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Module 1: System Overview
Module 2: Operation

2. Module 1: System Overview

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. Module 2: Operation
Module 2: Operation

12. 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

13. 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.

14. 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.

15. 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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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.