Functional Analysis and Control System for the Thermosiphon Chiller

Lukasz Zwalinski PH/DT/PO - Cooling

Introduction

Cascade refrigeration system with R23 as low temperature refrigerant and R404a as high temperature refrigerant

C6F14 brine circuit liquid tank Normal operation -64.93C to -70.25C Warm operation -14.85C to -20.81C Normal operation evap. Cascade condenser R404a Water condenser Surface R23

USA15 cavern Warm operation evap. Air condenser

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 UX15 • Economizer control => high pressure liquid refrigerant sub cooling cavern ATLAS ID Detector 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)

Supplier requirements Selected card Selected card channel number number I/O number number J&E Hall CERN CERN 48 AI 3x16AI 32 AI 3x16AI 4 AO 1x8AO 8 AO 1x8AO 128 DI 2x64DI 64 DI 1x64DI 64 DO 1x64DO 32 DO 1x32DO • EN-CV-DC hardware standard • Detector control system integration: same solution as already introduced by EN-ICE for Detector Gas Group

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Control system architecture V1

OWS OWS OWS DIP

Brine Thermosiphon

CERN GPN

Brine Chiller 1 Chiller 2 Water

CPU + I/O cards I/O cards I/O cards I/O cards M340 with Multi-Port Module

back plane extension

back plane extension back plane extension

ETHERNET IP

surface

Ring topology

Distributed I/|O

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Control system architecture V2

DIP OWS OWS OWS

Brine Thermosiphon

CERN GPN integration

Brine + Water Chiller 1 Chiller 2 Water

CPU + I/O cards I/O cards I/O cards I/O cards M340 with Multi-Port Module

back plane extension

back plane extension back plane extension

ETHERNET IP

surface

Ring topology

Distributed I/|O

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

Supplier CERN • Control & electrical & pneumatic cabinets • Schneider PLC and IO cards cabled up to the terminal blocks • PLC and PVSS software • All sensors and actuators respecting CERN • Terminal blocks (to be installed by supplier) standards • Templates for the documents to be delivered • Documents to be filled by supplier: by the supplier 1. General Control System Requirement 2. Functional Analysis with P&ID 3. Instrument List • Integration in CERN control systems, • Schneider 7.5” or equivalent touch panel connection to DCS • UNICOS Object List • UNICOS Logic Design

CERN limit

Terminal block Software Limit of the production supplier Instance Generator Collaboration of Supplier and CERN

Logic Generator

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

Supplier CERN (Chiller) Task Status Task Status Electrical design for compressor panel Electrical design for compressor panel Delivered Accepted (verification) Electrical design for control cabinet Electrical design for control cabinet Unknown ? ? (verification) Templates for the documents to be delivered Templates for the documents to be delivered Accepted Send by supplier by supplier

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

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

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

Schneider I/O cards and terminal blocks order Completed

Should be Schneider I/O cards and terminal blocks Currently Schneider I/O cards and terminal blocks done this installation impossible shipping to J&E Hall week UNICOS object list Should start UNICOS object design soon PLC software production Should start PVSS software production soon

Mirror software tests Not started

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO 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 a) Hardware b) Software 3.6 Actuator alarms a) Hardware b) Software 3.7 Actuator alarms parameters – recipes parameters 3.8 Limiting conditions 4. UNIT B …

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

Chiller System

Chiller 1 Chiller 2 Brine Water

R404 EV53003 R23 … To be defined To be defined EV53007

Economizer High Economizer Low CV59235 CV59326 temperature Temperature Has to be

CV59330 defined in Warm Operation CV59240 Normal CV59331 Evaporator EV59246 Evaporation Evaporator CV59332 next 2 weeks CV59333 maximum CV59232 CV59318 Cascade COMP59112 CV59233 CV59314 Condenser CV59301 CV59302 F59505A GT59364 Air Cooled F59505B Condenser F59505C F59505D

COMP59502 CV59201 CV59202 CV59213 GT59263

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO P&ID vs process decomposition Air Cooled Condenser Economizer HT Economizer LT

CV59235 Cascade Condenser

Normal operation evaporator

W arm operation evaporator

R404

R23

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Chiller 1 – Option modes and operation states

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

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 C6 F14 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 C6 F14 pump is confirmed as running.

[3] Available for Normal Operation: Both compressors are available to start. A C6 F14 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.

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Chiller 1 – Transition conditions

T0 = Transition from any state to STOP • A C 6F14 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 C 6F14 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:

T3 = Transition from STOP to Available Normal Operation:

• A C 6F14 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 o = 0], or has tripped, or is not available, AND the C6F14 brine temperature TT53101< -21.0 C.

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

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO R404 - compressor PCO operation states and transitions

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 T0 T0 T0 running STOP [0][1] T2 = ‘Starts per Hour’ timer is NOT running AND ‘Stop to Start’ timer is NOT running AND Avlb. [3] starter control panel switch is in the ‘ON’ position (AUTODI = NOT T4 1, OFFDI = 0  OnSt) AND T1 T3 T0 (EV-53007 or EV-53003 is open) AND T2 Run[4][5] Run C 6F14 Pump running. T3 = Chiller start command = Chiller.RunOrder T4 Non Eco.[6] Waiting [2] T4 = PT-59207 {R404a Compressor Discharge Pressure} <11.77 bara AND Economiser 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 C6 F14 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 Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Summary logic description table example

Stopped [1] Actuator Waiting [2] Available [3] Run [4] Run Non Economized [5] Tripped [0] Comp59502 OFF OFF ON ON ON IF (LS1=0 AND LS2=0) IF (LS1=0 AND LS2=0) THEN (IF (ACC OR WCC) THEN (IF (ACC OR WCC) THEN Regulation ON THEN Regulation ON AuPosR=TSC59263.Out AuPosR=TSC59263.OutO O ELSE_IF Normal THEN ELSE_IF Normal THEN Regulation ON Regulation ON OFF OFF OFF AuPosR=PSC59321) MS5926 AuPosR=PSC59321) AuPosR=0.0 AuPosR=0.0 AuPosR=0.0 ELSE_IF LS1=1 THEN ELSE_IF LS1=1 THEN IncSpd NOT permitted IncSpd NOT permitted ELSE_IF LS2=1 THEN ELSE_IF LS2=1 THEN Decreas AuPosR by Decreas AuPosR by _R404_MS59263_sr R404_MS59263_sr every every 30s (step 30s (step change!) change!) IF MC2=0 THEN AuPosR= from IF MC2=0 THEN AuPosR= commisioning:100* from commisioning:100* AuPosR= from AuPosR= from AuPosR= from R404_CV59201_pl /2 R404_CV59201_pl /2 CV59201 commisioning: 100* commisioning: 100* commisioning: 100* every 30s for Time=2s* every 30s for Time=2s* R404_CV59201_pl /2 R404_CV59201_pl /2 R404_CV59201_pl /2 R404_CV59201_pn R404_CV59201_pn pulse pulse number until number until MC2=1 MC2=1 IF MC1=1 AND MC2=1 IF MC1=1 AND MC2=1 AND CV59201.PosSt=0.0 AND CV59201.PosSt=0.0 OFF OFF OFF CV59202 THEN AuPosR= from THEN AuPosR= from AuPosR=0.0 AuPosR=0.0 AuPosR=0.0 commisioning ELSE commisioning ELSE AuPosR=0.0 AuPosR=0.0 IF TT59211 > R404_CV59213_tTStart IF TT59211 > THEN SET:Regulation R404_CV59213_tTStart ON AuPosR= THEN SET:Regulation ON OFF OFF OFF TC59213.OutO AuPosR = TC59213.OutO CV59213 AuPosR=0.0 AuPosR=0.0 AuPosR=0.0 IF TT59211< IF TT59211< R404_CV59213_tTStop R404_CV59213_tTStop THEN RESET: THEN RESET: Regulation Regulation OFF OFF AuPosR=0.0 AuPosR=0.0

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

Name Description Min Value Max Value Default Value Units Access Level Loading Solenoid Pulse R404_CV59202_pl 0.05 1.0 0.1 Sec Commissioning Length Unloading Solenoid R404_CV59201_pl 0.05 1.0 0.1 Sec Commissioning Pulse Length Liquid Injection R404_CV59213_pp 3.0 6.0 3.0 Sec Commissioning Solenoid Pulse Period Liquid Injection R404_CV59213_mpl Solenoid Minimum 0.2 1.0 0.2 Sec Commissioning Pulse Length Discharge Temperature to Start R404_CV59213_tTStart 50 90 75 oC Technician Liquid Injection Control Discharge Temperature to Stop R404_CV59213_tTStop 50 90 65 oC Technician Liquid Injection Control R404_Spare01 Not Used Speed Reduction every R404_MS59263_sr 30s when System 1 20 5 % Commissioning Limiting

Number of pulses R404_CV59201_pn every 30s when Motor 1 15 5 - Commissioning Current Limiting

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

Definition: Name Description Unit Calculation Range Oil Differential R404-ODP bar PT-59204 – PT-59242 0.0-20.0 Pressure Oil Filter Pressure R404-OFPD bar PT-59207 – PT-59204 0.0-10.0 Drop Discharge R404- DSH K See notes below 0.0-100.0 Superheat Limit System R404_LP_LS1 OR R404_LS1 BOOL Condition Level 1 R404_HP_LS1 OR Limit System R404_LP_LS2 OR R404_LS2 BOOL Condition Level 2 R404_HP_LS2 OR

Description:

Discharge Temperature (Saturated)(K) (T s at) is calculated from this equation:

Ts at = 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)

Ts at = Tsat59207 Then:

R404-DSH = TT-59211 + 273.15 - Ts at

Thermosiphon workshop §5 20th October 2011 L.Zwalinski – PH/DT/PO Summary and what’s next?

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

UNICOS project preparation:

Excel specification

PLC hardware configuration

Specification PLC & PVSS instance generation SCADA server

Instance Generator PVSS panel preparation MS Acsses DB

Process logic programation SCHNEIDER Premium PLC Logic Generator

Code compilation

All generated files will be kept in SVN service. Commisionig & operation

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