Wet Seal Rig Fds

Functional Design Specification for Seal A-D test rig.
Functional Design Specification

for
Seal A-D test rig
Prepared by: Tony Whiting

Javelin Controls Ltd
Prepared for Prospective Client.
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WetSealRigFDS Javelin Controls
Section 1 F.D.S....................................................................................................4
1.0 F.D.S Overview & Fundamentals....................................................................4
1.1 Test Rig Fundamentals...................................................................................4
Section 2 - Cimplicity System ............................................................................5
2.1 PC Requirements............................................................................................5
2.2 Communications. ............................................................................................5
2.3 Software..........................................................................................................5
2.3.1 Operating System ........................................................................................5
2.3.2 Utilities Norton Ghost ...................................................................................6
2.3.3 Utilities PC Anywhere ..................................................................................6
2.3.4 Cimplicity HMI Plant Edition .........................................................................6
2.3.5 Cimplicity Web View ....................................................................................6
2.4 Cimplicity Application ......................................................................................7
2.4.1 Supervisors set up screen............................................................................7
2.4.2 Operators set up screen ..............................................................................8
2.4.3 Operators Start Screen ..............................................................................11
2.4.4 Plant Graphic Screen with Alarm Banner...................................................11
2.4.5 Sensor & Transducer Screen.....................................................................13
2.4.7 Historic Data Compare...............................................................................15
Section 3 Loading Component and preparation for testing..........................16
3.1 Flood the System and Evacuate Air..............................................................16
3.2 Pressurising System. ....................................................................................16
3.3 Circulate Water. ............................................................................................16
3.4 Temperature Control.....................................................................................16
3.5 DC Motor control...........................................................................................16
Section 4 Control Panel HMI (Human Machine Interface) .............................17
4.1 HMI. ..............................................................................................................17
Section 5 Water Temperature Control.............................................................18
5.1 Cooling Loop PID..........................................................................................18
5.2 Heating Loop PID..........................................................................................18
Section 6 Pneumatic components & water pressure Control .......................19
6.1 Pneumatic Components................................................................................19
6.2 Water Pressure Control ................................................................................20
Section 7 Water Usage .....................................................................................21
7.1 Water Usage Detection.................................................................................21
7.2 Terminal Connections ...................................................................................21
7.3 XT950 Field Connection Terminals...............................................................21
Section 8 Motor, Drive & Motor Speed Transducer ......................................22
8.1 Motor.............................................................................................................22
8.2 Drive .............................................................................................................22
8.3 Motor Speed Tacho ........................................ Error! Bookmark not defined.
8.4 Motor Speed Pulse .......................................................................................22
Section 9 Torque Transducer ..........................................................................23
9.1 Torque Transducer .......................................................................................23
Section 10 Flow Transducer ............................................................................24
10.1 Flow Transducers .......................................................................................24
Section 11 Program Logical Controller (PLC) ................................................29
11.1 PLC Overview .............................................................................................29
11.2 PLC Components........................................................................................29
11.3 PLC I/O Description. ...................................................................................31
Section 12 Safety Circuit..................................................................................34
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12.1 Safety Circuit...............................................................................................34

Section 13 Electrical drawings ........................................................................36
13.1 Electrical Drawings .....................................................................................36
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Section 1 F.D.S
1.0 F.D.S Overview & Fundamentals
This F.D.S. is designed describe control philosophy of the A-D test rig as
interpreted by Javelin Controls. The purpose of and F.D.S is to highlight and
describe in detail each section of the test rig. Each section should then be
debated and edited to the satisfaction of all interested parties. The finished
document will describe the function and control philosophy of the test before
material purchase and manufacture.
1.1 Test Rig Fundamentals
The test rig described in this document is designed to test seals and record the
information on a PC for further analysis. It is also designed to automatically
protect against critical seal failure by stopping the test when test limits have been
exceeded.
The test rig is designed to control the environment of the test by controlling motor
speed, water inlet temperature and water pressure.
Various sensors and transducers monitor temperatures, pressures, speed,

torque, flow water usage etc. All information from the sensors will be saved by a
PC system at a sample rate dictated by the operator/supervisor.
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Section 2 - Cimplicity System
2.1 PC Requirements
PC Requirements
For the Cimplicity platform to work reliably we suggest a minimum hardware

specification for the PC:-
1 Intel 2.0 Ghz processor.

2 256Mb fast access RAM.
3 40 Gb IDE Hard Disk. & 1 x
Removable Caddies.
4 48 Speed CD/RW
5 1.44 Mb Floppy disk drive.
6 10/100 Network Card
7 56.6K Modem PCI Modem
8 64Mb ATI Radeon 7000 RTL
Graphics Card
9 PS2 Mouse & Keyboard.
2.2 Communications.
The Alan Bradley PLC communicates to the PC in RS232 using the DF1
Protocol. The effective range of RS232 commutations is limited to 50 feet. To
communicate over larger distances we need to convert the RS232 to RS485 with
a converter mounted local to the PLC. The RS485 will then need to be converted
back to RS232 local to the PC. The converters we intend to use are ‘ADAM 4520
Isolated 232/485 Converter & Brainbox Velocity RS232 & RS485 Serial PCI
Card.
2.3 Software
2.3.1 Operating System
Windows XP professional.
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2.3.2 Utilities Norton Ghost
Norton Ghost
• This is recommended as it would allow complete system backups

including the Operating System and Cimplicity System and Gathered data
acquired into SQL.
• Windows-based Interface: Provides the ability to configure and execute
imaging/backup sessions without relying on the traditional DOS shell and
Boot Diskette.
• Expanded list of supported CD/RW device: Provides the ability to write
Ghost Images for recovery directly to a broad range of devices supporting
recordable CD.
• Partition Cloning: Allows you to clone one or more individual partitions
rather than just the entire hard drive.
2.3.3 Utilities PC Anywhere
Norton PC Anywhere.
I believe you have non-Norton version of PC anywhere. I am sure this will suffice
but I do not have any details on this product. We assume that we would have
access to this particular software to allow us to remotely administer the system if
required.
2.3.4 Cimplicity HMI Plant Edition
Cimplicity is a SCADA (Supervisory Control and Data Acquisition) system

developed by GE Fanuc.
We suggest using the latest revision of this software, namely Cimplicity Plant
Edition, Version 6.0 – 75 Tag Runtime / Development with Allen Bradley DF1
communications Protocol. – This is currently being released with Service Pack 2.
The system has the ability to log data in a Microsoft SQL Compatible database
format. The system can be scaled as needs arise, and is currently widely used in
manufacturing industry, where reliability is a foremost priority
2.3.5 Cimplicity Web View
Cimplicity Webview, is an additional license which can be purchased which

allows all of the Cimplicity Graphics to be served up as web pages and viewed
using internet explorer on any networked computer.
The functionality can be restricted which would stop people from actually
stopping and starting tests or adjusting set points – however you would get full
real time information over the web as if you were sat at the test rig.
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2.4 Cimplicity Application
General
The Cimplicity Application will be developed in such a way that it can always be
modified or added to at a later date, using consistent looking graphics, point
naming conventions and Scripting documentation.
Every screen (Graphic) will have a common title bar and alarm banner at the
bottom of the screen.
Colour coding will be used to define certain states – e.g. red = alarm state, green
= healthy.
2.4.1 Supervisors set up screen
The set up screen has two levels. The first level is password protected to restrict
access to supervisors. The operators will be able to see the data, however they
will not be able to change any of the inputted values. In the supervisor screen the
system limits can be edited.
• The maximum permitted torque.

• The maximum permitted seal outlet temperature.
• The maximum permitted seat temperature.
• The permitted deviation from set point pressure.
• The permitted deviation from set point RPM.
• Acceptable flow rate.
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• Test duration.
• Data sample rate (see Note 1).
Note 1:
High sample rates will produce large files that create their own problems in
storage and can become unwieldy. By producing low sample rates the file can
lack meaningful data. To help with this quandary we suggest that we have a
second file that will continuously monitor the previous 30 min data at a very high
sample rate. This file will only be saved if the seal fails during a test. This high
resolution file can then be examined for clues to the seal failure. Should a test
not last 30 min only the high resolution file will be saved.
2.4.2 Operators set up screen
When a new seal is to be tested the operator enters the test parameters and
alarm values into the seal set-up screen. All parameters will have to be filled in
to enable the test to start.
Parameters. Description
1 Tester Name Selected from a drop down list box. When selected
the operator will be asked for a unique password.
2 Component No Unique number used to describe seal.
3 Text Box Free form text box for operator to describe special
properties of the seal under test.
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4 Direction of rotation This has to be entered and confirmed by the

operator.
5 Maximum normal The system will be set up with max permitted
running torque & trip torque limit set at 199 Nm. If this is exceed for
settings. more than 1 second the motor will shutdown.
Their will also be an adjustable torque limit that

can be set by the operator. This torque limit can be
disabled when required.
Note 1: With torque limit on the rig will adjusted the

acceleration ramp to keep torque below set point.
Note 2: There will be a window of time to achieve

set speed without reaching torque limit. If this time
is exceeded the test will be abandoned and an
alarm raised.
6 Test Speed. Sets the motor R.P.M that the test is to be carried
out at.
7 Inlet water temperature The operator sets the seal inlet water temperature.
There will also be a maximum permitted
temperature.
Note 1: The water inlet temperature is monitored

against the water outlet. Should the inlet water
temperature be higher than the outlet the
observation will be alarmed (probable incorrect
flexible pipe connection)
Note 2: To filter out nuisance trips the inlet water

temperature will have to exceed the set point for
one second.
8 Maximum outlet The operator sets the maximum acceptable seal

temperature. outlet temperature.
Note1: Setting the maximum temperature takes

into account temperature differentials between
inlet and outlet. i.e. if maximum outlet temperature
is 80º C with an inlet temperature of 25º C the
temperature differential is of 55º C. Should the
inlet temperature raise to 30º C the maximum
outlet temperature set point will be raised to 85º C.
Note 2: To filter out nuisance trips the outlet

temperature will have to exceed the set point for
one second.
9 Water Pressure set The water pressure will also have alarm points for
-9–
point & high low high and low pressure.

alarms.
Note 1: To filter out nuisance trips the water
pressure will have to reach an alarm set point for
one second.
10 Seal circulation or When the type of circulation has been selected a

pumped circulation. text screen will display which valves should be
open and which valves closed for the test to
commence.
11 Left hand seat Sets the maximum permitted temperature for the
maximum permitted left hand seals.
temperature.
Note 1: To filter out nuisance trips the seat
temperature will have to reach an alarm set point
for one second.
12 Right hand seat Sets the maximum permitted temperature for the
maximum permitted right hand seals.
temperature.
Note 1: To filter out nuisance trips the seat
temperature will have to reach an alarm set point
for one second.
13 Test duration The operator sets the test duration within the limits
set by the supervisor.
- 10 –
2.4.3 Operators Start Screen
The operator opens the “start up screen” in Cimplicity. This screen checks that
the rig is ready to start the test. It will instruct the operator what actions are
necessary to facilitate the test.
• Clear water usage load cell containers?

• Add water to Haskel storage tank?
• Is the factory air pressure OK?
• Is chiller on and is cooling water at set temperature?
• Is the circulation water pressure at set point?
• Is the circulation water temperature at set point?
• Is the heating loop working and is the inlet temperature at set point?
• Is the drive healthy and is the motor at set speed?
• Is water flow within acceptable range?
When all conditions have been met the “start button” will be made available on
the start up page. Once the operator has selected the start button the Cimplicity
test will begin and the data will start to be recorded.
Once the test has started all control push-buttons mounted locally to the test rig
will be disabled. The emergency stop buttons will remain active.
2.4.4 Plant Graphic Screen with Alarm Banner
- 11 –
When the test has been started the operator has a choice of running screens, the
first is an animated graphic of the test rig.
It will display the various pressures, temperatures, torque, speed, levels and flow
rates etc in text boxes located in the appropriate position on the graphic. The
hand and automatic valves will be displayed in their current positions. The level
of the water on the load cells will be displayed graphically and a text box water
usage in ml per hour.
The flow rate will be displayed in litres per min. The PLC will calculate the energy
produced by the seal by measuring the volume of water and the change of water
temperature between inlet and outlet manifolds. The energy produced will be
displayed in Watts.
The colour of the text will change to red should the value be out of range. Any
alarm will also appear in an alarm banner at the bottom of the screen. This text
box will give a fuller description of the alarm, its likely causes and set points.
- 12 –
2.4.5 Sensor & Transducer Screen.
The second running screen displays actual values of the sensors and
transducers along with alarm and set points. As with the first screen an alarm
banner will also be displayed.
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2.4.6 Current & Historic Trends
The third screen will show trends of all sensors and transducers. This screen will
be generated in real time. The operator will be able to view the trends at different
time intervals from two 2 minutes to the full term of the test.
- 14 –
2.4.7 Historic Data Compare.
The data from previous test or tests can be opened and compared against
current trends. This tool can be useful for monitoring long term trends or
comparing new designs against previous designs. The operator will be able to
look at a list of previous tests and select the data accordingly.
- 15 –
Section 3 Loading Component and preparation for testing
3.1 Flood the System and Evacuate Air
The operator mechanically fixes the seal onto the test rig. The flexible high
pressure water tubes are connected to the seal input and output connections.
The system is then flooded by opening water inlet and top bleed valves (hand
valves 1 & 2). The remaining air can be evacuated by starting water pump with
hand valve 2 open. While hand valve 2 remains open the pump starter will not
latch and the pump will only run with the pump start button depressed.
3.2 Pressurising System.
When the operator has evacuated the air and closed the water inlet and air bleed
valves (hand valves 1 & 2) the system can be pressurised. To pressurise the
system the operator presses the “pressurise system” push-button located on the
control panel door. The system will now be pressurised by the Haskel pump to
the value set in the set within the Cimplicity set up screen. Should the operator
discover a leak the pressure can be removed by selecting the “de-pressurise”
push-button. Once the leak has been repaired the system can be pressurised.
The water pressure is displayed on the control panel HMI.
3.3 Circulate Water.
With the system flooded and at pressure the water can be circulated using the
circulation pump. The operator presses the circulation pump start button and
pump will latch on. The water circulation rate is displayed on the HMI.
3.4 Temperature Control.
With the system flooded, pressurised and the water circulating the water
temperature can start to be controlled. The operator selects temperature control
start button and the system will start to control water temperature through the
cooling and heating loops. The water temperature of inlet and outlet manifolds
will be displayed on the HMI.
3.5 DC Motor control.
With the system flooded, pressurised, circulating water and at temperature set
point. The drive can be started by operating the start drive push-button. The
drive will accelerate to set speed.
Seals fitted with impellers will generate their own circulation. Once the drive is up
to speed the circulating pump will be stopped. The motor speed and flow rates
are displayed on the HMI.
- 16 –
Section 4 Control Panel HMI (Human Machine Interface)
4.1 HMI.
The HMI I have chosen is the Alan Bradley Panel View 550. It comes in various
types i.e. touch-screen, key pad & key pad/touch-screen. It can also come with a
printer port if required. The panel View 550 can handle text and limited graphics
and can use alarm banners to display faults. If required, various screens can be
password protected.
The right choice of HMI will depend on its intended use. If the HMI is only going
to be used to display values the touch-screen version will be more than
adequate.
However, if you intend to have the facility to enter values into the PLC such as
set points, alarm points speeds etc. the touch-screen with keypad would suit
best.
A printer port is available on both touch-screen and keypad. The printer

capability is quite limited but could be used to print time stamped data if required.
- 17 –
Section 5 Water Temperature Control.
Approximately 30 Litres of pressurised water is circulated by the seal in a closed

loop system. The water will be presented to the seal inlet at 30º C +/- 1º C. The
seal under test generates heat that the cooling loop needs to remove.
5.1 Cooling Loop PID
The cooling loop is controlled with a 3 way

proportional valve. A temperature probe mounted at
the outlet of the heat exchanger monitors the
temperature and adjusts the cold water flow through
the heat exchanger to maintain the outlet water
temperature. The target temperature for the cooling
loop will be approximately 25ºC.
The proportional valve is controlled by an analogue

4 to 20ma output from the PLC. The analogue
output will in turn be controlled by (Proportional /
Integral / Derivative) Closed Loop Control PID.
By controlling the cooling effect of the heat

exchange we will improve the overall stability of the
pressurised water circuit.
5.2 Heating Loop PID
With the water being presented to the heater at a nearly

constant temperature the heater will only require small
modulations to maintain 30º C at the seal inlet. We have
chosen a United Automation BM2 burst firing module.
This burst firing module incorporates the unique MONO -
LINKtm Gate to Gate firing feature which eliminates
cathode firing connections. Phase timing problems are
eliminated and the burst firing circuit prevents fast
changes in load current thus inhibiting Radio Frequency Interference.
The BM2 burst firing module is controlled an analogue 4 to 20ma output from the
PLC. The analogue output will in turn be controlled by Closed Loop Control PID.
- 18 –
Section 6 Pneumatic components & water pressure Control
6.1 Pneumatic Components
Pneumatics used on this test rig varies the pressure of the circulating water. The
component parts of the pneumatics are:
1 Lockable Shut off valve. Festo

183002 HEA-M1-G1/4. Used
to isolate pneumatic supply
during times of maintenance.
2 Component connector. Festo

183873 LV-M2/M3. Uses to
connect modules together.
3 Pressure build-up and dump

valve. Festo183096
HEM-M2-N1/4-10110
4 Pressure switch Festo 152704

PENV-PS/O-S-L-GH. Used to
check factory air pressure.
5 Filter Festo LF-M1-G1/8-CS.

Used to filter factory air to
5um.
6 Proportional pressure regulator

Festo MPPES-3-1/4-10-420.
This controller will vary
pneumatic pressure in
response to analogue out.
7 Angled plug socket Festo

161839. Used to connect
analogue output to control
valve.
- 19 –
6.2 Water Pressure Control
The seal will be pressurised to approximately 150 Bar by a Haskel pump. The
Haskel pump uses variable pneumatic pressure “0 to 8 bar” to produce variable
water pressure. A pressure transducer will be mounted in the high pressure
water pipe work to monitor the water pressure. The water pressure is maintained
by adjustments in air pressure controlled by the proportional pressure regulator.
The proportional pressure regulator is controlled by an analogue 4 to 20ma
output from the PLC. The analogue out put will in turn be controlled by Closed
Loop PID.
The proportional pressure regulator has an analogue output that could be used to
compare the relationship between water pressure and valve opening.
Pressure transducer.
Gem general purpose.
RS 348-8201. Used to
monitor water pressure.
- 20 –
Section 7 Water Usage
7.1 Water Usage Detection
Two Load cells weigh the collected water from each side of the seal to monitor
the water usage of the seals. At the start of the test both values are zeroed so
only newly collected water is recorded. If the water weighed is above a set point
the operator will be instructed to empty the containers and if weighed value is too
low the operator will be informed to replace container. This instruction will
appear on the Cimplicity start screen. Any large anomalies in water usage will be
alarmed on the Cimplicity running screens but will not halt the test. The load cells
require new amplifiers part No XT950 to interface with the PLC.
The Cimplicity system will display water levels in litres and usage in ml per
minutes. Cimplicity will only recognise positive increases in water weight, so that
if the container is empted during test cycle it will not affect the ml per minute’s
total. The HMI will only display the ml per hour total.
7.2 Terminal Connections
Connection between the XT950 unit and input/output signals, including power
supplies, are made via 2.5mm field terminal blocks inside the unit.
Access to the terminals is made through glands in the bottom of the case.
7.3 XT950 Field Connection Terminals
READ INSTRUCTION MANUAL BEFORE INSTALLATION
- 21 –
Section 8 Motor, Drive & Motor Speed Transducer
8.1 Motor
The motor fitted to the rig is a Thrige-Scott GB160-17BF, 70.9kW 400V DC. The
motor is no longer manufactured and has been superseded in recent years. The
motor is in good condition, and has been worked relatively lightly since its
purchase. It is believed that the motor has several years’ service ahead of it and
replacement will not be necessary.
8.2 Drive
The Thorn EMI Star Drive is no longer manufactured or supported. Should it fail
in service it is unlikely replacement parts will be obtainable. But like the motor it
has done very little work in service and it is believed that it has years of service
ahead of it.
The speed is controlled by a 0 to 10v analogue output from the PLC. The
analogue output is in turn controlled by Closed Loop PID. The speed loop is
closed by a speed transducer driven from the motor.
The drive however is unlikely to conform to current electrical noise regulations

and we suggest that we fit a Controls Techniques mains infeed line reactor type
M210 D-3308. This will reduce or remove RFI and mains notching.
8.3 Motor Speed Pulse
The analogue tacho described above may be hard to install. A simpler solution
would be to fit a proximity sensor, unfortunately the potential speed of the drive
means that more than one pulse could arrive during the program scan.
PLC scan time is 20 to 40ms
4000 RPM / 60sec = 66.66 pulses per second.
1 sec / 66.66 pulses = 15ms per pulse.
To overcome this problem we will require a pulse divider.

This can count pulses at very high speeds and output a
pulse when the preset value has been reached.
If we set the divider to 10:1 we would generate 1 pulse

approximately every 150ms and that one pulse would
represent 10 revolutions. With this information the speed can be calculated.
- 22 –
Section 9 Torque Transducer
9.1 Torque Transducer
Motor torque is measured by a HMB T5/200Nm torque transducer. The torque

transducer is connected to an amplifier and visual display unit A0104. Terminals
1 & 2 can be configured
to output a 4 to 20mA
signal to the PLC. The
PLC will monitor Torque
through the test. Should
the torque exceed an
adjustable set point the
test will be abandoned.
During the initial start up high torques can be generated, to avoid nuisance
tripping we intend monitor and if necessary adjust the acceleration the motor.
The set point speed will still have to be achieved within a given window of time
for the test to continue.
- 23 –
Section 10 Flow Transducer
10.1 Flow Transducers
There are various types of flow transducers available in the market place. They
vary in type accuracy and price. I have listed a selection of flow transducers to
choose from.
By identifying the flow rate we can calculate the energy generated by the seal
under test. We can also check the efficiency seal impellers.
- 24 –
- 25 –
- 26 –
- 27 –
- 28 –
Section 11 Program Logical Controller (PLC)
11.1 PLC Overview
The PLC will be used to monitor digital and analogue inputs from the test rig and
output analogue and digital information in response. It will be used to control the
various PID loops, and calculate values used or set by the Cimplicity system.
The test rig is in essence controlled by the PLC and monitored by Cimplicity.
The choice of PLC is not cast in stone and can be changed to suit company or
site standards.
We have selected Allen Bradley SLC500 range PLC for availability and flexibility.
It is modular in design and can be easily expanded if required. The Allen Bradley
SLC500 range has an extensive existing range cards to suit most test rig and
industrial applications.
11.2 PLC Components.
1 Power supply Produces 5 Amps at 5VDC

1746P2 to feed the back plane that
supplies the cards and
processor. It also 0.96
Amps at 24VDC.
2 Processor 503 processor 4K user &

1747L531 4K data memory.
3 10 Slot Rack The dimensions of 10 slot

1746A10 rack with a P2 power
W455mm x H171mm x
D145mm.
4 1746IB32 32 way digital input card.

32 Way Digital 10 to 30VDC. inputs
Input Card
- 29 –
5 1746OB16 16 way digital output card.

16 Way Digital 10 to 50VDC outputs
Output Card
6 1746NT8 8 way Thermocouple Input

8 Way Module.
Thermocouple
Input Module Type: J,K,T,E,NR,S,B,Mv
Temperature re-scale
resolution 1ºC and 0.1ºC.
7 1746NR4 4 way Thermocouple Input

4 Way Module.
Thermocouple
Input Module Type: J,K,T,E,NR,S,B,Mv
Temperature re-scale
resolution 1ºC and 0.1ºC.
8 1747N18 8 Way Analogue Input

8 Way Module, input types.
Analogue 0-20mA, 4-20mA, +/-20mA
Input Module. +/-10VDC, 0-5VDC
1-5VDC, 0-10VDC
9 1746NO4I 4 Way Analogue Output

4 Way Module.
Analogue
Output 0-21mA, +/-10VDC
Module.
- 30 –
11.3 PLC I/O Description.
Card 1 (32 way digital input card).
Address Description
I:1/0 Reset Button
I:1/1 Emergency Stop Button 1
I:1/2 Emergency Stop Button 2
I:1/3 Safety Relay Healthy
I:1/4 Factory Air Pressure OK
I:1/5 Coolmation CA26 Healthy
I:1/6 Drive Healthy
I:1/7 Valve 1 open
I:1/8 Valve 1 closed
I:1/9 Valve 2 open
I:1/10 Valve 2 closed
I:1/11 Water Pump Start Button
I:1/12 Water Pump Stop Button
I:1/13 Pressurise Water System
I:1/14 De-Pressurise Water System
I:1/15 Heat control on button
I:1/16 Heat control off button
I:1/17 Main drive start button
I:1/18 Main drive stop button
I:1/19 Pump motor runnable/running
I:1/20 Pump motor overload
I:1/21 Haskel pump water level OK
I:1/22 Motor speed Input Pulse
I:1/23 Spare
I:1/24 Spare
I:1/25 Spare
I:1/26 Spare
I:1/27 Spare
I:1/28 Spare
I:1/29 Spare
I:1/30 Spare
I:1/31 Spare
- 31 –
Card 2 (16 way digital output Card).
Address Description
O:2/0 Start Chillier. (Isolated with emergency stop).
O:2/1 Enable Drive. (Isolated with emergency stop).
O:2/2 Energise safety relay. (Isolated with emergency stop).
O:2/3 Pneumatic Dump Valve. (Isolated with emergency stop).
O:2/4 Run pump Motor. (Isolated with emergency stop).
O:2/5 Spare
O:2/6 Spare
O:2/7 Spare
O:2/8 Alarm Beacon
O:2/9 Spare
O:2/10 Spare
O:2/11 Spare
O:2/12 Spare
O:2/13 Spare
O:2/14 Spare
O:2/15 Spare
Card 3 (8 Way Thermocouple Input Module).
Address Description
I:3/0 Chillier water temperature. (Used for information & alarm)
I:3/1 Seal outlet left temperature. (Used for information & to stop
test if too high).
I:3/2 Seal outlet right temperature. (Used for information & to stop
test if too high).
I:3/3 Seal inlet left temperature. (Used for information and water
heater PID loop).
I:3/4 Seal inlet right temperature. (Used for information and water
heater PID loop).
I:3/5 Heat exchanger temperature. (Used for 3 way proportional
valve PID loop).
I:3/6 Spare
I:3/7 Spare
Card 4 (4 Way Thermocouple Input Module).

Address Description
I:4/0 Right Hand Seat temperature Probe 1 (Used for information
and alarm).
I:4/1 Right Hand Seat temperature Probe 2 (Used for information
and alarm).
I:4/2 Left Hand Seat temperature Probe 1 (Used for information
and alarm).
I:4/3 Left Hand Seat temperature Probe 2 (Used for information
and alarm).
- 32 –
Card 5 (8 Way Analogue Input Module).

Address Description
I:5/0 Torque Transducer. (Used for information & to stop test when
out of acceptable range).
I:5/1 Water Pressure Transducer. (Used for information, pressure
loop, and to stop test if pressure can not be maintained).
I:4/2 Left Seal Water Usage. (Used for information only).
I:5/3 Right Seal Water Usage. (Used for information only).
I:5/4 Water Flow Transducer (Used for information and to calculate
energy)
I:5/5 Spare
I:5/6 Spare
I:5/7 Spare
Card 6 (4 Way Analogue Output Module).

Address Description
I:6/0 3 Way Proportional Valve. (Used for cooling Loop PID).
I:6/1 Modulating Pressure Valve. (Used for high water pressure
loop).
I:6/2 Heater Thyristors Output. (Used in water heating PID loop).
I:6/3 Motor Speed Output. (Used for speed Loop).
- 33 –
Section 12 Safety Circuit
12.1 Safety Circuit
Two emergency stop buttons will be mounted local to the test rig. They will be
monitored by a Pilz relay. When the Pilz relay is operated it will stop the main
drive, remove pressure from system and close the heating and cooling loops.
By removing the enable from the drive the motor will coast to a stop. This may
take tens of seconds for the test rig to reach a zero speed.
By holding the enable on for a second with a timed safety relay, the main drive
could be driven to a stop. With this method the rig can achieve zero speed within
two seconds.
A risk assessment of the test rig should identify the correct safety philosophy for
the test rig.
- 34 –
- 35 –
Section 13 Electrical drawings
13.1 Electrical Drawings
The electrical drawings have made assumptions on completed design. The

templates will remain largely untouched but the contents will change to mirror
completed design.
- 36 –

Wet Seal Rig Fds

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Functional Design Specification for Seal A-D test rig.

Functional Design Specification

Prepared by: Tony Whiting

Prepared for Prospective Client.

12.1 Safety Circuit...............................................................................................34

1.0 F.D.S Overview & Fundamentals

1.1 Test Rig Fundamentals

Various sensors and transducers monitor temperatures, pressures, speed,

Section 2 - Cimplicity System

For the Cimplicity platform to work reliably we suggest a minimum hardware

1 Intel 2.0 Ghz processor.

2.3.1 Operating System

2.3.2 Utilities Norton Ghost

• This is recommended as it would allow complete system backups

2.3.3 Utilities PC Anywhere

2.3.4 Cimplicity HMI Plant Edition

Cimplicity is a SCADA (Supervisory Control and Data Acquisition) system

2.3.5 Cimplicity Web View

Cimplicity Webview, is an additional license which can be purchased which

2.4 Cimplicity Application

2.4.1 Supervisors set up screen

• The maximum permitted torque.

2.4.2 Operators set up screen

2 Component No Unique number used to describe seal.

4 Direction of rotation This has to be entered and confirmed by the

Their will also be an adjustable torque limit that

Note 1: With torque limit on the rig will adjusted the

Note 2: There will be a window of time to achieve

Note 1: The water inlet temperature is monitored

Note 2: To filter out nuisance trips the inlet water

8 Maximum outlet The operator sets the maximum acceptable seal

Note1: Setting the maximum temperature takes

Note 2: To filter out nuisance trips the outlet

point & high low high and low pressure.

10 Seal circulation or When the type of circulation has been selected a

2.4.3 Operators Start Screen

• Clear water usage load cell containers?

2.4.4 Plant Graphic Screen with Alarm Banner

2.4.5 Sensor & Transducer Screen.

2.4.6 Current & Historic Trends

2.4.7 Historic Data Compare.

Section 3 Loading Component and preparation for testing

3.1 Flood the System and Evacuate Air

3.2 Pressurising System.

3.3 Circulate Water.

3.4 Temperature Control.

3.5 DC Motor control.

Section 4 Control Panel HMI (Human Machine Interface)

A printer port is available on both touch-screen and keypad. The printer

Section 5 Water Temperature Control.

Approximately 30 Litres of pressurised water is circulated by the seal in a closed

5.1 Cooling Loop PID

The cooling loop is controlled with a 3 way

The proportional valve is controlled by an analogue

By controlling the cooling effect of the heat

5.2 Heating Loop PID

With the water being presented to the heater at a nearly

Section 6 Pneumatic components & water pressure Control

6.1 Pneumatic Components

1 Lockable Shut off valve. Festo

2 Component connector. Festo

3 Pressure build-up and dump

4 Pressure switch Festo 152704

5 Filter Festo LF-M1-G1/8-CS.