level LSH-250.1A (DI) alarm (LAH-250.1A (DI)) off,
 silo D-250.01A very high level LSHH-250.1A (AI) alarm (LAHH-250.1A (AI)) off,
 exhaust air throttle automatic valve VF-250.01A not in fault,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

54
By pressing the “Silo #A” button, the following operations will be done (2 different conditions are foreseen):

Step Action Duration Action Duration

DV-250.01A open in the direction of silo D-250.01A DV-250.01A not open in the direction of silos D-250.01A
IF
(ZLL-250.11 ON) (ZLL-250.11 not ON)
 Final plodder PL-204.01 stopped, if running.  Final plodder PL-204.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”11 5”11
PL-204.01 (blinking). 204.01 (blinking).
 Countdown tS11 reset and started.  Countdown tS11 reset and started.
 Blower B-250.01. stopped, if running.  Blower B-250.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”11  Pop-up “stand-by” appears next to blower B-250.01 5”11
250.01 (blinking). (blinking).
 Solenoid valve XY-250.11B set to open.
3  Exhaust air throttle automatic valve VF-250.01A 3”11  Solenoid valve XY-250.11B set to close. 3”11
set to open.
 Pop-up “stand-by” next to blower B-250.01
Until ZLL-
disappears. Diverting valve DV-250.01A set to open in the direction
4 1011 250.11 is ON
 Blower B-250.01 started again, only if it was of D-250.01A.
+ 6”11
running.
 Pop-up “stand-by” next to final plodder PL-
 Solenoid valve XY-250.11B set to open.
204.01disappears.
5 Y”11  Exhaust air throttle automatic valve VF-250.01A set 3”11
 Final plodder PL-204.01started again, only if it
to open.
was running, with a speed equal to the one before

55
 pressing pushbutton “Silo #A” plus X [%]31 for
Y”11, then it will return to the speed before
pressing pushbutton “Silo #A”.
 Solenoid valve X-250.101A set to open.
Sequence completed.
If timer tS expires before completing the sequence,
the sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the
two items are stopped.
 Pop-up “stand-by” next to blower B-250.01
6 / / disappears. 1011
 Blower B-250.01 started again, only if it was running.
 Pop-up “stand-by” next to final plodder PL-
204.01disappears.
 Final plodder PL-204.01started again, only if it was
running, with a speed equal to the one before pressing
7 / / pushbutton “Silo #A” plus X [%]31 for Y”11, then it Y”11
will return to the speed before pressing pushbutton
“Silo #A”.
 Solenoid valve X-250.101A set to open.
Sequence completed.

56
 If timer tS expires before completing the sequence, the
sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the two
items are stopped.

If all the conditions which permit the selection of soap noodles storage silo D-250.01A are effective, the “Silo #A” button will become grey to indicate
the possibility to activate the sequence itself, otherwise it is yellow (blinking - impossibility of activating the sequence).
When “Silo #A” key is active (i.e. relevant pushbutton pressed, DV-250.01A open in the direction of D-250.01A, XY-250.11B open and VF-250.01A
open), its colour will be green (still).
While the sequence to open DV-250.01A in the direction of silo D-250.01A is running, the colour of “Silo #A” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-250.01A and which ones are currently
activated or missing.

Conditions for silo D-250.01B to be selected are:

 interlocks activated,
 silo D-250.01B high level LSH-250.1B (DI) alarm (LAH-250.1B (DI)) off,
 silo D-250.01B very high level LSHH-250.1B (AI) alarm (LAHH-250.1B (AI)) off,
 exhaust air throttle automatic valve VF-250.01A not in fault,
 exhaust air throttle automatic valve VF-250.01B not in fault,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

57
By pressing the “Silo #B” button, the following operations will be done (4 different conditions are foreseen):

Step Action Duration Action Duration

DV-250.01A open in the direction of silos D-250.01B/C (ZLH- DV-250.01A open in the direction of silos D-250.01B/C (ZLH-250.11
IF 250.11 ON) AND DV-250.01B open in the direction of silo D- ON) AND DV-250.01B not open in the direction of silo D-250.01B
250.01B (ZLL-250.12 ON) (ZLL-250.12 not ON)
 Final plodder PL-204.01 stopped, if running.  Final plodder PL-204.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”11 5”11
PL-204.01 (blinking). 204.01 (blinking).
 Countdown tS11 reset and started.  Countdown tS11 reset and started.
 Blower B-250.01. stopped, if running.  Blower B-250.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”11  Pop-up “stand-by” appears next to blower B-250.01 5”11
250.01 (blinking). (blinking).
 Solenoid valve XY-250.11B set to open.
 Solenoid valve XY-250.12B set to open.  Solenoid valve XY-250.11B set to open.
3 3”11 3”11
 Exhaust air throttle automatic valve VF-250.01B  Solenoid valve XY-250.12B set to close.
set to open.
 Pop-up “stand-by” next to blower B-250.01
Until ZLL-
disappears. Diverting valve DV-250.01B set to open in the direction
4 1011 250.12 is ON
 Blower B-250.01 started again, only if it was of D-250.01B.
+ 6”11
running.
 Pop-up “stand-by” next to final plodder PL-
5 Y”11  Solenoid valve XY-250.12B set to open. 3”11
204.01disappears.

58
  Final plodder PL-204.01started again, only if it  Exhaust air throttle automatic valve VF-250.01B set
was running, with a speed equal to the one before to open.
pressing pushbutton “Silo #B” plus X [%]31 for
Y”11, then it will return to the speed before
pressing pushbutton “Silo #B”.
 Solenoid valve X-250.101B set to open.
Sequence completed.
If timer tS expires before completing the sequence,
the sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the
two items are stopped.
 Pop-up “stand-by” next to blower B-250.01
6 / / disappears. 1011
 Blower B-250.01 started again, only if it was running.
 Pop-up “stand-by” next to final plodder PL-
204.01disappears.
 Final plodder PL-204.01started again, only if it was
running, with a speed equal to the one before pressing
7 / / 31 11
Y”11
pushbutton “Silo #B” plus X [%] for Y” , then it
will return to the speed before pressing pushbutton
“Silo #B”.
 Solenoid valve X-250.101B set to open.

59
 Sequence completed.
If timer tS expires before completing the sequence, the
sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the two
items are stopped.

Step Action Duration Action Duration

DV-250.01A not open in the direction of silos D-250.01B/C DV-250.01A not open in the direction of silos D-250.01B/C (ZLH-
IF (ZLH-250.11 not ON) AND DV-250.01B open in the direction 250.11 not ON) AND DV-250.01B not open in the direction of silo D-
of silo D-250.01B (ZLL-250.12 ON) 250.01B (ZLL-250.12 not ON)
 Final plodder PL-204.01 stopped, if running.  Final plodder PL-204.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”11 5”11
PL-204.01 (blinking). 204.01 (blinking).
 Countdown tS11 reset and started. Countdown tS11 reset and started.
 Blower B-250.01. stopped, if running.  Blower B-250.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”11 Pop-up “stand-by” appears next to blower B-250.01 5”11
250.01 (blinking). (blinking).
 Solenoid valve XY-250.11B set to close.
3  Solenoid valve XY-250.11B set to close. 3”11 3”11
 Solenoid valve XY-250.12B set to close.
Until Until (ZLH-
 Diverting valve DV-250.01A set to open in the  Diverting valve DV-250.01A set to open in the
4 ZLH- 250.11 is ON
direction of D-250.01B/C. direction of D-250.01B/C.
250.11 is AND ZLL-

60
 ON +  Diverting valve DV-250.01B set to open in the 250.12 is ON)
6”11 direction of D-250.01B. + 6”11
 Solenoid valve XY-250.11B set to open.  Solenoid valve XY-250.11B set to open.
 Solenoid valve XY-250.12B set to open  Solenoid valve XY-250.12B set to open
5 3”11 3”11
 Exhaust air throttle automatic valve VF-250.01B  Exhaust air throttle automatic valve VF-250.01B set
set to open. to open.
 Pop-up “stand-by” next to blower B-250.01
 Pop-up “stand-by” next to blower B-250.01
disappears.
6 1011 disappears. 1011
 Blower B-250.01 started again, only if it was
 Blower B-250.01 started again, only if it was running.
running.
 Pop-up “stand-by” next to final plodder PL-  Pop-up “stand-by” next to final plodder PL-
204.01disappears. 204.01disappears.
 Final plodder PL-204.01started again, only if it  Final plodder PL-204.01started again, only if it was
was running, with a speed equal to the one before running, with a speed equal to the one before pressing
pressing pushbutton “Silo #B” plus X [%]31 for pushbutton “Silo #B” plus X [%]31 for Y”11, then it
7 Y”11, then it will return to the speed before Y”11 will return to the speed before pressing pushbutton Y”11
pressing pushbutton “Silo #B”. “Silo #B”.
 Solenoid valve X-250.101B set to open.  Solenoid valve X-250.101B set to open.
Sequence completed. Sequence completed.
If timer tS expires before completing the sequence, If timer tS expires before completing the sequence, the
the sequence is stopped and alarm is given. sequence is stopped and alarm is given.

61
 The pop-ups “stand-by” next to final plodder PL- The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the 204.01 and blower B-250.01 disappears and the two
two items are stopped. items are stopped.

If all the conditions which permit the selection of soap noodles storage silo D-250.01B are effective, the “Silo #B” button will become grey to indicate
the possibility to activate the sequence itself, otherwise it is yellow (blinking - impossibility of activating the sequence).
When “Silo #B” key is active (i.e. relevant pushbutton pressed, DV-250.01A open in the direction of D-250.01B/C, XY-250.11B open, DV-250.01B
open in the direction of D-250.01B, XY-250.12B open and VF-250.01B open), its colour will be green (still).
While the sequence to open DV-250.01A/B in the direction of silo D-250.01B is running, the colour of “Silo #B” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-250.01B and which ones are currently
activated or missing.

Conditions for silo D-250.01C to be selected are:

 interlocks activated,
 silo D-250.01C high level LSH-250.1C (DI) alarm (LAH-250.1C (DI)) off,
 silo D-250.01C very high level LSHH-250.1C (AI) alarm (LAHH-250.1C (AI)) off,
 exhaust air throttle automatic valve VF-250.01A not in fault,
 exhaust air throttle automatic valve VF-250.01B not in fault,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

62
By pressing the “Silo #C” button, the following operations will be done (4 different conditions are foreseen):

Step Action Duration Action Duration

DV-250.01A open in the direction of silos D-250.01B/C (ZLH- DV-250.01A open in the direction of silos D-250.01B/C (ZLH-250.11
IF 250.11 ON) AND DV-250.01B open in the direction of silo D- ON) AND DV-250.01B not open in the direction of silo D-250.01C
250.01C (ZLH-250.12 ON) (ZLH-250.12 not ON)
 Final plodder PL-204.01 stopped, if running.  Final plodder PL-204.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”11 5”11
PL-204.01 (blinking). 204.01 (blinking).
 Countdown tS11 reset and started.  Countdown tS11 reset and started.
 Blower B-250.01. stopped, if running.  Blower B-250.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”11  Pop-up “stand-by” appears next to blower B-250.01 5”11
250.01 (blinking). (blinking).
 Solenoid valve XY-250.11B set to open.
 Solenoid valve XY-250.12B set to open.  Solenoid valve XY-250.11B set to open.
3 3”11 3”11
 Exhaust air throttle automatic valve VF-250.01C  Solenoid valve XY-250.12B set to close.
set to open.
 Pop-up “stand-by” next to blower B-250.01
Until ZLH-
disappears. Diverting valve DV-250.01B set to open in the direction
4 1011 250.12 is ON
 Blower B-250.01 started again, only if it was of D-250.01C.
+ 6”11
running.
 Pop-up “stand-by” next to final plodder PL-
5 Y”11  Solenoid valve XY-250.12B set to open. 3”11
204.01disappears.

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  Final plodder PL-204.01started again, only if it  Exhaust air throttle automatic valve VF-250.01C set
was running, with a speed equal to the one before to open.
pressing pushbutton “Silo #C” plus X [%]31 for
Y”11, then it will return to the speed before
pressing pushbutton “Silo #C”.
 Solenoid valve X-250.101C set to open.
Sequence completed.
If timer tS expires before completing the sequence,
the sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the
two items are stopped.
 Pop-up “stand-by” next to blower B-250.01
6 / / disappears. 1011
 Blower B-250.01 started again, only if it was running.
 Pop-up “stand-by” next to final plodder PL-
204.01disappears.
 Final plodder PL-204.01started again, only if it was
running, with a speed equal to the one before pressing
7 / / 31 11
Y”11
pushbutton “Silo #C” plus X [%] for Y” , then it
will return to the speed before pressing pushbutton
“Silo #C”.
 Solenoid valve X-250.101C set to open.

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 Sequence completed.
If timer tS expires before completing the sequence, the
sequence is stopped and alarm is given.
The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the two
items are stopped.

Step Action Duration Action Duration

DV-250.01A not open in the direction of silos D-250.01B/C DV-250.01A not open in the direction of silos D-250.01B/C (ZLH-
IF (ZLH-250.11 not ON) AND DV-250.01B open in the direction 250.11 not ON) AND DV-250.01B not open in the direction of silo D-
of silo D-250.01C (ZLH-250.12 ON) 250.01C (ZLH-250.12 not ON)
 Final plodder PL-204.01 stopped, if running.  Final plodder PL-204.01 stopped, if running.
 Pop-up “stand-by” appears next to final plodder  Pop-up “stand-by” appears next to final plodder PL-
1 5”11 5”11
PL-204.01 (blinking). 204.01 (blinking).
 Countdown tA11 reset and started. Countdown tA11 reset and started.
 Blower B-250.01. stopped, if running.  Blower B-250.01. stopped, if running.
2  Pop-up “stand-by” appears next to blower B- 5”11 Pop-up “stand-by” appears next to blower B-250.01 5”11
250.01 (blinking). (blinking).
 Solenoid valve XY-250.11B set to close.
3  Solenoid valve XY-250.11B set to close. 3”11 3”11
 Solenoid valve XY-250.12B set to close.
Until Until (ZLH-
 Diverting valve DV-250.01A set to open in the  Diverting valve DV-250.01A set to open in the
4 ZLH- 250.11 is ON
direction of D-250.01B/C. direction of D-250.01B/C.
250.11 is AND ZLH-

65
 ON +  Diverting valve DV-250.01B set to open in the 250.12 is ON)
6”11 direction of D-250.01C. + 6”11
 Solenoid valve XY-250.11B set to open.  Solenoid valve XY-250.11B set to open.
 Solenoid valve XY-250.12B set to open  Solenoid valve XY-250.12B set to open
5 3”11 3”11
 Exhaust air throttle automatic valve VF-250.01C  Exhaust air throttle automatic valve VF-250.01C set
set to open. to open.
 Pop-up “stand-by” next to blower B-250.01
 Pop-up “stand-by” next to blower B-250.01
disappears.
6 1011 disappears. 1011
 Blower B-250.01 started again, only if it was
 Blower B-250.01 started again, only if it was running.
running.
 Pop-up “stand-by” next to final plodder PL-  Pop-up “stand-by” next to final plodder PL-
204.01disappears. 204.01disappears.
 Final plodder PL-204.01started again, only if it  Final plodder PL-204.01started again, only if it was
was running, with a speed equal to the one before running, with a speed equal to the one before pressing
pressing pushbutton “Silo #C” plus X [%]31 for pushbutton “Silo #C” plus X [%]31 for Y”11, then it
7 Y”11, then it will return to the speed before Y”11 will return to the speed before pressing pushbutton Y”11
pressing pushbutton “Silo #C”. “Silo #C”.
 Solenoid valve X-250.101C set to open.  Solenoid valve X-250.101C set to open.
Sequence completed. Sequence completed.
If timer tA expires before completing the sequence, If timer tA expires before completing the sequence, the
the sequence is stopped and alarm is given. sequence is stopped and alarm is given.

66
 The pop-ups “stand-by” next to final plodder PL- The pop-ups “stand-by” next to final plodder PL-
204.01 and blower B-250.01 disappears and the 204.01 and blower B-250.01 disappears and the two
two items are stopped. items are stopped.

If all the conditions which permit the selection of soap noodles storage silo D-250.01C are effective, the “Silo #C” button will become grey to indicate
the possibility to activate the sequence itself, otherwise it is yellow (blinking - impossibility of activating the sequence).
When “Silo #C” key is active (i.e. relevant pushbutton pressed, DV-250.01A open in the direction of D-250.01B/C, XY-250.11B open, DV-250.01B
open in the direction of D-250.01C, XY-250.12B open and VF-250.01C open), its colour will be green (still).
While the sequence to open DV-250.01A/B in the direction of silo D-250.01C is running, the colour of “Silo #C” key will be green (blinking).
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary to select silo D-250.01C and which ones are currently
activated or missing.

67
If the LAH (DI) or LAHH (AI) of the selected silo goes from off to on, then an alarm is given so that
operator is alerted to manually change the silo. In this case the relevant silo pushbutton becomes
yellow (as per above description), but the valves will remain in the same position until the operator
selects another silo.
Notes:
 if interlocks are activated, to select a silo, it will be necessary to push on the relevant
pushbutton (a proper sequence will put all the valves in the correct position); it will not be
possible to directly open / close any of the diverting valves (DV-250.01A/B),
 to open / close any of the diverting valves (DV-250.01A/B) by pushing on it, interlocks have
to be disabled.

6.25 Silo bottom fluidization

The purpose of the “Silos bottom fluidization” sequences is to allow the injection of compressed air
in the bottom of the silos D-250.01A/B/C to fluidize the noodles providing vigorous pulse shaking to
the noodles in the bottom parts facilitating the relevant discharges, by:
 decision of the operator opening the relevant valves,
 external inputs.

On the video page of TPCP, next to the silo D-250.01A, a table with the following values:
 timer trun, A11 [s],
 timer tstop, A11 [s]
has to be shown. The timers work as countdown.

Conditions for “Silo D-250.01A bottom fluidization” sequence to be effective are:

 interlocks activated,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

When the operator wants to start the injection of air in the bottom part of silo D-250.01A, the solenoid
valve XY-250.201A has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-250.01A,
2. open solenoid valve XY-250.201A for an interval of time trun, A (countdown is shown on the
video page of D-250.01A),
3. when timer trun, A expires, the solenoid valve XY-250.201A is closed and the timer trun, A is
reset,

68
 4. When the solenoid valve XY-250.201A is stopped, timer tstop, A is started (countdown is shown
on the video page of D-250.01A),
5. When timer tstop, A expires, the “Silo D-250.01A bottom fluidization” sequence is restarted
from point 2 and the timer tstop, A is reset.

The “Silo D-250.01A bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101A (one-shot command),
 available open/close signal (available external DI) on (one-shot command)32.

Conditions for “Silo D-250.01A bottom fluidization” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched,
 exhaust air throttle automatic valve VF-250.01A not open after the sequence is started (it’s
not a condition necessary to start the sequence, since it is open by the sequence itself),
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201A
while the sequence is running.
 available open/close signal (available external DI) off32.
When the sequence is stopped, the timers trun, A and tstop, A are reset.

If all the conditions which allow the activation of the sequence are effective, the solenoid valve XY-
250.101A becomes grey without lock to indicate the possibility to activate the sequence, otherwise it
is grey with a lock (impossibility of activating the sequence).
When “Silo D-250.01A bottom fluidization” sequence is active, pop-up “D-250.01A bottom
fluidization ON” is shown, while when the sequence is stopped, the pop-up is hidden.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Silo D-250.01A bottom fluidization” sequence and which ones are currently activated
or missing.

On the video page of TPCP, next to the silo D-250.01B, a table with the following values:
 timer trun, B11 [s],
 timer tstop, B11 [s]
has to be shown. The timers work as countdown.

Conditions for “Silo D-250.01B bottom fluidization” sequence to be effective are:

 interlocks activated,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

69
When the operator wants to start the injection of air in the bottom part of silo D-250.01B, the solenoid
valve XY-250.201B has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-250.01B,
2. open solenoid valve XY-250.201B for an interval of time trun, B (countdown is shown on the
video page of D-250.01B),
3. when timer trun, B expires, the solenoid valve XY-250.201B is closed and the timer trun, B is
reset,
4. When the solenoid valve XY-250.201B is stopped, timer tstop, B is started (countdown is shown
on the video page of D-250.01B),
5. When timer tstop, B expires, the “Silo D-250.01B bottom fluidization” sequence is restarted
from point 2 and the timer tstop, A is reset.

The “Silo D-250.01B bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101B (one-shot command),
 available open/close signal (available external DI) on (one-shot command)33.

Conditions for “Silo D-250.01B bottom fluidization” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched,
 exhaust air throttle automatic valve VF-250.01B not open after the sequence is started (it’s
not a condition necessary to start the sequence, since it is open by the sequence itself),
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201B
while the sequence is running.
 available open/close signal (available external DI) off33.
When the sequence is stopped, the timers trun, A and tstop, A are reset.

If all the conditions which allow the activation of the sequence are effective, the solenoid valve XY-
250.101B becomes grey without lock to indicate the possibility to activate the sequence, otherwise it
is grey with a lock (impossibility of activating the sequence).
When “Silo D-250.01B bottom fluidization” sequence is active, pop-up “D-250.01B bottom
fluidization ON” is shown, while when the sequence is stopped, the pop-up is hidden.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Silo D-250.01B bottom fluidization” sequence and which ones are currently activated
or missing.

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On the video page of TPCP, next to the silo D-250.01C, a table with the following values:
 timer trun, C11 [s],
 timer tstop, C11 [s]
has to be shown. The timers work as countdown.

Conditions for “Silo D-250.01C bottom fluidization” sequence to be effective are:

 interlocks activated,
 exhaust air filter F-250.05 fan or exhaust air filter F-250.06 fan running.

When the operator wants to start the injection of air in the bottom part of silo D-250.01C, the solenoid
valve XY-250.201C has to be open. This operation will:
1. open exhaust air throttle automatic valve VF-250.01C,
2. open solenoid valve XY-250.201C for an interval of time trun, C (countdown is shown on the
video page of D-250.01C),
3. when timer trun, C expires, the solenoid valve XY-250.201C is closed and the timer trun, C is
reset,
4. When the solenoid valve XY-250.201C is stopped, timer tstop, C is started (countdown is shown
on the video page of D-250.01C),
5. When timer tstop, C expires, the “Silo D-250.01C bottom fluidization” sequence is restarted
from point 2 and the timer tstop, C is reset.

The “Silo D-250.01C bottom fluidization” sequence can be started by:

 operator by opening the solenoid valve XY-250.101C (one-shot command),
 available open/close signal (available external DI) on (one-shot command)34.

Conditions for “Silo D-250.01C bottom fluidization” sequence to be stopped:

 one or more conditions necessary to run the sequence not matched,
 exhaust air throttle automatic valve VF-250.01C not open after the sequence is started (it’s
not a condition necessary to start the sequence, since it is open by the sequence itself),
 decision of the operator of stopping the sequence by closing solenoid valve XY-250.201C
while the sequence is running.
 available open/close signal (available external DI) off34.
When the sequence is stopped, the timers trun, A and tstop, A are reset.

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If all the conditions which allow the activation of the sequence are effective, the solenoid valve XY-
250.101C becomes grey without lock to indicate the possibility to activate the sequence, otherwise it
is grey with a lock (impossibility of activating the sequence).
When “Silo D-250.01C bottom fluidization” sequence is active, pop-up “D-250.01C bottom
fluidization ON” is shown, while when the sequence is stopped, the pop-up is hidden.
A dedicated help video page has to be foreseen in order to show all the conditions that are necessary
to activate the “Silo D-250.01C bottom fluidization” sequence and which ones are currently activated
or missing.

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7 APPENDIX

P&I Drawings

Number Section Revision

X-21039-104 Sh. 1 EDTA Section 0

X-21039-117 Sh. 1 to 2 Glycerine and EHDP Sections 0

X-21039-124 Sh. 1 Kettle Section 0

X-21039-126 Sh. 1 to 7 SCTU Continuous Saponification Plant 0

X-21039-201 Sh. 1 C Dryer Plant 0

X-21039-250 Sh.1 to 2 TPCP Pressure Pneumatic Conveying System 0

1
For each control loop, a proper pop-up has to be shown on the video page next to the relevant loop with:
- set point (SP),
- present value (PV),
- output (%) (e.g. valve stroke or motor speed),
- “automatic” / “manual” control selection,
- access to trends visualization and PID management.
2
The maximum flow for FICQ-124.3 control loop (and thus for pumps P-124.03A/B) has to be limited as described here
below:
- if the control loop FICQ-124.3 is in automatic, the maximum set point, that the operator can write, will be 1500
kg/h (10% of the maximum flow of the saponification),
- if the control loop FICQ-124.3 is in manual, the maximum speed (%), that the operator can write, will be 87%
(100% speed corresponds to 60 Hz).
P-124.03A/B – Inverter 100% speed = 60 Hz
1440 kg/h 1500 l/h 50 Hz ~ 83.3%
1500 kg/h 1562.5 l/h 52.1 Hz ~ 86.8%

3
PLC will receive n° 3 input signals from FE/FIT-126.2: n° 3 “4 ÷ 20 mA inputs” to be converted into mass flow rate
(FIT-126.2), temperature (TIT-126.2) and density (DIT-126.2) measurement.
4
PLC will receive n° 3 input signals from FE/FIT-126.4: n° 3 “4 ÷ 20 mA inputs” to be converted into mass flow rate
(FIT-126.4), temperature (TIT-126.4) and density (DIT-126.4) measurement.
5
Auto reset of reactor R-126.02 high pressure PIT-126.10 alarm (PAH-126.10) and reactor R-126.02 low pressure PIT-
126.10 alarm (PAL-126.10) must be foreseen.
6
Auto reset of reactor R-126.02 high temperature TE/TT-126.9 alarm (TAH-126.9) and reactor R-126.02 low temperature
TE/TT-126.9 alarm (TAL-126.9) must be foreseen.
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7
This signal must have a button (shown on the video page of SD-204.01) to enable (ON - green colour) / disable (OFF -
red colour) the function. If it is disabled, the alarm can be given, but any interlock / sequence relevant to it will not be
activated.
8
This signal must have a button (shown on the video page of C-206.03) to enable (ON - green colour) / disable (OFF -
red colour) the function. If it is disabled, the alarm can be given, but any interlock / sequence relevant to it will not be
activated.
9
Connected to physical signal and not to the delay of the alarm (auto reset).
10
EDTA feed tank D-104.01 must have a button to select if the EDTA transfer pump and automatic valve AV-104.4 will
be used on automatic (LSL-104.1 interlocks n. 3 and 4 enabled) or on manual (LSL-104.1 interlocks n. 3 and 4 disabled).
If LSH-104.1 is on, the transfer pump will be stopped and the automatic valve AV 104.4 will be locked to close position
with both the operating modes, manual or automatic (LSH-104.1 interlocks n. 1, 2, 5 and 6); when LSH-104.1 (physical
signal) goes from on to off, the lock on the valve will be removed and the automatic mode will be enabled, if it was
previously selected.
11
Time can be changed in a dedicated video page.
12
“Fault” has to be considered as “not open”. Elements (valves or motors) listed int the “ACTIONS (THEN)” of the
interlock will not be locked only if at least one of the valves listed in the “CONDITIONS (IF)” is open.
13
Glycerine feed tank D-117.06 must have a button to select if the glycerine transfer pump and automatic valve AV-
117.4A will be used on automatic (LSL-117.6 interlocks n. 15 and 16 enabled) or on manual (LSL-117.6 interlocks n. 15
and 16 disabled). If LSH-117.6 is on, the transfer pump will be stopped and the automatic valve AV 117.4A will be locked
to close position with both the operating modes, manual or automatic (LSH-117.6 interlocks n. 13, 14, 17 and 18); when
LSH-117.6 (physical signal) goes from on to off, the lock on the valve will be removed and the automatic mode will be
enabled, if it was previously selected.
14
EHDP feed tank D-117.08 must have a button to select if the EHDP transfer pump and automatic valve AV-117.4B
will be used on automatic (LSL-117.8 interlocks n. 25 and 26 enabled) or on manual (LSL-117.8 interlocks n. 25 and 26
disabled). If LSH-117.8 is on, the transfer pump will be stopped and the automatic valve AV 117.4B will be locked to
close position with both the operating modes, manual or automatic (LSH-117.8 interlocks n. 23, 24, 27 and 28); when
LSH-117.8 (physical signal) goes from on to off, the lock on the valve will be removed and the automatic mode will be
enabled, if it was previously selected.
15
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH-124.104A, start AG-
124.03A and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-124.104A gives only an alarm
(only when signal is on for more than a pre-set time), JAHH-124.104A activates immediately the interlock.
16
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH-124.104B, start AG-
124.03B and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-124.104B gives only an alarm
(only when signal is on for more than a pre-set time), JAHH-124.104B activates immediately the interlock.
17
Brine feed tank D-126.04 must have a button to select if the brine transfer pump and automatic valve AV-126.24 will
be used on automatic (LSL-126.4 interlocks n. 68 and 69 enabled) or on manual (LSL-126.4 interlocks n. 68 and 69
disabled). If LSH-126.4 is on, the transfer pump will be stopped and the automatic valve AV 126.24 will be locked to
close position with both the operating modes, manual or automatic (LSH-126.4 interlocks n. 66, 67, 70 and 71); when
LSH-117.8 (physical signal) goes from on to off, the lock on the valve will be removed and the automatic mode will be
enabled, if it was previously selected.

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18
Control valve is closed when controller is on manual mode with output equal to 0% and relevant XY solenoid valve
closed, while the control valve has to be considered open when controller is on a position different from (manual mode
with output equal to 0%) and relevant XY solenoid valve open.
Example: if the valve is in automatic control with the XY solenoid valve open and output equal to 0%, the valve has to
be considered open.
19
This interlock must have a button (shown on the video page of AV-117.5A) to enable (ON - green colour) / disable
(OFF - red colour) the interlock itself.
20
When AV-204.1 goes from open to closed, after 5” PIC-204.10 is set on manual mode and control valve PV-204.10 is
blocked open 100% (relevant XY solenoid valve is set to open), then valve AV-204.3 opens for 5” (time can be changed
in a dedicated video page). When the blowing time expires, the automatic steam valve AV-204.3 is closed. At this point,
also PV-204.10 is closed (opening 0%, PIC on manual and relevant XY solenoid valve set to close).
21
When AV-204.2 goes from open to closed, after 5” valve AV-204.4 opens for 10” (time can be changed in a dedicated
video page), then the automatic steam valve closes.
22
The value for the alarm can be changed in a dedicated video page (to define a value for JAHH-204.101, start SD-204.01
and after the transitory, verify the torque and add 10% ÷ 15% for safety). JAH-204.101 gives only an alarm (only when
signal is on for more than a pre-set time), JAHH-204.101 activates immediately the interlock / stand-by sequence.
23
Semi-barometric condenser C-206.03 must have a button to select if the level switch LSH-206.3 will be used on
automatic (LSH-206.3 interlocks n. 131 and 132 enabled) or on manual (LSH-206.3 interlocks n. 131 and 132 disabled).
24
High and Very High pressures sets are 25 barg and 40 barg fixed not changeable. Consensus to restart after very high
pressure situation has to be given by operator. Contact type normally closed: in case of wire cutting, system gives alarm.
25
Plodder PL-204.01 must have a button to enable (ON - green colour) / disable (OFF - red colour) the interlocks n. 139
and 140.
26
The value for the maximum selectable speed of blower B-250.01 can be changed in a dedicated video page. The
maximum speed should be limited around 80% (100% - 50 Hz).
27
To be indicated as “Water charge within tolerance” in help page.
28
In general, the “HH”, “H”, “L” and “LL” alarms of all control loops of mass flows will be developed as deviations (%)
between process value and set point.
The deviations will follow the logic here below described.
A dedicated video page will be programmed to:
- input max ± % allowed deviation vs. set point for every mass flow meter loop (can be a different value for any
of the loop),
- input max allowed time (seconds) within which the above deviation is tolerated for every mass flow meter loop
(can be a different value for any of the loop).
Example:
Loop FICQ-126.1A: set point 3000 kg/h (oil #1 to reactor), max allowed deviation ± 0.5% (that is ±15 kg/h), max
allowed time 30” (time can be changed in a dedicated video page).
Suppose that FICQ-126.1A measures at a certain point >3016 (or <2984) kg/h for more than 30” consecutively:
this will activate the “anomalous condition of flow rate deviation”.
It is sufficient that only one of the several mass flow meters goes under this condition to activate the “anomalous
condition”.
Another timer has to be set in order to give the time after which the “deviation of actual flow” will be activated (until the
timer is not expired, the deviation alarms, and their effects, will be disabled):
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 - for FICQ-104.1, FICQ-117.8, FICQ-126.1A, FICQ-126.2, FICQ-126.3 and FICQ-126.4, the timer (one common
timer) will be started with the “Reactor feeding” sequence activation,
- for FICQ-117.6, the timer will be started with the “Additives feeding” sequence activation,
- for FICQ-124.3, the timer will be started when pump P-124.03A (or P-124.03B) is started.
High / Low deviations give alarm only (without delay).
Very high / Very low deviations (after the delay described above) activate “Saponification stand-by” sequence (exception
FICQ-124.3 which only gives an alarm).
A button has to be foreseen for each raw material in order to enable (ON) / disable (OFF) the deviation control.
29
For the pumps P-104.01, P-117.06, P-117.08 and P-126.04, the possibility of excluding the single pumps from the
sequence is foreseen (i.e. don’t need in the current production recipe). If a raw material / additive has been excluded from
the actual recipe (i.e. set point “0” kg/h), it will be ignored by the control system. Exception is made for “Saponification
stand-by” sequence.
30
“Time-out” timers (time can be changed, for each timer, in a dedicated video page) have the purpose to check that the
operations requested by the relevant feeding / recycle sequences have been completed (opening / closing valves) within
the “time-out”.
If one or more operations that should be done by a feeding / recycle sequence have not been completed within the “time-
out”, alarm will be given (further information can be found in sequences section).
If a condition which should trigger the stand-by goes ON or a condition necessary to activate the relevant feeding / recycle
sequence goes OFF, “Saponification stand-by” sequence is immediately activated, also if the time-out timer is still
running.
31
The value for the final plodder PL-204.01 speed increasing can be changed in a dedicated video page. If the speed of
final plodder PL-204.01 given by the speed before silo selection plus X is bigger than 100%, the speed will be limited to
100%.
32
This signal must have a button (shown on the video page of D-250.01A) to enable (ON - green colour) / disable (OFF
- red colour) the function. If it is disabled, the sequence relevant to it will not be activated.
33
This signal must have a button (shown on the video page of D-250.01B) to enable (ON - green colour) / disable (OFF
- red colour) the function. If it is disabled, the sequence relevant to it will not be activated.
34
This signal must have a button (shown on the video page of D-250.01C) to enable (ON - green colour) / disable (OFF
- red colour) the function. If it is disabled, the sequence relevant to it will not be activated.

76