Cryogenic Plant Controls - Configuration

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Presentation transcript:

Cryogenic Plant Controls - Configuration Chris Scanlon Cryoplant Controls Hardware FDR September 13, 2017 1

Configuration - Charges Is the overall Control Architecture defined and approved? Are the control cabinets adequately tagged, identified, and mapped? Are Instruments, Wires, Inputs/Outputs identified (tagged, labeled) and listed? Is the number of installed spares commensurate with the magnitude of the project? (this includes installed spare: I/O cards, Terminals, …) Is the equipment listed adequate? (this includes type of: PLCs, I/O modules, terminal blocks, cabinets, …) Is the hardware assembly adequate and safe? This includes: Cabinet internal lay-out, cables and wires in and out, ferrules, touch-safe contacts, breakers, racks, mounting/back panel, internal lights, internal sockets, front panel lights and panel, etc… 2 Cryoplant Controls Hardware FDR, September 13, 2017

Is the overall Control Architecture defined and approved? Configuration Is the overall Control Architecture defined and approved? Control architecture is defined by: P&IDs Functional Requirements Documents Interface Control Documents Engineering Notes All are approved and released. 3 Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture Document Number Document Title LCLSII-2.7-FR-0492 Cryogenic Controls Functional Requirements Specification LCLSII-4.1-FR-0327 Cryogenic Systems Integration LCLSII-4.8-FR-0244 Cryogenic Plant Functional Requirements Specification LCLSII-1.2-IC-0278 Radiation Safety System Controls to Accelerator Systems, Cryogenic Systems, Photon Systems, and Infrastructure Systems LCLSII-2.5-IC-0056 Accelerator Systems to Cryogenic Systems LCLSII-4.9-EN-0289 Cryogenic Distribution System Control Loop Functions LCLSII-4.9-EN-0255 Cryogenic Distribution System and Cryomodule Failure Mode and Effects Analysis LCLSII-4.8-EN-0336 Cryoplant Margin, Operability and Maintainability 000-PFP-0011 Cryogenic Distribution System P&ID F10022915 Cryomodule P&ID LCLSII-4.8-EN-0803 LCLS-II Cryoplant Flowmeter Sizing LCLSII-4.8-EN-0754 LCLS-II Cryoplant Interface Box Control Functions Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture Document Number Document Title Status Technical Specification for the Fabrication of Enclosed Industrial Control Panels Rev - Various Cryogenics Plant Phase 1 Controls Drawings Rev A Submitted to document control Cryogenics Plant Phase 2 Controls Drawings Rev - Submitted to document control JLab produced documentation supporting the procurement of the cryoplant controls enclosures. LCLS-II Cryo Controls Integration Workshop, February 8, 2017

Control Architecture Document Number Document Title Status 79120-C6003 Cryogenics Plant Utility System Software Rev 0 79120-C6002 Cryogenics Plant Gas Management System Software 79120-C6001 Cryogenics Plant Warm Helium Compressor Software Rev - C1303 NT 400 Cryogenics Plant 4K Cold Box Software Rev 1 79222-C6001 Cryogenics Plant 2K Cold Box Software Various Cryoplant P&IDs Various revisions LCLS-II Cryo Controls Integration Workshop, February 8, 2017

Control Architecture: Systems Cryoplant control ends at the interface of the building to the CDS and cooling water. The cryoplant is split into 7 main systems, each controlled by one PLC. Each warm compressor is controlled by its own PLC. PLC Systems: Utility / Gas Mgmt / 4K CB / 2K CB / Warm Comps Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture: Systems 7 PLC systems total in both cryoplants. 21 total PLCs in the cryoplants. Each PLC has an HMI in the same enclosure 45 enclosures being purchased in this procurement Each warm compressor is controlled by its own PLC. These are already purchased and were delivered on each compressor. One per cryoplant of each of: Gas Management System 4K Cold Box 2K Cold Box One utility system is shared by both cryoplants and covers the shared subsystems. Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture: Systems Each PLC has an HMI in the same enclosure The HMI screens will close as possible to the SLAC EDM screens and PFDs JLab gas management system screen Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture: Systems P&IDs Utility 79120-0009 79120-0010 79120-0011 79420-0000 79520-0000 79520-0001 79520-0002 79622-0001 79720-0000 79821-0000 System P&ID Gas Management 79120-0002 79120-0006 79120-0013 79621-0000 79621-0001 79622-0000 4K Cold Box 79520-0002 79622-0001 79720-0000 2K Cold Box LP Compressor 79120-0003 MP Compressor 79120-0004 HP Compressor 79120-0005 Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture: PLC Network Hardware interface: Gigabit/Fast Ethernet at IT room switch Software interface: Produced/consumed tags, IOCs to EPICS To Cooling Towers (SLAC scope) To CP2 Fiber To CDS and CMs (SLAC scope) Cryoplant Controls Hardware FDR, September 13, 2017

Control loop examples by system Control Architecture Control loop examples by system Gas Management Controls Warm compressor inlet/outlet pressures (via bypass valves) Mass in/out valves Utility System Controls Recovery compressor bypass valve Recovery compressor inlet valve LN2 valve to purifier heat exchanger Overarching integrated control is SLAC scope and is not part of this review. Cryoplant Controls Hardware FDR, September 13, 2017

Adsorber regeneration heaters Turbine bearing and brake pressure Control Architecture 4K Cold Box Controls LN2 level HP flow partitioning Adsorber regeneration heaters Turbine bearing and brake pressure Turbine speed control Dewar levels Shield temperatures and pressures 2K Cold Box Controls Cold compressor speeds Outlet and bypass valves Cryoplant Controls Hardware FDR, September 13, 2017

Control Architecture: 4K Cold Box Proposed cryoplant hardware provides for the above cold box operation Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Are the control cabinets adequately tagged, identified, and mapped? Yes, they are tagged and identified in assembly drawings. 15 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Control cabinets are mapped in installation drawings. This design was approved in the installation FDR. 79221-1705 16 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Are Instruments, Wires, Inputs/Outputs identified (tagged, labeled) and listed? Yes, I/O are located, tagged and labeled in the wiring drawings. 79120-1554 Field cables are labeled in the wiring drawings. 17 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Field cables are labeled in the CAPTAR list. The CAPTAR list included in the GC’s installation package 18 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Field cables are labeled in the installation drawings. 79221-1705 19 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Instruments and field cables are labeled in the installation drawings. Field cables labeled starting with L2CP. This design was approved in the installation FDR. 79120-1713 20 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Is the number of installed spares commensurate with the magnitude of the project? (this includes installed spare: I/O cards, Terminals, …) Yes, there are spare I/O on each type of I/O, but additional installed spares are not provided. Space is available to install additional I/O cards and terminal blocks if that is necessary, in addition to open I/O on existing cards. Available card space allows for 20% spares per I/O type for future expansion, if needed. 5% of spares are provided on the shelf. 30% additional spare wire pairs are provided in cable runs. 79221-1003 21 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Extra space is available in the PLC enclosures to install additional terminal blocks, if needed. 22 Cryoplant Controls Hardware FDR, September 13, 2017 79120-1550

Configuration Is the equipment listed adequate? (this includes type of: PLCs, I/O modules, terminal blocks, cabinets, …) Filtered cooling fans are provided with each PLC cabinet to cool internal components and prevent dust buildup 79221-1000 23 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Controllogix PLCs are more than adequate for controlling the cryoplants. PLC controller has a large margin on processing power. JLab 4K Cold Box PLC Scan Time (5560 controller) Normal: 22ms Maximum: 75ms 5580 has a minimum performance boost of 10x Expected scan time with 5580 controller Normal: 2.2ms Maximum: 7.5ms Air Liquide requires a maximum scan time of 120ms. Cryoplant Controls Hardware FDR, September 13, 2017

Configuration The chose PLC controllers have a large margin on memory JLab 4K Cold Box PLC RAM (L62, 4MB) 19% used LCLS-II 4K Cold Box PLC RAM (L81, 3MB) Expected maximum used: 0.75MB (25%) Cryoplant Controls Hardware FDR, September 13, 2017

Configuration The L81 controllers have a large margin on I/O capabililty JLab 4K Cold Box PLC I/O 16% used LCLS-II 4K Cold Box PLC I/O Digital I/O: 34 of 128,000 maximum Analog I/O: 190 of 4,000 maximum Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Terminal blocks are cage clamp type to eliminate the possibility of screws loosening and are rated for the appropriate current 27 Cryoplant Controls Hardware FDR, September 13, 2017

Software specifications match the P&IDs and wiring drawings. Configuration Electrical enclosures are of the appropriate NEMA rating (NEMA 12 or 4) I/O modules, TBs, cabinets cover all I/O in cryoplant, according to P&IDs. Software specifications match the P&IDs and wiring drawings. Digital output (relay) cards can drive loads of up to 2A and each output is individually fused. Analog input and output cards have 16/15 bit resolution, respectively, providing plenty of resolution for precise process control. 28 Cryoplant Controls Hardware FDR, September 13, 2017

CP controls hardware same as JLab CHL2 Examples: Configuration CP controls hardware same as JLab CHL2 Examples: Controllers and I/O cards – Allen Bradley Controllogix Pressure Transducers – GE Unik 5000 Differential Pressure Transducers – Rosemount 3051CD Platinum RTDs – Rosemount 214 - Fed into Cryocon Temperature Diodes – Lakeshore - Fed into Cryocon Gauges Signal from these instruments are compatible with the enclosed hardware, including CANbus for the cold compressors Subsystems have been approved and purchased. 29 Cryoplant Controls Hardware FDR, September 13, 2017

Standardized hardware was chosen to reduce the spares need Configuration Standardized hardware was chosen to reduce the spares need One I/O card per type Two PLC controllers Three terminal blocks Two pressure transducer models with four pressure ranges Differential pressure transmitters in three pressure ranges Subsystem specifications have already been approved and purchased Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Is the hardware assembly adequate and safe? This includes: Cabinet internal lay-out, cables and wires in and out, ferrules, touch-safe contacts, breakers, racks, mounting/back panel, internal lights, internal sockets, front panel lights and panel, etc… All components in the PLC cabinets >49 Volts are finger safe and are concentrated in the upper left hand corner of the PLC cabinets. This allows hazardous voltages to be more easily avoided. 31 Cryoplant Controls Hardware FDR, September 13, 2017 79222-1000

Large electrical enclosures are seismically rated. Configuration Large electrical enclosures are seismically rated. The PLC enclosure floor anchoring design was performed by SmithGroup and was BIO approved. Anchoring requirements 32 Cryoplant Controls Hardware FDR, September 13, 2017

Configuration Low voltage cables exiting cabinets are specified in the CAPTAR list. (See slide 17) Internal and external wire gauges are specified on the controls enclosure drawings and are coordinated with breaker sizes per Article 310 of the NEC 2014. Each enclosure containing >49 Volts will have an LED voltage indicator on the door. 33 Cryoplant Controls Hardware FDR, September 13, 2017

Is the hardware assembly adequate and safe? The PLC cabinets each include a power strip to power the Cryocons with additional space for additional devices 34 Cryoplant Controls Hardware FDR, September 13, 2017 79222-1000

Is the hardware assembly adequate and safe? The PLC cabinets each include two overhead, 400 Lumen LED fixures 35 Cryoplant Controls Hardware FDR, September 13, 2017 79120-1502

Configruation Heat generated inside the cabinet is removed by fans and filter grilles. These fans are sufficient to reject the ~500W of heat generated inside the cabinet and keep the temperature inside below 50°C. 36 Cryoplant Controls Hardware FDR, September 13, 2017 79120-1502

I/O Breakdown System/IO type Analog Input Analog Output Digital Input Digital Output Temperatures (Pt&Diode) Warm He Comp 11 3 24 9 33 Gas Mgmt 34 4 7 12 Utility 89 21 52 42 4K Cold Box 85 45 60 2K Cold Box 19 Many valves and pressure transducers have HART communication. This provides Remote configuration Advanced diagnostics Access to additional variables (i.e. valve readback without additional input) Cryoplant Controls Hardware FDR, September 13, 2017

Summary The cryoplant control architecture is defined and approved. The control cabinets are tagged, identified and mapped as shown in the assembly and installation drawings. All instruments, wires and I/O are tagged, labelled and listed as shown in the wiring and installation drawings. Adequate spares are included as operational, installed and on the shelf spares. The provided mix reduces the cost and wear of operational spares which may never be used, while still allowing room for expansion. The equipment specified is adequate. All of the instruments have been accounted for. Equivalent equipment has been running at JLab for years. The hardware assembly is adequate and safe. UL and NEC guidelines were followed. Requests from SLAC have been added to the JLab design such as internal lighting and voltage indicators. Cryoplant Controls Hardware FDR, September 13, 2017