functional analysis and control system for the thermosiphon chiller lukasz zwalinski ph/dt/po -...
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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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
back plane extension
CPU + I/O cards I/O cards I/O cards
Chiller 1 Water
I/O cards
back plane extension
Control system architecture V2
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
Ring topology
M340 with Multi-Port Module
Brine Thermosiphon
ETHERNET IP
surface
Brine + Water
CERN GPN
OWS OWS OWSDIP
Distributed I/|O
Chiller 2
back plane extension
back plane extension
CPU + I/O cards I/O cards I/O cards
Chiller 1 Water
I/O cards
back plane extension
integration
Split of responsibilities
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
• 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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
CV59235
Economizer HTAir Cooled Condenser
Cascade Condenser
R404
R23
Warm operation evaporator
Economizer LT
Normal operation evaporator
Chiller 1 – Option modes and operation states
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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?
Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO
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