Functional Design Specification PPLLP v2.0

SSM InfoTech Solution Pvt. Ltd.
Project No: 1000515

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

X-force Recipe and SCADA System for Pramod paint
(Asian Paints)
Version Description of Change Prepared By Reviewed By Date

P0 Initial draft Nirav Mistry Vijay Ahire 7th Jan 2022
A1 Approved by customer
PRAMOD PAINTS LLP

SSM InfoTech Solution Pvt. Ltd. Project No: 1000515
Index
1. INTRODUCTION.................................................................................................................................... 3
2. PURPOSE.............................................................................................................................................. 4
3. SCOPE.................................................................................................................................................. 4
3.1 SCADA SYSTEM................................................................................................................................. 4
3.2 BATCH SYSTEM................................................................................................................................. 4
3.3 CONTROL SYSTEM............................................................................................................................ 4
4. ASSUMPTIONS...................................................................................................................................... 4
5. ABBREVIATIONS................................................................................................................................... 5
6. FUNCTIONAL REQUIREMENT................................................................................................................ 6
6.1 EXISTING SYSTEM ARCHITECTURE..................................................................................................... 6
6.2 PROPOSED SYSTEM ARCHITECTURE.................................................................................................. 7
6.3 PROCESS DATA FLOW....................................................................................................................... 8
7 USER REQUIREMENTS........................................................................................................................... 9
8 PLANT OPERATION............................................................................................................................. 10
8.2 PROCESS OVERVIEW....................................................................................................................... 11
8.2.1 SFG PRODUCTION (BLACK BOX)........................................................................................................ 12
8.2.1.1 WEIGH CAPTURE............................................................................................................................. 13
8.2.2 FG PRODUCTION............................................................................................................................... 14
8.2.2.1 RM WEIGHT CAPTURE..................................................................................................................... 16
8.2.2.2 BB WEIGHT CAPTURE....................................................................................................................... 17
8.2.2.3 MIXING........................................................................................................................................... 17
8.2.2.4 PACKING......................................................................................................................................... 18
8.2.3 QC LAB............................................................................................................................................. 19
9 REPORT.................................................................................................................................................... 20
9.1 BATCH REPORT...................................................................................................................................... 20
9.2 PACKING REPORT.................................................................................................................................. 20
9.3 QC REPORT.......................................................................................................................................... 21
PRAMOD PAINTS LLP

1. INTRODUCTION
The Pramod paints is located at Piduguralla, Guntur, and Andhra Pradesh. There is only one type of
product is being manufactured and 5 type of packing at plant.
For manufacturing Plant is equipped with Weigh hopper, Blender (mixer), weigh scale, packing
machine etc. On daily basis, operator receives work order on printed paper containing batch
information, control instructions, and quality checks etc. Operator prepare material required for the
batch and uses HMI panels to control the equipment such as mixer, valve etc. Supervisor make
entry in register of batch information which collected during manufacturing process.
SCADA and BMS system to be implemented to automate/digitize manufacturing process and reduce
paper based operations.
Manufacturing order/Batch information will be entered by operator in to BMS system. Batch

information will be displayed in to the SCADA system. Operator can select, and start respective batch
on the equipment. Information related to the phase wise material addition and other control
instruction will be visible while operation/phase is in progress. Control instructions such as mixer
speed in RPM, Mixing time will be passed to the control system (PLC). Inputs from operators will be
collected for physical checks. At the end, Batch report will be facilitated to view batch information
containing all the phases and material addition along with control instructions and data collected
during manufacturing.
This document further describes functional design detail for the SCADA and BMS system to be
designed/implemented for Pramod paints (Asian Paint) plant.
PRAMOD PAINTS LLP

2. Purpose
The purpose of the document is to define overall all system components and its functions such
as SCADA system, Batch system and process control system.
3. Scope
The scope of the document is to define functionalities for system component
3.1 SCADA System

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

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

Control system will have logic to control phase for the recipes. Phase logic will be defined and
owned in PLC. PLC will be interfaced with field equipment such as Blender, weigh scale, valve,
VFD, PLC logic will control the field equipment plus operator has facility to run equipment from
the HMI as well.
4. Assumptions
Following are the assumptions for the project.
• Operation will be kept manual and operator driven, System will provide guidance, but
supervisor may decide to run mixer for more time than the prescribed by the recipe and
control parameters.
• All process parameter will be provided to SCADA through PLC
• Required logics and interlock are programmed in PLC.
• There are recipes will be configured in the SCADA or Batch system. Recipes will have fixed
phases however material quantity, and control instruction such as mixing time can be
dynamic. Phases cannot be dynamically added/removed in recipe. If such requirement rarely
exists, then automation, batch system side development will be required.
• All mixer and valve control done through PLC and HMI
PRAMOD PAINTS LLP

5. Abbreviations
Abbreviations Description
BOM Bill of Material
RM Raw Materials
RPM Revolution per minute (RPM) is a Unit of Measure
SCADA Supervisory Control and Data Acquisition
HMI Human Machine Interface
XBMS X-force Batch Management System
PLC Programmable logic controller
FG Finish goods
BB BalckBox
WS Weigh scale
RAL Rotary Air lock
Table 1 - Abbreviation
PRAMOD PAINTS LLP

6. Functional Requirement
6.1 Existing System Architecture
6 packing
machine 2 BB weigh scale
Figure 1 - Existing System Architecture
- Plant is equipped with 3 weigh hopper, 3 Blender system, 3 packing hopper and control
valves.
- All mention field equipment’s are controlled by PLC AB micro 850 system individually.
- HMI is used to operate machine via PLC.
- Packing system is control and monitored by VT corp controller it works separately from PLC.
- Weigh scale used for weighment of RM for Black Box preparation is done separately not
integrated with any control system.
PRAMOD PAINTS LLP

6.2 Proposed system Architecture
Figure 2 - Proposed System Architecture
Above figure shows proposed system architecture in which 3 individual PM system, Weigh scale and
packing machine system are integrated with one application.
- To achieve integration with existing HMI and PLC connected to Port switch and port switch
further connected with HUB switch.
- Weigh scale are facilitated with TCPIP and can communicate with PLC through HUB switch
connection.
- VT Corp controller has RS485 provision which can convert to ModbusTCP using converter
VT Corp packing system controller communicate with PLC through HUB switch connection.
PRAMOD PAINTS LLP

6.3 Process data Flow
Feild equipment PLC Thin client & Mobile client
weigh scale Allen bradly MIcro850 SCADA

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

SN SFG Source for source for PLC

(Black box preparation) SCADA

1 Weight of DOLOMITE (Kg) PLC BB1 WS
2 Weight of Tylose (Kg) PLC BB1 WS

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

SCADA
1 Weight of DOLOMITE (Kg) PLC weigh hopper RM
2 Weight of White cement (Kg) PLC weigh hopper RM
3 Weight of SFG (black box) (Kg) PLC weigh hopper BB
4 RM1 discharge time PLC logic in plc
(weigh hopper to blender) (min)
5 BB discharge time PLC logic in plc
(BB weigh hopper to blender) (min)
6 Mixing time (min) PLC logic in plc
7 FG discharge time PLC logic in plc
(blender to packing hopper) (min)
8 FG bags weight (Kg) PLC or VT corp controller
Direct VT corp controller
9 FG bags count (Nos.) PLC or VT corp controller
Direct VT corp controller
10 QC Parameter Manually entered by
Operator
7 User Requirements
User requirements for SCADA and Automation systems are as below;
• Batch Management system to control and run recipe through automation system.
• Visualization tool for Operator/supervisor interaction with Automation and Batch
Management system.
• Record process parameter (Mixing time, material transfer time, Weigh of RM and FG,
counts of FG bags.
• Batch report including batch information such as materials, weights, control parameters,
and quality parameters.
PRAMOD PAINTS LLP

8 Plant operation
8.1 Process Flow legends
The process flow depicts user interaction, process flow, and user actions/activity. To read the
process flow in the respective sections Following legends are used.
Symbol Description
User action in system interface

User action
User physical actions

User physical
action
Process or sub process

Process/
sub
process
Non digital process or paper based operation
Manual
operation
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8.2 Process overview
 Production involves with multiple process flow like Semi finish goods batching process,
Finish goods batching process, SFG packing process, FG packing process and QC process.
All this process are concluded in overall process flow chart.
 As per production planning and scheduling, No. of batch/ day are created as per daily
schedule and machine capacity based on which finish goods (FG) are Produced. In process of
FG production various process of weighing, mixing and transfer of material will be held.
 To support proper FG mixing process, semi finish good (Black Box) batching process is
executed. As per FG production qty, RM for black box is decided to produce SFG. SFG
production contains process of RM weighing, mixing, and packing. SFG produced will further
used in FG production.
 On completing of FG production, packing process starts. FG packing involves bag Filling, bag
counting and weighing process.
 QC lab process support to check Quality parameters of produced FG. QC samples are
taken during packing process. Once QC test is passed overall batch is completed.
Figure 3 – Process overview

8.2.1 SFG production (Black box) Flow Diagram
START
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Production
planning
/scheduling
Production Personal:
Create PO Supervisor enter PO details as per planning
(Refer 1st screen BB PO Creation)
Start batch
Supervisor select batch and press start button
(Refer 2nd screen BB Mixing)
Weighment of
RM Production Personal:
1. Supervisor guide workman to pick RM as

defined in Recipe
2. Workmen place Raw materials on weigh
Record RM scale as per Supervisor guidance
Weight 3. Supervisor gives confirmation on Tab once
suitable weight is displayed
More RM
to weigh?
YES
NO
RM charging
in Blender
Mixing
proces
s Production Personal:
1. Fill SFG In bags and put on weigh scale

SFG filling
& weighing
Weight Production personal:
capture 1. Supervisor gives confirmation on Tab once

suitable weight is displayed
END
1. BB PO creation
Step1 : open BB po selection screen
Step2 : select qty. of BB
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Step3 : PO number will generate automaticaly and recipe for given qty. will displyed
2. Black Box Select and start Batch

Step1: Next navigate to BB phase control screen
Step2: select PO and select machine
Step3: As per machine capacity no. of batch created
Step4: select batch and press start
Step5: Batch status will updated as shown in image
3. Black Box Weighment of RM
Step1: After starting batch navigate to RM

Step2: press start for weighment
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Step3: put one by one material on scale

Step4: press accept to capture correct weight
Black Box Packing and weighing
Step1: on completing mixing navigate to packing

Step2: to start packing select batch ID and weigh scale
Step3: start weighment of packed bag and put bags on weigh scale
Step4: No. of bags counts updated on pressing accept button
Step 5: on completing all bags weighing press weighment completed and BB batch end here
8.2.2 FG production
START
Launch work orders on Daily and Daily+1 basis
PRAMOD PAINTS LLP

Production
planning
/scheduling
Production Personal task in BMS

Create PO
1. Add work order details in BMS
2. Release work order
3. Selects product code, work order and starts the
Batch
Start batch
Production personnel
Weighment of 1. Supervisor guide workman to pick RM as
defined in Recipe
SFG (black box) 2. Supervisor guide other workman to Pick
specific batch of BB
3. Supervisor enter specific BB batch no. in BMS
4. Workman charge BB in BB weigh hopper
Record RM Record BB 5. Workmen charge RM in Weigh hopper
Weight Weight
Production personnel task in BMS
More RM Ensure correctness of RM & BB weight as

to weigh? per recipe and record the weight in tab
YES Production personnel task in BMS
Add multiple RM as define in recipe
Start RM Start BB
discharge in Discharge in
Blender Blender
NO
Production personnel task with existing HMI
Post RM charging in weigh hopper
Mixing Start discharge hopper in blender
On completing of 50% RM, BB discharge start
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Production personnel
Transfer FG On completing mixing time blender valve will be

open by supervisor to transfer material from blender
to packing hopper, on completing transfer blender
valve will be closed
Packing
END
Create PO
Step1: Select Finish good button and select PO creation
Step2: select finish good and Qty. as per planning
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PO number will generate automatically, and recipe will be displayed as per machine capacity and
planed Qty.
Batch control pahse
Step1: Next navigate to finish good phase control screen

Step2: select PO and select machine
Step3: As per machine capacity no. of batch created
Step4: select batch and press start
Step5: Batch status will updated as shown in image
8.2.2.1 RM Weight capture
RM weight capture is PLC auto process.
Step1: Press weighment for RM weighing process

Step2: select Batch ID and press start weighment
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Step3: workman charge 1st RM as per recipe through gayroshaker and bucket conveyor
Weigh value displayed in actual weight
Step4: On reaching target weight of 1st RM gayroshaker and bucket conveyor stopped
Step5: to capture weight press accept
Step6: For next RM charging production personnel give command from HMI
Step7: For Multiple RM charge step1 to 6 is repeated
8.2.2.2 BB Weight capture

Black box charging is same process as define for RM weight capture bur Weigh hopper will
be change
.2.2.3 Mixing
Mixing is PLC auto process as below
- Post discharging of all RM in blender RM weigh hopper and BB weigh hopper valve
closed.
- After closing of all valve mixing timer start in plc and same value displayed in BMS
- Timer stopped while mixing timer = preset mixing time
- Mixing time capture in to BMS through PLC.
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8.2.2.4 Packing
Packing is semi auto process perform by VT corp controller system.

Step1: work man put nonwoven sack to packing outlet
Step2: work man press button to fill bags
Step3: VT corp controller get command to fill bag
Step4: packaged bag weight and no. of bags captured by BMS system through VTcorp
system
8.2.3 QC LAB
QC is sample analysing process done by lab personnel
Step 1: QC personnel take sample during packing
Step2: select batch no: in system
Step 3: perform test as required
Step 4: Enter QC parameter Value in system
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Step 5: if QC parameter Actual value meets LSL and USL criteria system displayed pass or fail status
in final remarks
Step 6: on completing QC LAB personnel press completed button
9 Report
Production personnel will able to generate report and will be in following format
9.1 Batch Report

To create batch report navigate to report screen and select batch report, select batch to generate
report
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9.2 Packing Report

report
.3 QC Report
report
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PRAMOD PAINTS LLP

Functional Design Specification PPLLP v2.0

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SSM InfoTech Solution Pvt. Ltd.

Project No: 1000515

FUNCTIONAL DESIGN SPECIFICATION

Version Description of Change Prepared By Reviewed By Date

PRAMOD PAINTS LLP

PRAMOD PAINTS LLP

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

PRAMOD PAINTS LLP

3.1 SCADA System

3.2 Batch System

3.3 Control System

PRAMOD PAINTS LLP

BOM Bill of Material

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

SCADA Supervisory Control and Data Acquisition

HMI Human Machine Interface

XBMS X-force Batch Management System

PLC Programmable logic controller

RAL Rotary Air lock

PRAMOD PAINTS LLP

6.1 Existing System Architecture

Figure 1 - Existing System Architecture

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6.2 Proposed system Architecture

Figure 2 - Proposed System Architecture

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6.3 Process data Flow

Feild equipment PLC Thin client & Mobile client

weigh scale Allen bradly MIcro850 SCADA

PRAMOD PAINTS LLP

SN SFG Source for source for PLC

2 Weight of Tylose (Kg) PLC BB1 WS

SN FG Source for Source for PLC

User requirements for SCADA and Automation systems are as below;

PRAMOD PAINTS LLP

8.1 Process Flow legends

User action in system interface

User physical actions

Process or sub process

PRAMOD PAINTS LLP

8.2 Process overview

Figure 3 – Process overview

PRAMOD PAINTS LLP

Create PO Supervisor enter PO details as per planning

(Refer 1st screen BB PO Creation)

(Refer 2nd screen BB Mixing)

1. Supervisor guide workman to pick RM as

1. Fill SFG In bags and put on weigh scale

Weight Production personal:

capture 1. Supervisor gives confirmation on Tab once

PRAMOD PAINTS LLP

2. Black Box Select and start Batch

3. Black Box Weighment of RM

Step1: After starting batch navigate to RM

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Step3: put one by one material on scale

Black Box Packing and weighing

Step1: on completing mixing navigate to packing

Launch work orders on Daily and Daily+1 basis

PRAMOD PAINTS LLP

Production Personal task in BMS

Production personnel task in BMS