functional analysis and control system for the thermosiphon chiller lukasz zwalinski ph/dt/po -...

Functional Analysis and Control System for

the Thermosiphon Chiller

Lukasz Zwalinski PH/DT/PO - Cooling

Introduction

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO

liquidtank

USA15cavern

Surface

ATLAS IDDetector

UX15cavern

Normal operation evap.

R404aCascade condenser Water condenser

R23

Warm operation evap. Air condenser

C6F14 brine circuit

Normal operation -64.93C to -70.25C

Warm operation -14.85C to -20.81C

Cascade refrigeration system with

R23 as low temperature refrigerant and

R404a as high temperature refrigerant

Main control actions for R23 circuit:• Flow control threw normal operation evap. => to ensure SH vapour condition• Compressor speed control => to mach required load• Hot gas injection control => if required capacity is less then capacity of the compressor• Economizer control => high pressure liquid refrigerant sub cooling

Main control actions for R404 circuit:• Flow control threw cascade condenser => to ensure SH vapour condition (Normal operation)• Compressor speed control => to mach required load• Hot gas injection control => if required capacity is less then capacity of the compressor (Warm operation)• Economizer control => high pressure liquid refrigerant sub cooling (Normal operation)• Air cooled condenser fan control in case of water failure


Introduction

• Schneider Premium PLC based control system

• UNICOS framework

• System size (I/O number)

Chiller Brine + Water (Stephane’s talk)

• EN-CV-DC hardware standard

• Detector control system integration: same solution as already

introduced by EN-ICE for Detector Gas Group

Supplier requirementschannel number

J&E Hall

Selected card number

CERN48 AI 3x16AI4 AO 1x8AO

128 DI 2x64DI64 DO 1x64DO

I/O numberSelected card

numberCERN

32 AI 3x16AI8 AO 1x8AO64 DI 1x64DI32 DO 1x32DO

Control system architecture V1


Ring topology

M340 with Multi-Port Module

Brine Thermosiphon

ETHERNET IP

surface

Brine

CERN GPN

OWS OWS OWSDIP

Distributed I/|O

Chiller 2

back plane extension


CPU + I/O cards I/O cards I/O cards

Chiller 1 Water

I/O cards


Control system architecture V2


Ring topology

M340 with Multi-Port Module

Brine Thermosiphon

ETHERNET IP

surface

Brine + Water

CERN GPN

OWS OWS OWSDIP

Distributed I/|O

Chiller 2



CPU + I/O cards I/O cards I/O cards

Chiller 1 Water

I/O cards


integration

Split of responsibilities


• Control & electrical & pneumatic cabinets cabled up to the terminal blocks

• All sensors and actuators respecting CERN standards

• Documents to be filled by supplier: 1.2. Functional Analysis with P&ID3. Instrument List

• Schneider 7.5” or equivalent touch panel

Supplier• Schneider PLC and IO cards• PLC and PVSS software• Terminal blocks (to be installed by supplier)• Templates for the documents to be delivered

by the supplier

• Integration in CERN control systems, connection to DCS

• UNICOS Object List• UNICOS Logic Design

CERN

Terminal blockLimit of the supplier

Logic Generator

Instance Generator

Softwareproduction

Collaboration of Supplier and CERN

CERN limit

General Control System Requirement

Status


Supplier CERN (Chiller)

Task Status Task Status

Electrical design for compressor panel Delivered Electrical design for compressor panel (verification) Accepted

Electrical design for control cabinet Unknown ? Electrical design for control cabinet (verification) ?

Templates for the documents to be delivered by supplier Accepted Templates for the documents to be delivered

by supplier Send

Functional analysis (preparation) Delivered Functional analysis (verification) Accepted

Instrumentation list (preparation) Delivered Instrumentation list (verification) Accepted

Schneider I/O cards and terminal blocks selection (providing all details to J&E Hall) Completed

Schneider I/O cards and terminal blocks order Completed

Schneider I/O cards and terminal blocks installation

Currently impossible

Schneider I/O cards and terminal blocks shipping to J&E Hall

Should be done this

week

UNICOS object listUNICOS object design

Should start soon

PLC software productionPVSS software production

Should start soon

Mirror software tests Not started

Functional analysis organization


In accordance with EN-ICE template functional analysis contains:

1. General process description

2. Process decomposition

3. UNIT A

3.1 UNITA controlled devices description: type + parameters

3.2 Operational states description

a) Definition

b) Transition condition

c) Logical sequences

d) Sub unit and actuators logic

3.3 User command definition

3.4 Computed variables

3.5 UNIT / PCO Alarms

e) Hardware

f) Software

3.6 Actuator alarms

g) Hardware

h) Software

3.7 Actuator alarms parameters – recipes parameters

3.8 Limiting conditions

4. UNIT B …

EDMS 1165941

Process decomposition


Economizer High temperature

Warm Operation Evaporator

Cascade Condenser

Air Cooled Condenser

Economizer Low Temperature

Normal Evaporation Evaporator

CV59235

CV59240EV59246

CV59232CV59233

F59505AF59505BF59505CF59505D

COMP59502CV59201CV59202CV59213GT59263

COMP59112CV59301CV59302GT59364

EV53003EV53007

CV59326

CV59330CV59331CV59332CV59333CV59318CV59314

R404

Chiller 1 Chiller 2 Brine Water

R23 …

Chiller System

To be definedTo be defined

Has to be defined in

next 2 weeksmaximum

P&ID vs process decomposition


CV59235

Economizer HTAir Cooled Condenser

Cascade Condenser

R404

R23

Warm operation evaporator

Economizer LT

Normal operation evaporator

Chiller 1 – Option modes and operation states


States:[0] Stopped: Both compressors are switched off all outputs are off except either EV53003DO or EV53007DO

[1] Available for Warm Operation (WCC): The R404a compressor is not running, but is available to start, EV-53003 is confirmed open, EV-53007 is closed. The chiller is using the Water Cooled Condenser and the manual changeover valves have been set for this condenser. A C6F14 pump is confirmed as running.

[2] Available for Warm Operation (ACC): The R404a compressor is not running, but is available to start. EV-53003 is confirmed open, EV-53007 is closed. The chiller is using the Air Cooled Condenser and the manual changeover valves have been set for this condenser. Condenser fans are healthy and switched to auto. A C6F14 pump is confirmed as running.

[3] Available for Normal Operation: Both compressors are available to start. A C6F14 pump is confirmed as running and either EV-53003 or EV-53007 is open.

[4] Warm Operation with Air Cooled Condenser ACC: The R404a compressor is running. EV-53003 is open ,EV-53007 is closed. The R23 compressor is not required, so its status is ignored. Air Cooled condenser is running.

[5] Normal Operation: Both compressors are running. EV-53003 is closed, EV-53007 is open.

[6] Warm Operation with Water Cooled Condenser WCC: The R404a compressor is running. EV-53003 is open, EV-53007 is closed. The R23 compressor is not required, so its status is ignored. Water Cooled Condenser is running.

Option modes:

MAINTANACE: In this state, all equipment is stopped and there is no way to re-activate actuators from the program. All interlocks related to this unit are disabled.

OPERATION: nominal state in which Chiller is operated

Chiller 1 – Transition conditions


T0 = Transition from any state to STOP• A C6F14 pump running = 0• EV-53003 AND EV-53007 = closed• EMSDI = 0• PSU1DI AND PSU2DI = 0• The R404a compressor {COMP-59502} is tripped• Chiller.RunOrder falling edge

T1 = Transition from STOP to Available Air Cooled Condenser• A C6F14 pump must be confirmed as running• Either EV-53003 or EV-53007 must be open• Master Emergency Stop healthy [EMSDI = 1]• Either PSU1 or PSU2 healthy [PSU1DI = 1 or PSU2DI = 1]• The R404a compressor is available or running• The manual changeover valves have been set for air cooled condenser operation.• At least three of the four air cooled condenser fans {F-59506A – F-59506D} are healthy [F59506A_TDI - F59506D_TDI = 1] and switched to Auto [F59506A_A - F59506D_A = 1]

T2 = Transition from STOP to Available Water Cooled Condenser:• A C6F14 pump must be confirmed as running• Either EV-53003 or EV-53007 must be open• Master Emergency Stop healthy [EMSDI = 1]• Either PSU1 or PSU2 healthy [PSU1DI = 1 or PSU2DI = 1]• The R404a compressor is available or running• The manual changeover valves have been set for water cooled condenser operation.

T3 = Transition from STOP to Available Normal Operation:• A C6F14 pump must be confirmed as running• Either EV-53003 or EV-53007 must be open• Master Emergency Stop healthy [EMSDI = 1]• Either PSU1 or PSU2 healthy [PSU1DI = 1 or PSU2DI = 1]• The R404a compressor is available or running• The R23 compressor is available or running• The manual changeover valves have been set for water cooled condenser operation.

T4 = Transition from Normal Operation to Warm Operation: • Whilst running in Normal Operation, • The R23 compressor has either been commanded off by the operator, or switched off at the compressor starter panel [R23 Compressor AUTODI

= 0], or has tripped, or is not available, AND the C6F14 brine temperature TT53101< -21.0oC.

T5 = Transition from Warm Operation Water Cooled Condenser to Normal Operation: • R23 compressor unit is Available –AND• Manual Operator transition request from Warm Operation to Normal Operation

R404 - compressor PCO operation states and transitions


STOP [0][1]

Waiting [2]

T1T0

Avlb. [3]

Run[4][5]Run

Non Eco.[6]

T2

T0 T0 T0

T3

T4

NOT T4

T0 = R404.RunOrder falling edge OR the switch on the compressor starter control panel (AUTODI =

0, OFFDI = 1 OffSt).T1 = ‘Starts per Hour’ timer is running OR Stop to Start timer is

runningT2 = ‘Starts per Hour’ timer is NOT running AND

‘Stop to Start’ timer is NOT running ANDstarter control panel switch is in the ‘ON’ position (AUTODI = 1, OFFDI = 0 OnSt) AND(EV-53007 or EV-53003 is open) AND

C6F14 Pump running.

T3 = Chiller start command = Chiller.RunOrderT4 = PT-59207 {R404a Compressor Discharge Pressure} <11.77

bara ANDEconomiser is switched off (NOT EHT.RunOrder)

[0] Tripped: A ‘Full Stop Interlock’ has been implemented. The compressor is not running; one or more of the compressor operating parameters has reached a software trip threshold and stopped the compressor, or a hard wired protection device has stopped the compressor.

[1] Stopped: The compressor is not running, it is not tripped. The compressor has been commanded to stop either by the operator or by the switch on the compressor starter control panel (AUTODI = 0, OFFDI = 1).

[2] Waiting: The compressor is not running. It is not tripped. The starts per hour timer is running, or (EV-53007 and EV-53003 is not open), or C6F14 Pump not running.

[3] Available: The compressor is not running, it is not tripped, it is not waiting, the starter control panel switch is in the ‘ON’ position (AUTODI = 1 OFFDI = 0). The compressor is waiting for a command to start

[4] Running Auto: The compressor has been selected to ‘Auto’ on the local HMI and has been commanded to start and is running normally within the designed operating envelope and can vary its speed according to the R404a Compressor Speed Controller.

[5] Running Manual: The compressor has been selected to ‘Manual’ on the local HMI and has been commanded to start by the manual ‘soft key’ start button on the HMI and can vary its speed according to the local ‘soft keys’ Manual Speed Increase & Manual Speed Decrease.

[6] Running non economised: The compressor has been commanded to start and is running normally within the designed operating envelope and can vary its speed according to the R404a Compressor Speed Controller if selected to auto, or by the local ‘soft’ buttons on the HMI if selected to manual, but PT-59207 {R404a Compressor Discharge Pressure} <11.77 bara and the economiser is switched off

Summary logic description table example


ActuatorStopped [1]

Waiting [2] Available [3] Run [4] Run Non Economized [5]Tripped [0]

Comp59502 OFF OFF ON ON ON

MS5926 OFF AuPosR=0.0

OFF AuPosR=0.0

OFF AuPosR=0.0

IF (LS1=0 AND LS2=0) THEN (IF (ACC OR WCC)

THEN Regulation ON AuPosR=TSC59263.OutO ELSE_IF Normal THEN

Regulation ON AuPosR=PSC59321) ELSE_IF LS1=1 THEN

IncSpd NOT permitted

ELSE_IF LS2=1 THEN Decreas AuPosR by _R404_MS59263_sr

every 30s (step change!)

IF (LS1=0 AND LS2=0) THEN (IF (ACC OR WCC)

THEN Regulation ON AuPosR=TSC59263.OutO

ELSE_IF Normal THEN Regulation ON

AuPosR=PSC59321)

ELSE_IF LS1=1 THEN IncSpd NOT

permitted ELSE_IF LS2=1 THEN Decreas

AuPosR by R404_MS59263_sr every

30s (step change!)

CV59201AuPosR= from

commisioning: 100* R404_CV59201_pl /2

AuPosR= from commisioning: 100* R404_CV59201_pl /2

AuPosR= from commisioning: 100* R404_CV59201_pl /2

IF MC2=0 THEN AuPosR= from

commisioning:100* R404_CV59201_pl /2

every 30s for Time=2s* R404_CV59201_pn pulse number until

MC2=1

IF MC2=0 THEN AuPosR= from commisioning:100*

R404_CV59201_pl /2 every 30s for Time=2s*

R404_CV59201_pn pulse number until MC2=1

CV59202 OFF AuPosR=0.0

OFF AuPosR=0.0

OFF AuPosR=0.0

IF MC1=1 AND MC2=1 AND

CV59201.PosSt=0.0 THEN AuPosR= from commisioning ELSE

AuPosR=0.0

IF MC1=1 AND MC2=1 AND CV59201.PosSt=0.0

THEN AuPosR= from commisioning ELSE

AuPosR=0.0

CV59213 OFF AuPosR=0.0

OFF AuPosR=0.0

OFF AuPosR=0.0

IF TT59211 > R404_CV59213_tTStart

THEN SET:Regulation ON AuPosR=

TC59213.OutO IF TT59211<

R404_CV59213_tTStop THEN RESET:

Regulation OFF AuPosR=0.0

IF TT59211 > R404_CV59213_tTStart

THEN SET:Regulation ON AuPosR= TC59213.OutO

IF TT59211<

R404_CV59213_tTStop THEN RESET: Regulation

OFF AuPosR=0.0

Alarm parameters and recipes parameters


Name Description Min Value Max Value Default Value Units Access Level

R404_CV59202_plLoading Solenoid Pulse

Length0.05 1.0 0.1 Sec Commissioning

R404_CV59201_plUnloading Solenoid

Pulse Length0.05 1.0 0.1 Sec Commissioning

R404_CV59213_ppLiquid Injection

Solenoid Pulse Period3.0 6.0 3.0 Sec Commissioning

R404_CV59213_mplLiquid Injection

Solenoid Minimum Pulse Length

0.2 1.0 0.2 Sec Commissioning

R404_CV59213_tTStartDischarge Temperature to Start Liquid Injection

Control50 90 75 oC Technician

R404_CV59213_tTStopDischarge Temperature to Stop Liquid Injection

Control50 90 65 oC Technician

R404_Spare01 Not Used

R404_MS59263_srSpeed Reduction every

30s when System Limiting

1 20 5 % Commissioning

R404_CV59201_pn Number of pulses

every 30s when Motor Current Limiting

1 15 5 - Commissioning

Computed variables


Name Description Unit Calculation Range

R404-ODPOil Differential

Pressurebar PT-59204 – PT-59242 0.0-20.0

R404-OFPDOil Filter Pressure

Dropbar PT-59207 – PT-59204 0.0-10.0

R404- DSHDischarge Superheat

K See notes below 0.0-100.0

R404_LS1Limit System Condition Level 1

BOOLR404_LP_LS1 ORR404_HP_LS1 OR

R404_LS2Limit System Condition Level 2

BOOLR404_LP_LS2 ORR404_HP_LS2 OR

Description:Discharge Temperature (Saturated)(K) (Tsat) is calculated from this equation:

Tsat = A + (B x (LnP)) + (C x ((LnP)^2)) + (D x ((LnP)^3))

Discharge Superheat = Discharge Temperature (Actual)(K) – Discharge Temperature (Saturated)(K)• Range <-35.0,60.0>• Dead band 0.085K• Tsat is available and archived in PVSS

Where A = 226.9570901

B = 20.82789774

C = 2.485671782

D = 0.208949075

P = PT-59207 {R404a Compressor Discharge Pressure} (bara)

Tsat = Tsat59207

Then:

R404-DSH = TT-59211 + 273.15 - Tsat

Definition:

Summary and what’s next?


SCHNEIDER Premium PLC

All generated files will be kept in SVN service.

SCADA server

Logic Generator

Instance Generator

Specification

MS Acsses DB

Commisionig& operation

Code compilation

Process logic programation

PVSS panel preparation

PLC & PVSS instance generation

PLC hardware configuration

Excel specification

UNICOS project preparation:

Chiller Functional Analysis and I/O List accepted on 12.10.2011

Hardware Ethernet IP tests in progress.

In 2 weeks time I’ll start preparation of UNICOS object list

functional analysis and control system for the thermosiphon chiller lukasz zwalinski ph/dt/po -...

Documents

flow control

control cabinetunknown

compressor economizer

control cabinet verification

zwalinski phdtpo slide

load hot gas injection

c warm operation

status thermosiphon