Brix Meter Replacement Work AIO-Sukabumi OC-3 PDF

Brix Meter Replacement Work OC3 PT IWAI DAICHINDO PLANT TECH INDONESIA Work Schedule  Specification 『Brix Meter Replacement Procedure』 for AIO OC-3 ① ＜Hardware replacement＞ 1. Confirmation befo...

Brix Meter Replacement Work OC3 PT IWAI DAICHINDO PLANT TECH INDONESIA Work Schedule  Specification 『Brix Meter Replacement Procedure』 for AIO OC-3 ① ＜Hardware replacement＞ 1. Confirmation before replacing dimension and wiring 2. Check on PLC communication with the unit 3. Turn off the unit 4. Replacing with new unit 5. Replace the wiring 6. Organize wiring 7. Turn on new unit power ② ＜Program update＞ 1. Comparison on the back-up data 2. Stop the PLC after the back-up match 3. PC parameter (switch setting) change writing 4. Program file batch writing 5. Reset PLC 6. Run the PLC 7. Run PC diagnose and confirm of no error 8. Save program back-up  Specification 『Brix Meter Replacement Procedure』 for AIO OC-3 ③ ＜New Brix Meter unit check ＞ (Stand alone) 1. Operation using actual liquid syrup (measured by circulating it in the blender unit with manual operation included) 2. Pass if within the margin of error. 3. Records are made of Brix meter indicator numbers and PLC monitor, TP monitor display, and SCADA monitor display, respectively. Test Liquid Sensor Difference PLC Difference Difference Touch Panel SCADA Unit PLC (Base) Display (Base – Sensor) Value (Sensor – PLC) (Base – PLC) Display Display Pass/Fail Pass/Fail 1 5.95 5.984 -0.034 5.995 -0.011 -0.045 5.995 5.995 Pass Pass 2 6.36 6.358 0.002 6.370 -0.012 -0.010 6.370 6.370 Pass Pass 3 6.26 6.263 -0.003 6.275 -0.012 -0.015 6.274 6.275 Pass Pass 0.05% AIO Production Standard Center SP 6.29% (passing range in production; upper limit is 6.64%, lower limit is 5.94%) ±0.35 Brix SP used upon production is 6.16% *The accuracy of the sensor alone in the Atago instruction manual is ±0.05%.  Specification 『Brix Meter Replacement Procedure』 for AIO OC-3 ③ ＜New Brix Meter unit check ＞ (Stand alone) 2nd test 1st test Sensor Display TP Display Sensor Display TP Display AIO Base Liquid AIO Base Liquid  Specification 『Brix Meter Replacement Procedure』 for AIO OC-3 ③ ＜New Brix Meter unit check ＞ (Stand alone) 3rd test Sensor Display TP Display AIO Base Liquid  Specification ④ ＜Others ＞ 【 Issue on proximity switch input of SB2101 and SB2102】AIO OC-3 requested investigation to determine the cause of the problem and the result as follows: Investigated the wiring in the SB2101 field pull box and found an error in the connection. We have already modified the wiring according to the panel wiring diagram shown on the right. Please check the wiring of SB2102 by the customer in the same way. Since COMs are common, P1, P2, and C1 are connected to the same terminals. Please check the cable from the panel to the pull box by wire number or wire color. After correcting the wiring, an I/O check was performed and the inputs of P2 and C1 returned to normal. However the P1 input still on the same condition the possibilities are as follows: 1. The proximity switch are broken 2. Is the PLC P1 address X76 is forced to have the output ON? Please have a hearing inside AIO. If the P1 are set forced output to be always on please cancel it and please check if the problem is solved by I/O check after canceling the forced output. *Note: If in the future AIO need a SB proximity switch for IWAI equipment, please contact us for a quote.  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Analysis of the most recent temperature drop occurrence from SCADA records (November 14, 2024, 10:29 a.m. Temperature drop occurred. *Sterilizer all trend instrument data *Flowrate and Temperature data  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Information based on hearing interview with OC-3 ・About one year ago, a drop in sterilization temperature began to occur after the equipment sterilization temperature stabilized 2. After the temperature drop occurs, the equipment is cooled and restarted. At that time, the equipment is started up by manually supplying water to the hot water system. (There are cases of failure.) ・Aging equipment around the hot water system has already been replaced with new equipment one after another (relief valves, etc.). ・P412 is being replaced with a PB pump instead of a PA pump. (March 2024) *P411 has already been replaced with a PB pump. (The current operator's understanding is that it has been a PB pump from the beginning. However, according to IWAI delivery records, PA pumps were initially delivered.) ・The customer changed the sterilization temperature setting of the equipment from 125°C to 130°C. The reason was that TIA415 on return had to be set to 125°C, so the setting was raised. (In the software, the TM count condition is 121°C or higher. (The TM count condition in the software is 121°C or higher, but this setting was probably made at the customer's request when the equipment was first delivered.)  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Assumption based on SCADA record condition. ・Temperature drop occurs about 1 min after entering ST8 stabilization 2. Cooling temperature is fine after entering ST7 stabilization 1. As for the flow rate, it drops momentarily upon switching to ST8 and then rises to match the flow rate selection of 15 t/h. There seems to be no major problem with this either. ・Similarly for the pressure, there is a momentary blip when ST8 is switched from a closed loop to an open loop, but after that it quickly settles back to the pressure balance for water operation, so there seems to be no major problem. ・It is possible that the hot water line is just before boiling or is boiling. ・checked the historical IWAI parameter backups and found that the temperature setting for instrument sterilization for TICA 412 was 125°C. The TM count requirement for sterilization retention is 121°C or higher. ・Upon interview, we were informed that at some point the TICA412 setting was changed to 130°C so that TIA415 (return) would be 125°C. This may have caused the hot water line to exceed the boil suppression pressure. ・Based on the above, we assumed that cooling began during stabilization and that the hot water line cooled down, resulting in insufficient hot water flow due to condensation, which made it difficult to control the temperature of TICA 412.  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Advice and Suggestions. ・From the results of this survey, we assume that some of the previous changes (including parameter changes) have had some impact. ・If possible, please try to test TICA412 with the SP4 setting back to the original 125°C. If it now starts up without showing a temperature drop, this may prove that this setting change is the cause. ・However, since AIO has been managing the sterilization temperature of the equipment at a higher temperature for some time, it may be difficult even within the customer to lower the temperature setting without clarification of the past history, etc. ・We will provide an estimate for re-adjustment of sterilizer. (3 days of work; 2 days for test run and adjustment, 1 day to witness the operation) + expenses.  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Hardware inspection. *Hardware equipment inspection is performed, however no particular problem areas are found. Reference information: Explanation of how to supply water to the hot water system after plate disassembly and maintenance (Water is drained from the hot water circulation line when the hot water line is disassembled or the plate is disassembled). 1. No.1 ball valve close. 8. Close ball valve No.3. 2. No.2 ball valve open. 9. Close ball valve No.2. 3. No.3 ball valve open (Half). 10. Confirm flow indicator No.5 stable. 4. No.4 HWP ON. 11. HWP No.4 OFF. 5. Confirm flow indicator No.5 have flowrate. 6. Confirm sight glass No.6 that air are discharged. 7. Once it is confirmed that some air has been discharged from the sight glass. (Continue to No.8),  Specification ④ ＜Others ＞ 【 OC3 product sterilizer Temperature drop occurs frequently in the temperature stabilization 】 Other request ・Regarding the HTU outlet temperature TIA413 (2 elements), AIO had previously purchased a thermometer made by EH and had to replace it once every 2 weeks due to cracks. ・Currently, AIO purchases a thermometer from IWAI (Okazaki), which has been replaced for a month and no cracks have appeared yet. AIO will continue to monitor the situation. Thank You