Home Module 1: System Overview Module 2: Operation

Module 1: System Overview

System Overview The Mega SBD100, Model 145/147 is a two-process station system (A-station and B-station) designed to blend up to two liquid constituents and distribute the resulting blended slurry to a single global loop with multiple points-of-use (POU). System Overview

Sequence of Operations Overview Slurry Addition Circuit The raw slurry is drawn from one of two drums to the blend engine and simultaneous mixing of standby drum using a pneumatic dual diaphragm pump Automated flush/purge functions for both standby and dispensing circuits The material is then pumped through a 10" filter and into the blend tank Filter features manual isolation, bypass, degassing, flush/purge, and drain functions Visual pressure indication allows operator to view pressure drop across filter for determining replacement Slurry supply circuit uses capacitive level sensing to determine when a drum is empty, allowing for system to switch drum supply circuits automatically Sequence of Operations

Sequence of Operations Overview, continued Slurry Blend Slurry blending is performed through batch addition of constituents to one of two blend tanks, while other station supplies slurry to global loop UPW and slurry added in this fashion Up to 5 recipes can be stored, only 1 active at a time Scales meter addition of each liquid into blend tank If slurry added first (with only one incidence of slurry addition in recipe), flow meters alter end quantities of remaining constituents to maintain fixed ratio when slurry quantity overshot After all liquids added to tank, tank circulates for prescribed time and blend is analyzed prior to allowing for distribution Conductivity and pH methods used for qualification and monitoring Sequence of Operations

Sequence of Operations Overview, continued Slurry Dispense Dispense operations provide blended chemical to single global loop using a series pump arrangement Chemical supply pressure in global loop controlled via PID relationship between flow/pressure meter readings and pump RPM Back pressure is controlled via global loop return pressure transducer readings and dome-loaded, pneumatic, back pressure regulator Each station shares blend and dispense duties in turn When liquid level in one station reaches specified low point, alternate stations begins creating a batch When new batch is complete and qualified and original station’s tank level reaches low batch transfer setpoint, new batch begins dispensing to global loop Original station with spent batch then taken off global loop Sequence of Operations

Sequence of Operations Overview, continued Slurry Dispense, continued Complex sequence ensures minimal pressure fluctuation during swap Operator can choose to transfer remaining contents of spent batch to new batch or perform hard swap instead of standard swap process Sequence of Operations

Sequence of Operations Overview, continued Filtration Both stations allow for filtration in either local (blend) or distribution modes Filter system equipped with 3 filter banks, each possessing single filter Each has automated isolation, degassing, pre-pressurization, and flush/purge capability Both stations in global filtration can share global loop filter bank or spare filter bank Will switch automatically to available spare bank based on pressure differential inputs across filters, timed filter replacement setpoints, or operator intervention Sequence of Operations

Sequence of Operations Overview Accessory Functions Several accessory function typically included in dual station system design Flush/purge Tank is filled with water, circulated throughout dispense system for a period, then series of pumped and passive drain steps applied System then purged and drained with UN2 until most/all liquid removed Metrology During distribution, conductivity and pH probes meter various slurry characteristics and notify operator of deviations from upper/lower limits Sequence of Operations

Sequence of Operations Overview, continued Accessory Functions, continued Sampling Accessed/initiated by operator during auto or maintenance manual modes Can quantify amount of blend to be sampled, after which prompts allow operator to remove sample, close sample door, and begin sample flush/purge Sequence of Operations

Module 2: Operation Module 2: Operation

HMI Overview The HMI on the SBD100 M145 and SBD100 M147 is a simple to use touch screen. Buttons on the top and left of the screen are used to access other screens in the system. Buttons within the screen operate various functions relating to that screen. HMI Overview

System Startup The system is initially set up and powered on by an operator or engineer with an administrative password. Refer to Restarting after EMO if restarting the system. System Startup Toggle the AC Disconnect switch to the ON position. Ensure the EMO is disengaged (pulled out). Press the green Start button on the front of the Controls cabinet. When the startup is complete, the Main Menu is displayed.

Logging In The system defaults to Guest user permission with limited controls and functions. With a higher level of permission, the user password authorizes the user to view and/or edit various controls in the system. Logging In From the top of any screen, press the Login button on menu bar to access the Log On dialog box. Press the User Name field and use the onscreen keyboard to enter a name, and then press the enter key. Press the Password field and enter the corresponding password. Press OK to exit the Log On dialog.

Restarting after an EMO or Unexpected Shutdown If the system shuts down while running an operation, it does not continue where it left off after the restart. An Abort decision is required before continuing to Local or Global recirculation to ensure a high-quality batch in the tank. If the system is shut down due to an EMO condition, pull the EMO button out before the next step. Toggle the AC Disconnect switch to the ON position. Ensure the EMO is disengaged (pulled out). Press the green Start button on the front of the Controls cabinet. Restarting after EMO

Station Swap Control The Station Swap Control Dialog allows operator to select the type of swap action to perform manually. Station Swap Control To access, from the Station A/B Overview screen for a station in global recirculation, press the Swap Stations button. Transfer to Alt Station – Transfers slurry to alternate station; typically, the next station to go online Swap to Alt Station – Swaps tanks with the slurry from the new tank Hard Swap to Alt Station – Immediately swaps tanks with no steps taken to eliminate pressure transients Execute – Loads swap setting chosen

Flush/Purge Batch aborts may be necessary if process parameters, such as pH and density, are out of specification range or if the batch becomes contaminated. Batch abort (flush/purge) is used to drain and flush the blend tank, and when a thorough cleaning is necessary. A gravity drain dumps the entire blend tank contents to the drain, leaving residual fluid in the process piping. Authorization is needed before proceeding with a batch abort. Flush/Purge

Flush/Purge, continued To access, from the Station A/B Overview screen, press the Station Abort button. The Flush/Purge Control dialog also displays whenever transferring a station from Manual to Auto. Flush/Purge

Flush/Purge, continued Gravity Drain Only – Sends tank contents to gravity drain Complete Flush/Purge – Performs complete station flush/purge Reset Flush/Purge – Resets flush/purge sequence Based on the abort sequence chosen, select the action to perform at the end of the abort sequence. If you choose… Your choices are… Gravity Drain Only Put station in manual Standby Start new batch Complete Flush/Purge Reset Flush/Purge Put station in local recirculation Flush/Purge Execute – Starts sequence as chosen in steps 1 and 2

Sampling system chemistry exposes the operator to chemical hazards. CAUTION Chemical Hazard! Sampling system chemistry exposes the operator to chemical hazards. Wear the following PPE when taking samples: Acid-resistant gloves Chemical safety goggles and full- face shield Protective clothing such as a lab coat, apron, or coveralls Use an approved container to hold the sample. Sampling

NOTICE Sampling, continued Ensure the system is currently in dispense mode. If not, wait to take a sample until in dispense mode. Open the sample cabinet door. Place the sample container (open) into the sample cabinet. Open the sample needle valve one (1) turn only for the sample and fill the sample bottle according to site procedures. NOTICE Opening the needle valve too much may cause pressure transients on the system resulting in excess sample flow to knock over empty the sample bottles. Sampling Carefully remove the sample and close the sample door. Remove PPE and dispose according to site regulations and MSDS requirement.