Let us give some example PID Controller on Booster Pump application like on the left picture. Feedback Process Value (PV) is Actual Pressure (Bar), Set Point (SP) PID is Set Pressure (Bar), and output Measurement Value (MV) is VSD Reference Frequency (Hz).  This is the mechanism. Whenever the difference between PV & SP negative, PID Controller increasing output MV. Otherwise when the difference between PV & SP positive, PID Controller decreasing output MV. How fast the PID Controller could execute error calculation are depend on cycle speed on each controller and type of PID function.  There are several PID function base on control actions, which are P, I, PI, PD. PI function is widely used for Booster Pump application.

This is the PID & Alternate control system on Booster Pump application. There are 1 unit Pressure Transmitter,  1 unit PLC and 2 units Booster Pump that controlled by 1 unit VSD. Because of most VSD have PID Controller, we design the PI controller in the VSD. These are the several case :

• At the first time start PID in VSD with Pump A. VSD adjusting output frequency (Hz) into Pump A so that Actual Pressure (Bar) close to Set Pressure (Bar).
• Case 1 : Pump A couldn’t reach the target of Set Pressure (Bar), then PLC set 50Hz into Pump A and start PID in VSD with Pump B.
• Case 2 : Actual Pressure (Bar) is too high so that VSD set 0Hz into Pump B. This case make PLC to stop Pump B and start PID in VSD with Pump A.
• Case 3 : Actual Pressure (Bar) still on high pressure so that VSD set 0Hz into Pump A. This case make PLC to stop Pump A. That mean booster Pump A and B on the sleep condition.
• Case 4 : Suddenly Actual Pressure (Bar) drop to below Set Pressure (Bar). This case make PLC start PID in VSD with Pump B because of the last running pump before sleep is Pump A. This mechanism important to make sure all pumps have same running hour.

With the PID & Alternate control system, we could just add booster pump without add more VSD  to increase efficiency and capacity on Booster Pump Station. Mostly, Booster Pump Stations are using PID & Alternate control system because it could saving more cost for electrical energy consuption.

All of animation and graphical developed by Wonderware ArchestrA 3.0.

• Microsoft XP Professional Service Pack 2 – minimum operating system
• Microsoft SQL Server 2005 Service Pack 2 – repository database when running ArchestrA application
• Wonderware Intouch 10 – main template to insert ArchestrA symbol libraries

• Wonderware Application Server 3.0 – develop the ArchestrA symbol libraries

• TCP Driver Communication – setting IP address SLC500 and mapping address between tagname HMI and memory address PLC (on this case I use DAServer : DASABTCP 1.1 SP2)

Please select the ArchestrA IDE shortcut on Start Menu so you could create a galaxy database to save all of ArchestrA symbol libraries. On this case, I will create an ArchestrA Stand Alone HMI (local supervisory monitoring) by selecting the galaxy type : Base_InTouch.cab. After you have successful create a galaxy database, you could use this galaxy to connect ArchestrA IDE environment. If you have any problem when creating a galaxy database, please check your antivirus and firewall configuration. Some of antivirus or firewall block this application because of security reason.

On the ArchestrA IDE environment, you should create an Intouch template where will used to connect Wonderware Intouch. There are two methods : Create new Intouch application or Import existing Intouch application. After you have successful create new Intouch template, then Intouch – WindowMaker application will opened at the end of step. Until this step, you have successful configure Wonderware Intouch base ArchestrA symbol libraries. This configuration allow you to insert default ArchestrA symbol libraries into Intouch – WindowMaker by click the Embed ArchestrA Graphic icon on Intouch – WindowMaker.

If you need to modify or create new ArchestrA symbol, you could click View -> Graphic Toolbox (Ctrl+Shift+P). On the Graphic Toolbox menu, you could create new Graphic Toolset to save all of your ArchestrA symbols. Double click the new symbol so you could enter ArchestrA Symbol Editor Window. On here, you could insert ArchestrA default symbol then modify or embed it with other symbol so could match with your HMI design. To maximize your symbol design, you could insert 3 dimension image, check box, calender, list box, etc.

ArchestrA Symbol Editor could provide you with the complete menu for graphical design and inserting script code for each or overall symbols. This facilities will help you to create an animation or editing display value on each symbol. ArchestrA symbol libraries provide the most of graphical symbol for anything HMI developement.

On the ArchestrA Symbol Editor, defining the new variable on your script not counted as new tagname. Its mean, you could maximize your tagname usage so could cost down the budget to paid more tagname licence. Its different with Wonderware Intouch, where each of new variable definition will counting as new tagname. Actually, on the Intouch there is function so your new variable that not counted as new tagname, which is :

DIM <new variable> AS <variable type>

But Intouch has limited space to save more script compared with Wonderware ArchestrA. If you insert many script into Intouch menu (Application, Condition, Data Change), you will have more problem potential when running HMI Intouch, example : delaying data transfer, blank HMI page, etc.

On this ArchestrA chapter, I inserting Toggle Button and Light Indicator into symbol SLC500_a, and Slider and Analog Indicator into symbol SLC_500_b. Then on each Intouch window, I embed symbol SLC500_a into Intouch window SLC500_a, and symbol SLC500_b into Intouch window SLC500_b. This is the detail configuration for Intouch – WindowMaker :

Window SLC500_a

• Access Name : SLC500_a, Node Name : <blank>, Application Name : DASABTCP, Topic Name : SLC500_a, Protocol : SuitLink
• Tagname Button and Light are I/O Discrete with Access Name : SLC500_a, Check Box : Use Tagname as Item Name

Window SLC500_b

• Access Name : SLC500_b, Node Name : <blank>, Application Name : DASABTCP, Topic Name : SLC500_a, Protocol : SuitLink
• Tagname Slider and Analog are I/O Real with Access Name : SLC500_b, Check Box : Use Tagname as Item Name

Please download my example project on here.

Each of Access Name will connect to specific IP address of SLC500 via DAServer. For SLC500 you should install DASABTCP DAServer in the System Management Console (SMC). The SMC menu allow you to configure IP Address, Connection Timeout, Topic Name, Mapping Address tagname HMI and memory address PLC, etc. This screeshoot showing the DAServer configuration for SLC500.

The bellow screenshot is the runtime HMI Intouch base on ArchestrA symbol libraries. As you can see on bellow, there are full improvement on graphical symbol libraries when you create HMI Intouch base ArchestrA symbol libraries.

After that, you could backup your ArchestrA project into file format *.aaPKG, backup your tagname usage into file format *.csv, or publish your ArchestrA project into Intouch application. After you publish an ArchestrA project into Intouch application, you just could use the ArchestrA symbols and can’t modify its.

I hope, the short review of HMI Intouch base ArchestrA symbol libraries could help you to perform the HMI development. If you have any questions or need more technical support about Wonderware I could help you. Don’t hesitate to contact me please.

After that, I am join to team of Biodiesel Plant. Then I choose to develop the user friendly interface for control and process monitoring of physical variables on biodiesel plant. Actually, this interface had been develop by other team but not finished well. With my capability on HMI (Human Machine Interface) Wonderware Intouch 10, I choose my self to repair and finish the HMI development.

My scope of work on HMI Development of biodiesel plant are

• Repair and modification the static display so could close enough to represent the actual process on biodiesel plant.
• Embedded the historical trends and data logging table to record and display the physical process variables, such as mass flow, volume flow, temperature, level, and pressure.
• Optimize the usage of I/O tagname so could handle most of control and monitoring process variables.
• Create the input paramaters for PID (Proportional, Integral and Derivative) controller. The PID will handle the single close loop control system. Its will help the operator when conduct fine tuning of PID controller. PID will adjust the speed of motor drive so the process variable could close enough to the set point parameter.

When project team perform the commisioning, I became the project lead to help the instrument services and callibrations. Beside that, I am also help to check the analog signal (4 – 20 mA) from field instruments to PLC (Programmable Logic Controller) and DC power to instruments.

After we could ensure all of the instruments, relay contactors, inverters and PLC hardware could running as well, then we conduct to trial running of biodiesel plant. During the trial running, there is no significant problem that disturb variables process.

For the safety standard operational procedure, I am also built a security level on HMI. I set the available menu for operator, supervisor, and administrator. The security level will help owner to monitoring all process variables on biodiesel plant and who is have sign in and that they doing while biodiesel plant running.

While I conduct commisioning of biodiesel plant, Automation Engineering Division of PT. SIER have a great deal with the new automation project, which is Crushing Area and Barge Loading for PT. Berau Coal in Kalimantan. As general, the automation system is similar with KAYAN, but there are significant facilities that embeded on this project, which are using one HMI to control 3 PLC, Allen Bradley SLC 5/05 PLC netwoking and temperature aquisitions data (modbus protocol).

I have responsibility to decide what kind of HMI type that suitable for this project. With the little information about wonderware product, I decide to develop HMI using Archestra Patch 03. This software offering very nice user interface HMI, best animation capabilities, smart symbol libraries and possibility to save many tagname usage. As you can see on left side, this is the HMI that I have develop for crushing area and barge loading PT. Berau Coal. You can see how it very nice HMI runtime. The wonderware representative in Indonesia also told me if Wonderware Archestra that realease on May 2008 is the best HMI on this year, it become the leading HMI development nowdays.

Of course, I could ensure that Wonderware Archestra very suitable and stable HMI for all automation control and monitoring. As you can see above, I have build the standard HMI that have summaries and historical alarm record, historical trend, configuration for security level, general emergency stop, real time clock, popup menu for special case operation, etc.

Because the owner requirement, I develop HMI for stand alone application. This means, HMI just monitoring one plant at moment. HMI can’t comunicate with other existing HMI or sent process data to server computer. All of automation control and monitoring just in field control room. If the enterprise level need some of field data, he should ask the HMI operator to print out the document data.

The general procedure of HMI development using Wonderware Archestra are :

• Create the galaxy database on Archestra Environment. You should decide to use Based_InTouch.cab or Based_Application_Server.cab development. By creating the galaxy database you would have many archestra symbol libraries that could embeded on your HMI template (Intouch WindowMaker).
• Create new template that connected with Intouch WindowMaker. When you are working on Intouch WindowMaker in Archestra environment, you could embeded archestra symbol libraries as you want.
• Beside that, you could edit the standard symbol or create new symbol or unite many symbols to become one symbol.
• When you create new symbol that consist of archestra standard symbol, you could insert script for animation or controlling. The basic programming script on Archestra enviroment do not use tagname. This is different with Intouch, where the basic programming script need the tagname definition. You could imagine when your customer need very complex HMI function and animation. You should have define many memory tagname that I think its useless because the runtime licence is base tagname usage. But when you use Archestra development this problem solve as well and you could save more the tagname usage. It means that you could develop competitive HMI for your customer.
• Of course, you need the best hardware computer because when you want develop HMI using Wonderware Archestra you need Microsoft SQL Server 2005 Patch 2.

Wonderware Intouch 10 could used to develop an excellent HMI for Chemical Process, Petrochemical, Oil & Gas, Material Handling, Steel Furnace, etc. Wonderware Intouch could give most function that needed HMI.

But the nowdays there is the best HMI from Wonderware, which is Wonderware Archestra. by using the Wonderware Archestra, we could maximaze the usage of I/O tagname, embeded the nice symbol and animation, and easy HMI development for the other project.

If you need a service on HMI programming, I could help you to develop HMI for your project by using Wonderware Intouch or Archestra. I could offer the competitive cost for the HMI programming service.