Fds Spin 004

Functional Design Specification Spin Test Rig
Functional Design Specification

for
Spin Test Rig
Prepared by: Tony Whiting

Javelin Controls Ltd
Prepared for Prospective Client.
Version 3.1
12TH April 04
-1–
fdsSpin003 Javelin Controls
Section 1 F.D.S....................................................................................................3
1.0 F.D.S Overview & Fundamentals....................................................................3
1.1 Test Rig Fundamentals...................................................................................3
1.2 F.D.S. to Manufacture Specification................................................................3
Section 2 - Cimplicity System ............................................................................4
2.1 PC Requirements............................................................................................4
2.2 Communications. ............................................................................................4
2.3 Software..........................................................................................................4
2.3.1 Operating System ........................................................................................4
2.3.2 Cimplicity HMI Plant Edition .........................................................................4
2.3.3 Cimplicity Web View ....................................................................................4
2.4 Cimplicity Application ......................................................................................5
2.4.1 Seal Type Test Defaults Screen. .................................................................5
2.4.2 Operators Automatic set up screen..............................................................7
2.4.3 Operators manual start screen.....................................................................8
2.4.3.1 Static test in manual..................................................................................9
2.4.3.2 Dynamic test in manual.............................................................................9
2.4.3.3 Seal Settle Manual Spin..........................................................................10
2.4.4 Plant Graphic Screen with Alarm Banner...................................................10
2.4.5 Sensor & Transducer Screen.....................................................................10
2.4.8 Historic Data Compare...............................................................................13
2.5 Database Convention. ..................................................................................14
2.6 Test Certificate..............................................................................................14
2.7 Network Connection......................................................................................15
2.7.1 Network PC................................................................................................15
Section 3 Loading & Clamping Component ...................................................16
3.1 Mounting Seal & Clamping ...........................................................................16
Section 4 Pneumatic Control ...........................................................................16
4.1 Pneumatic Overview .....................................................................................16
4.2 Transducer Overview....................................................................................16
4.3 Pneumatic Control Overview.........................................................................16
4.4 Pneumatic Components................................................................................17
Section 5 Motor & Drive ...................................................................................18
5.1 Motor Details.................................................................................................18
5.2 Drive Details..................................................................................................18
5.2 Drive Controls Current ..................................................................................18
5.3 Drive Controls Speed Loop ...........................................................................18
5.4 Drive Controls EMC ......................................................................................18
Section 6 Program Logical Controller (PLC) ..................................................19
6.1 PLC Overview ...............................................................................................19
6.3 PLC I/O Description. .....................................................................................19
Section 7 Safety Circuit....................................................................................21
7.1 Safety Circuit.................................................................................................21
Section 8 Electrical drawings ..........................................................................21
8.1 Electrical Drawings .......................................................................................21
-2–
Section 1 F.D.S
1.0 F.D.S Overview & Fundamentals
This F.D.S. is designed to describe the control philosophy of the Spin Test Rig as
interpreted by Javelin Controls. The purpose of an 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 print a pass
certificate when appropriate and record the test information on a PC for further
analysis. The general design will automatically protect against set up or critical
seal failures during test.
The test rig is designed to control the environment of the test by controlling motor
speed, pneumatic pressures and monitoring temperatures and flows.
Various sensors and transducers monitor temperatures, pressures, speed and

flows. All the information that the sensors produce will be saved by the Cimplicity
system at a sample rate dictated by the operator/supervisor.
In the case of a seal or set up failure the test rig will automatically remove all
forms of power to the rig. (See safety circuit).
1.2 F.D.S. to Manufacture Specification
Once the F.D.S. has been agreed by all parties it can form the specification for
manufacture of the test rig.
-3–
Section 2 - Cimplicity System

Cimplicity is a PC based SCADA (Supervisory Control and Data Acquisition)
system developed by GE Fanuc. It is designed to communicate in both
directions, the PLC allowing the operator to view the test status or modify
settings to suit individual tests requirements.
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 64Mb ATI Radeon 7000 RTL
Graphics Card
8 PS2 Mouse & Keyboard.
2.2 Communications.
The Alan Bradley PLC communicates to the PC in RS232 using the DF1
Protocol.
2.3 Software
2.3.1 Operating System
The operating system will be Windows XP professional.
2.3.2 Cimplicity HMI Plant Edition
We suggest using the latest revision of this software, namely Cimplicity Plant
Edition, Version 6.0 – 75 tag system 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
the manufacturing industry, where reliability is a foremost priority.
2.3.3 Cimplicity Web View
-4–
Cimplicity Webview, is an additional license which can be purchased. It 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.
Cimplicity Webview can be a nice touch as a sales and marketing technique but
has little practical use on day to day running of the rig.
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 / mimic) 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.
There will be two access levels:–

OPERATOR and SUPERVISOR
Appropriate access is gained by logging on to the computer as OPERATOR (No

Password) or SUPERVISOR (NT Specified Password).
When logged on as SUPERVISOR you will gain full access to all Seal Test Rig
variables and be able to modify alarm limits and create new Seal Types.
2.4.1 Seal Type Test Defaults Screen.
The supervisor set up screen is password protected to restrict access to

supervisors. The operators will be able to see the settings of test selected but
will not be able to alter its values. The supervisor screen is designed to set limits
for each type of seal. The supervisor will also be able set-up new seal types in
this screen.
-5–
• The minimum & maximum motor speed.

• The minimum & maximum permitted dynamic test pressure.
• The minimum & maximum permitted static test pressure.
• The minimum & maximum permitted flow for dynamic test.
• The minimum & maximum permitted flow for static test.
• The minimum & maximum gas consumption % dynamic test.
• The minimum & maximum gas consumption % static test.
• Set the time for dynamic test.
• Set the time static test.
• The maximum seat temperature differential from ambient probe 1 & 2.
• The maximum seat temperature differential air inlet outlet probe 3 & 4.
• The maximum motor current output.
• Operators names and pass words.
• Set the information sample rate. (see note 1)
Note 1:
High sample rates will produce large files that create their own problems in
storage and usability. 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 test at 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. As the operator changes the standard sample rate the
Cimplicity screen will display the estimated file size in k bites.
Seal type Test Defaults will be stored as recipe files; there will be one file per
seal type. Typically the parameters of the seal can be altered, and new seal
types created using this page. Each Seal Type would contain information about
both Static and Dynamic tests as follows:-
-6–
The parameters can be viewed by the OPERATOR, however only SUPERVISOR

would be able to change any of the data.
2.4.2 Operators Automatic set up screen
When a seal is to be tested the operator selects the seal type from drop down
list. The parameters will be automatically loaded into the screen. The operator
will then be required to fill in some details 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 password.
2 Component No Unique number used to describe seal.
3 Text Box Free form text box for operator to describe any
special properties of the seal under test. This text
box is not a requirement for starting the test.
4 Direction of rotation This has to be entered and confirmed by the

operator.
5 Temperature probe The operator selects ambient probe differential

selection. and/of inlet outlet temperature differential.
Cimplicity checks that the rig is ready to start the test and will instruct the
operator of any actions are necessary to facilitate the test i.e.
-7–
• Is the safety circuit healthy?

• Is the factory air pressure OK?
• Is the set up screen complete and if not what hasn’t been filled in?
• Is the motor healthy?
When all conditions have been met the “two hand start buttons” will be made
available. Once the operator pressed the start buttons simultaneously the auto
test will begin and data will start to be recorded.
Generally the test will start with a static for check “X” minutes. If the static test is
successful the seal will automatically go to dynamic test. The dynamic test will
check the seal for “X” minutes and providing the seal doesn’t hit any critical limits
the seal will complete the dynamic test and return to a static test for “X” minutes.
With the full test cycle complete the resulting data will dictate a pass of fail. With
the teat complete all forms of motive force will be removed from test rig.
The criteria for pass/fail can be edited a supervise level to pass a seal that was
only a marginal failed.
If any of the alarm points are exceed the system crash stop and the fault will be
described on the alarm banner.
This would typically look as follows:
2.4.3 Operators manual start screen.
-8–
The operator opens the “manual start up screen” in Cimplicity. The operator will
then be required to fill in some details 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 password.
2 Component No Unique number used to describe seal.
3 Text Box Free form text box for operator to describe any
special properties of the seal under test. This text
box is not a requirement for starting the test.
4 Direction of rotation This has to be entered and confirmed by the

operator.
Cimplicity checks that the rig is ready to start the test and will instruct the
operator of any actions are necessary to facilitate the test i.e.

• Is the factory air pressure OK?
• Is the set up screen complete and if not what hasn’t been filled in?
2.4.3.1 Static test in manual
The static tests pressure will be imported from the last test, but can be adjusted
by the operator to any value within the supervisor’s set limits.
The static test duration will also be imported from the set up screen, and can be
adjusted by the operator from 1 to 99 minutes.
When all required data is complete the two hand buttons will be enabled. When
operator presses the start buttons simultaneously the static test will commence at
set pressure and for the set duration. The time of the static test can be adjusted
on the fly.
Two test stop buttons, one on the screen and one mounted local to the rig can
aborted the test any time. If the pneumatic pressure, gas flow, motor current or
motor speed alarm points are exceed the system crash stop and the fault will be
described on the alarm banner.
2.4.3.2 Dynamic test in manual.
The dynamic tests pressure will be imported from the set up screen, but can be
adjusted by the operator to any value within the supervisor’s set limits.
The dynamic test duration will also be imported from the set up screen and can
be adjusted by the operator from 1 to 999 minutes.
-9–
When an operator presses the two hand start buttons simultaneously the
dynamic test will commence at set pressure and for the set duration. The time of
the static test can be adjusted on the fly.
Two test stop buttons, one on the screen and one mounted local to the rig can
abort the test at any time. If the pneumatic pressure, gas flow, motor current or
motor speed alarm points are exceeded the system will crash stop and the fault
will be described on the alarm banner. Whenever a manual test is stopped the
operator will be asked whether he/she wishes to save the results.
2.4.3.3 Seal Settle Manual Spin
Within the manual program there is provision to settle the seal by spinning it.
Cimplicity will check that the seal is correctly set-up to allow the rig to spin i.e.

• Is the pressure on the seal within set limits.
If all parameters are OK a manual motor two hand start buttons will be enabled.
This button is located next to the rig. The motor will only spin while the button is
depressed and the required conditions have been met.
2.4.4 Plant Graphic Screen with Alarm Banner
When an auto 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 pneumatic pressures, air flows, probe temperatures, motor
current and speed. The information will be displayed in text boxes located in the
appropriate position on the graphic. The flow rate will be displayed in ml/min; the
pressure will be displayed in bar, motor speed in RPM, motor current in Amps
and temperatures ºC.
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.
2.4.5 Sensor & Transducer Screen.
The sensor & transducer 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.
This will have an appearance as follows:-
- 10 –
2.4.6 Current Trends
The current trends 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 10 seconds to 20 minutes.
This will have the following appearance:-
- 11 –
2.4.7 Test Result Screen
Once the test is completed, the test results page will display the following data:-
Seal Type & Product ID

Operator Name
Test type
Table of Test Result Data
Gas Consumption each side / vs Total Gas Consumption
Overall PASS / FAIL Decision.
Note: You will still have access to the trended data logged during the test.
Note also, that if the test finished prematurely, the last portion of the test
will be captured in the high speed trends for further examination.
This screen will have the following appearance:-
- 12 –
2.4.8 Historic Data Compare.
This will allow two previously logged tests to be compared one against the other.
The screen displays two sets of trends and for each you would need to select a
seal type and product ID.
- 13 –
This would typically look as follows:
2.5 Database Convention.
When a test is brought to a conclusion the data is saved into the database.
The fields of each record will contain specific information relating to the Seal
type, Product Id, Test type, Test Pass/Fail, Reason for fail and logged data.
The test types can be Static Manual, Static Auto, Dynamic Manual and Dynamic
Auto.
Reason for failure will include a fault code which would be a 0 when the test is
passed and a number greater than 0, relating to failure reasons stored in another
table.
As with all tests there is a fast trend that will capture data at a higher rate than
the normal trends. If a test fails, then this data will also be archived into the main
table, which can be viewed later.
2.6 Test Certificate
This will automatically be printed when a test is brought to a successful

conclusion. It is assumed that a networked printer will be made available for this
purpose, and that the appropriate printer drivers are obtainable.
The test certificate will take the following form:
- 14 –
2.7 Network Connection
2.7.1 Network PC.
It will be necessary to connect the PC to your factory network; we have assumed

that your IT department will carry out this phase of the test rig installation.
However we can prepare the PC for networking if we are given addresses and
protocol information.
- 15 –
Section 3 Loading & Clamping Component

3.1 Mounting Seal & Clamping
The seal is mounted into the rig with the dowel located into the base. The swing
arm is pulled over to the locking position and clamped. The seal is secured by
screwing down the clamp. As the clamp is tightened the tension bar is lifted into
retaining slots that prevent the tension from swinging open. Safety switch
monitor the tension bar position and when made the tension bar is safely
retained. The test rig will be at a zero emergency state before the tension bar can
be opened.
Section 4 Pneumatic Control

4.1 Pneumatic Overview
The seals are tested statically and dynamically. On the static test the seal is
tested with high pressure at relatively high volume i.e. (12 bar at approximately
6,000ml/min) on the dynamic test both the pressure and flow is lower i.e. (3 bar
at 500ml/min).
4.2 Transducer Overview
At your suggestion I have investigated Hastings flow meters. The 200 series that
you currently use takes 7 seconds to read through full scale. This is too slow for
our application. Hastings does however manufacture a 300 series that suits our
purpose well. Having read the specification I believe we can monitor both high
and low flow through the same transducer.
4.3 Pneumatic Control Overview
Manual control limits the operator/supervisor to two pre-set values i.e. 3 bar and
10 bar. Both set points are manually adjustable by pressing the appropriate set
pressure push button within the pneumatic cabinet the pressure will be displayed
on the regulator and on the SCADA screen. The output stability of a manual
pressure regulator is approximately 1% of full scale. We intend to use 0 to 16 bar
- 16 –
regulator for the 12 bar test, and 0 to 4 bar regulator on the 3 bar test. We should
achieve a pressure accuracy of 0.16 bar on the high flow test and 0.04 bar on the
low flow test.
4.4 Pneumatic Components.
No Description Purpose
1 Manual isolation valve lockable Used to isolate pneumatic supply at times
in the off position of maintenance.
2 Pneumatically driven dump This valve is used to dump high pressure
valve. air during an emergency stop or when the
system is isolated.
3 Pressure switch factory air. Used to check factory air pressure is
above operational minimum.
4 Control air pressure switch. This analogue pressure switch monitors
the control pressure after the pressure
regulators. The PLC monitors the
pressure.
5 Filter regulator 0 to 8 bar. Used to dry factory air and to set pressure
for intensifier. The intensifier will be set to
approximately 14 bar @ 4:1 = 3.5 bar. This
will also be the source pressure for the
dynamic test.
6 High pressure regulator 0 to 16 Used to manually set pressure for the high
bar. pressure test i.e. 12 bar.
7 Low pressure regulator 0 to 4 Used to manually set pressure for the low
bar. pressure test i.e. 3 bar.
8 High pressure reservoir This reservoir is sized to hold enough high
pressure air (at 14 bar approximately) to
maintain the static test for 4 min at 12 bar.
9 One way valves. These valves are designed to isolate the
high pressure from the low pressure
circuits.
10 Manual flow restrictors These flow restrictors are designed to
restrict the maximum flow attainable to
protect the gas flow transducers.
11 3/2 electrically operated Used to turn on and off high pressure
solenoid valve static test air. In the absence of power to
the solenoid the valve will close removing
high pressure air from the seal.
12 3/2 electrically operated Used to dump accumulated pressure at
solenoid valve teat rig & for pressure setup.
- 17 –
Section 5 Motor & Drive
5.1 Motor Details
Manufacturer: Brook Crompton.

Size : 7.5 kW
Volts : 380 - 415
F.L.C.(Amps): 14.0 – 13.3
Hz : 50
R.P.M. : 3480 @ 50Hz
Type : AC
Serial No : IEC 60034 DA132SJ G259938
5.2 Drive Details
Manufacturer: Mitsubishi.
Model : Freqrol –A100 FR-A140E – 7.5K-EC
Volts : 380 - 460
Power : 7.5kW 16 Amp
Hz : 50/60
Serial No : IEC C69973009 TC100A312G52 BC1 32U894A
5.2 Drive Controls Current
The drive has only 1 configurable analogue output, and your specification
requests information on both motor speed and current. I have chosen to
configure the drive analogue output to transmit motor current to the PLC via a
0-10v.
5.3 Drive Controls Speed Loop
As I don’t have an analogue output to check the speed I have made allowance to
install a proximity sensor. As I have changed the PLC to The Micrologix 1500 the
scan times are faster than SLC 500 I had previously chosen, typically 1ms. This
PLC Also contains 2 high speed counters that can accept pulses up to 20kHz. By
changing the PLC we have removed the need for a pulse divider.
5.4 Drive Controls EMC
The drive doesn’t conform to current electrical noise regulations and we suggest
that we fit a mains infeed line filter. This will reduce the emitted EMC but is still
unlikely conform to current regulations.
We will also change the current wiring method and add ferrite rings on the drive if
practical.
- 18 –
Section 6 Program Logical Controller (PLC)
6.1 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.
We have selected Allen Bradley Micrologix 1500 range PLC for speed and
flexibility. It is modular in design and can be easily expanded if required. The
Allen Bradley Micrologix 1500 range has an extensive existing range cards to suit
most test rig and industrial applications.
6.3 PLC I/O Description.
Base Unit (16 way digital input).
Address Description
I:0/0 Motor speed Input Pulse
I:0/1 Emergency Stop Button 1 & 2
I:0/2 Spare
I:0/3 Safety Relay Healthy
I:0/4 Factory Air Pressure OK
I:0/5 Drive Healthy
I:0/6 Start Test Button
I:0/7 Stop Test Button
I:0/8 Tension beam in position switch 1
I:0/9 Spare
I:0/10 Drive running / at zero speed
I:0/11 Drive overload
I:0/12 Two hand safety relay status
I:0/13 Reset Button
I:0/14 Low pressure set push-button
I:0/15 High pressure set push-button
- 19 –
Base Unit (12 way digital output).
Address Description
O:0/0 Motor drive contator
O:0/1 Drive Forward Rotation
O:0/2 Drive Reverse Rotation
O:0/3 High pressure solenoid
O:0/4 Spare (Isolated with emergency stop).
O:0/6 Pressure release & pressure setup solenoid.
O:0/8 Alarm Beacon (Maintained)
O:0/9 Reset Lamp
O:0/10 Start push-buttons
O:0/11 Stop Button
Card 1 (4 Way Analogue Input Module).

Address Description
I:1/0 “High Flow” Out Put Flow Transducer
I:1/1 “High Flow” In Put Flow Transducer
I:1/2 Air pressure Transducer.
I:1/3 Motor current
Card 2 (4 Way Analogue Input Module).

Address Description
I:2/0 Temperature probe 1 (ambient)
I:2/1 Temperature probe 2 (seat probe)
I:2/2 Temperature probe 3 (inlet air temperature)
I:2/3 Temperature probe 4 (outlet air temperature)
Card 3 (2 Way Analogue Output Module).

Address Description
I:3/0 Motor Speed Output. (Used for speed Loop).
I:3/1 Spare
- 20 –
Section 7 Safety Circuit

7.1 Safety Circuit
An emergency stop button and a safety position switches will be monitored by a

Pilz relay. When the Pilz relay is operated it immediately remove the enable
signal from the drive. The drive contactor will be released after a short delay
allowing the motor to be driven to a stop rather than allowing it to coast to a stop.
After a short delay the air pressure will be dumped and the motor isolated from
its supply.
Section 8 Electrical drawings
8.1 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.
- 21 –

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Functional Design Specification Spin Test Rig

Functional Design Specification

Prepared by: Tony Whiting

Prepared for Prospective Client.

1.0 F.D.S Overview & Fundamentals

1.1 Test Rig Fundamentals

Various sensors and transducers monitor temperatures, pressures, speed and

1.2 F.D.S. to Manufacture Specification

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

The operating system will be Windows XP professional.

2.3.2 Cimplicity HMI Plant Edition

2.3.3 Cimplicity Web View

Cimplicity Webview, is an additional license which can be purchased. It allows all

2.4 Cimplicity Application

Colour coding will be used to define certain states – e.g.

There will be two access levels:–

Appropriate access is gained by logging on to the computer as OPERATOR (No

2.4.1 Seal Type Test Defaults Screen.

The supervisor set up screen is password protected to restrict access to

• The minimum & maximum motor speed.

The parameters can be viewed by the OPERATOR, however only SUPERVISOR

2.4.2 Operators Automatic 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

5 Temperature probe The operator selects ambient probe differential

• Is the safety circuit healthy?

This would typically look as follows:

2.4.3 Operators manual start screen.

2 Component No Unique number used to describe seal.

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

• Is the safety circuit healthy?

2.4.3.1 Static test in manual

2.4.3.2 Dynamic test in manual.

2.4.3.3 Seal Settle Manual Spin

• Is the safety circuit healthy?

2.4.4 Plant Graphic Screen with Alarm Banner

2.4.5 Sensor & Transducer Screen.

This will have an appearance as follows:-

2.4.6 Current Trends

This will have the following appearance:-

2.4.7 Test Result Screen

Seal Type & Product ID

This screen will have the following appearance:-

2.4.8 Historic Data Compare.

This would typically look as follows:

2.5 Database Convention.

2.6 Test Certificate

This will automatically be printed when a test is brought to a successful

The test certificate will take the following form:

2.7 Network Connection

2.7.1 Network PC.

It will be necessary to connect the PC to your factory network; we have assumed

Section 3 Loading & Clamping Component

Section 4 Pneumatic Control

4.2 Transducer Overview

4.3 Pneumatic Control Overview

4.4 Pneumatic Components.