Control Logic for ATLAS Thermosiphon chiller brine and water circuit L. Zwalinski – EP/DT March 2016 Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control for ATLAS thermosiphon chiller, brine and water system Standard CERN UNICOS control system Control layer: 1 PLC Schneider Premium located in SX1 SCADA Layer: 1 WinCC-OA Project located in CCR External communications Exchange of temperature and set-point with Thermosiphon PLC (hardwire) Interlocks sent to DSS (hardwire): to be done Process data and installation status sent to ATLAS DCS (MODBUS) Publication of all sensors/alarms/status for ATLAS DCS (DIP) Alarm summaries sent to CCC (LASER) Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control for ATLAS thermosiphon chiller, brine and water system Documentation All control logic is described in Functional Analysis: Water and Brine system EDMS #1216919 Functional analysis C6F14 Chiller No 1 EDMS #1165941 Brine and water circuit I/O commissioning tests EDMS #1323221 Specification of control interface between Thermosiphon 60kW - Chiller Cooling Control System and ATLAS Detector Control System EDMS #1541750 Specification of CCC alarms for the Thermosiphon 60kW Chiller, Brine and Water system EDMS #1355443 Control Logic for ATLAS thermosiphon chiller brine and water circuit

Overall control system architecture Control Logic for ATLAS thermosiphon chiller brine and water circuit

Brine and Water circuit decomposition CIP1301 CIP1301R FI1301ON FI1301R PV1302 EH1301ON EH1301R PV1301 PV1801 EH1301 PCV1303 SX1 Brine Water Chiiller1 EDMS 1165951 Pump1 Pump2 CIP1302 CIP1302R FI1302ON FI1302R PV1304 CIP1501 CIP1501R TapWater PV1901 Chiiller2 Xxxxxx?? Control Logic for ATLAS thermosiphon chiller brine and water circuit

Normal operation evaporator Warm operation evaporator Chiller P&ID vs process decomposition Air Cooled Condenser Economizer HT Economizer LT CV59235 Cascade Condenser Normal operation evaporator Warm operation evaporator R404 R23 Chiller is very complex machine! Control Logic for ATLAS Thermosiphon circuit

Chiller circuit decomposition Control Logic for ATLAS thermosiphon chiller brine and water circuit

Overall Chiller Brine and Water commands - decomposition System operation states:   BRINE WATER Chiller1 STOP OFF OPERATION ON Man.ON MAINTENACE Maint. SX1 master PCO: CSMA_SX1_AirFlow_AL CSMA_SX1_230VAC_FS CSMA_SX1_24VDC_FS CSMA_SX1_PLC_R_FS CSMA_SX1_EMS_FS CSMA_SX1_AirP_FS In consequence => all water, brine and chiller system will STOP!! Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Water Circuit in SH1 WATER system & Pump PCO [Stop]: This is the fail safe state in which all units and actuators are stopped. [Run]: Nominal state in which Water system is operated with one pump and tap water units in Operation mode. Selected pump depends on the priority or availability. [Maintenance]: Water system is in Maintenance and all units are in Maintenance mode. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Water Circuit regulations Tap water inlet valve control (PV1901) - based on water system pressure (PT1901) SET to OPEN if PT1901 < tL RESET to CLOSE if PT1901 > tH Chiller water inlet control valve (PCV1531) - controlled on R404 compressor discharge pressure, however at the moment best chiller performance is achieved when the valve is fully open. Alarms which stop all water system: Leak alarm Main insulator is off High temperature PDT No flow etc. Alarms which stop individual pump: 1 2 In consequence => chiller shall run in Warm Mode CSMA_WP1_NoFlow_FS CSMA_WP1_HT_FS CSMA_WP1_Com_FS CSMA_WP1_CB_FS CSMA_WP1_EMS_FS etc. In consequence => second pump will start automatically Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Brine Circuit Brine system & Pump PCO [Stop]: This is the fail safe state in which all units and actuators are stopped but tank control.   [Run]: Nominal state in which Brine system is operated with one pump unit in operation mode. Pump is selected by the priority or availability. [Maintenance]: Brine system is in Maintenance and all sub units are in Maintenance mode. Additional functionalities: pump auto swap procedure based on priority selection leak detection mechanism tank pressure control. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Brine Circuit regulations 1) CIP1301x pump speed control: MV: dP over the pump SP: 5.0 bara 2) PCV1304 3 way bypass valve control: MV: chiller return temperature TT1308 SP: Brine temperature set point – 0.5 3) EH1301 - Brine dummy load (40kW heater) control: MV: brine temperature before TS condenser TT1109 SP: Brine temperature set point arrives from TS PLC. 4) PCV1303 Brine, condenser by-pass valve control: always fully OPEN 5) PV801 & PV1802 keep tank pressure inside 2-3bara “window” 5 4 1 3 2 Control Logic for ATLAS thermosiphon chiller brine and water circuit

Stop all the Brine system Brine Circuit Alarms CSMA_B_Llevel_AL Too low C6F14 level - LT1301 FS Stop all the Brine system CSMA_B_PT1303_AL Brine pressure PT1303 too high CSMA_B_HP_AL PT1301 OR PT1302 too high CSMA_B_LP_AL Brine pressure before filters too low CSMA_B_HT_AL Any Brine TT except TT1310 too high CSMA_B_MSec_FS NOT Msec_OK CSMA_B_Leak_AL Brine leak rate too high AL Only for information CSMA_B_MV1305_SI Manual outlet valve closed SI Brine system start is not allowed CSMA_B_EH1301_nfl_TS Brine heater No Flow Alarm TS STOP EH1301 CSMA_B_EH1301HT_ST Heater temperature exceeded CSMA_B_CB_ST NOT CB_EH1301_OK CSMA_B_Triac_ST NOT EH1301OK CSMA_B_TS_ST NOT TS1301 CSMA_BP1_FI1301_FS FI1301 not OK Stop Pump 1 and start Pump 2 CSMA_BP1_FI1301C_FS FI1301 command problem CSMA_BP1_HT_FS NOT CIP1301PTC CSMA_BP1_HP_FS NOT PS1301 CSMA_BP1_LP_FS Pump low pressure alarm CSMA_BP1_GS_FS Valve closed alarm CSMA_BP1_EMS_FS Emergency Stop Button Alarm CSMA_BP1_CB_FS Circuit Breaker Tripped CSMA_BP1_HP_AL Pump1 high pressure exceeded CSMA_BP1_PDT1301_AL Pump1 differential pressure exceeded Control Logic for ATLAS thermosiphon chiller brine and water circuit

Brine Circuit – pumps detailed view Control Logic for ATLAS thermosiphon chiller brine and water circuit

Chiller stepper (operation modes) Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller stepper [0] Stopped: Both compressors are switched off, either by the operator or by the switches on the individual compressor starters [R404a Compressor AUTODI = 0 and OFFDI = 1 and R23 Compressor AUTODI = 0 and OFFDI = 1], all outputs are off including EV53003DO {C6F14 ‘Warm Operation’ Evaporator} and EV53007DO {C6F14 ‘Normal Operation’ Evaporator}. [1] Available for Warm Operation (WCC): The R404a compressor {COMP-59502} is not running, but is available to start, (see Operation State Definition for each compressor). EV-53003 is closed [GH53003 = 0], EV-53007 is closed [GL53007 = 1]. The chiller will be using the Water Cooled Condenser and the automatic changeover valves have been set and confirmed for this condenser; EV-59266 is closed [GL59266 = 1], EV-59267 is open [GH59267 = 1], EV-59268 is closed [GL59268 = 1]. A C6F14 pump is confirmed as running [2] Available for Warm Operation (ACC): The R404a compressor {COMP-59502} is not running, but is available to start (see Operation State Definition for each compressor). EV-53003 is closed [GH53003 = 0], EV-53007 is closed [GL53007 = 1]. The chiller is using the Air Cooled Condenser and the automatic changeover valves have been set and confirmed for this condenser; EV-59266 is open [GH59266 = 1], EV-59267 is closed [GL59267 = 1], EV-59268 is open [GH59268 = 1]. 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. (see Operation State Definition for each compressor). A C6F14 pump is confirmed as running and both EV-53003 {C6F14 ‘Warm Operation’ Evaporator} or EV-53007 {C6F14 ‘Normal Operation’ Evaporator} are closed [GH53003 = 0, and GH53007 = 0]. The chiller is using the Water Cooled Condenser and the automatic changeover valves have been set and confirmed for this condenser; EV-59266 is closed [GL59266 = 1], EV-59267 is open [GH59267 = 1], EV-59268 is closed [GL59268 = 1]. [4] Warm Operation with Air Cooled Condenser ACC: The R404a compressor {COMP-59502} is running. EV-53003 is open [GH53003 = 1], EV-53007 is closed [GL53007 = 1], The R23 compressor {COMP-59512} is not required, so its status is ignored. Air Cooled condenser is running. [5] Normal Operation: Both compressors are running. EV-53003 is closed [GL53003 = 1], EV-53007 is open [GH53007 = 1]. [6] Warm Operation with Water Cooled Condenser WCC: The R404a compressor {COMP-59502} is running. EV-53003 is open [GH53003 = 1], EV-53007 is closed [GL53007 = 1], The R23 compressor {COMP-59512} is not required, so its status is ignored. Water Cooled Condenser is running. During ‘Normal Operation’, the chiller will pulldown the C6F14 ‘brine’ temperature from -22.00OC to -70.25 OC through the ‘Normal Operation’ Evaporator {E-59509} after opening actuated isolating valve {V-53007} and closing actuated isolating valve {V-53003}. The ‘brine’ Chiller will then produce a cooling capacity between 36kW and 180kW. However, {V-53007} will not open until R23 suction pressure reaches a normal operating level. When the chiller operates in “Warm Operation” mode the R23 circuit will not be required. During “Warm Operation” the chiller will pulldown the ‘brine’ temperature from 0.0oC to -20.81oC through the ‘Warm Operation’ Evaporator {E-59516} after opening actuated isolating valve {V-53003} while keeping actuated isolating valve {V-53007} closed. The Chiller will then produce a cooling capacity between 10kW and 50kW. Nonetheless, V-053003 will not open if the upstream ‘brine’ temperature is below -22°C. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller global alarms Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller R404 circuit Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller R404 stepper [1] Stopped: The compressor is not running. 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) or a ‘Full Stop Interlock’ has been triggered (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). [2] Waiting: The compressor is not running. It is not tripped. The starts per hour & stop to start timer are running OR (EV53007 OR EV53003 is open). [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/Manual: The compressor has been selected to ‘Auto’ on the local HMI or WINCC OA 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 OR the compressor has been selected to ‘Manual’ on the local HMI or WINCC OA and has been commanded to start by the manual ‘soft key’ start button on the HMI or manual start via PCO faceplate 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. However, IF Ch1_R404_PT59207 {R404a Compressor Discharge Pressure} <11.77 bara OR R404a Compressor Speed < 85% then the economiser is switched off. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Chiller high temperature stage Alarms Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller R23 circuit Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Chiller R23 stepper [1] Stopped: The compressor is not running. 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) or one or more of the compressor operating parameters has reached a software trip threshold, or a hard wired protection device has stopped the compressor. [2] Waiting: The compressor is not running. It is not tripped. The starts per hour timer & stop to start timer are running, or EV53007 is open (GH53007 = 1, OffSt) OR C6F14 brine flow is <= 6.0 kg/s [3] Available: The compressor is not running, it is not tripped, it is not waiting, and the starter control panel switch is in the ‘ON’ position (AUTODI = 1 & OFFDI = 0). The compressor is waiting for a command to start. C6F14 brine flow is >= 10.0 kg/s and not T0. [4] Start Inhibit: The compressor is not running, it is available, it has been commanded to start but is prevented because Ch1_CC_PT-59321 {Cascade Condenser Inlet Pressure} > 16.0 bara. [5] Running Auto/Manual: The compressor has been commanded to start and is running normally within the designed operating envelope and can vary its speed according to the R23 Compressor Speed Controller if selected to auto OR the compressor has been selected to ‘Manual’ on the local HMI or WinCC OA and has been commanded to start by the manual ‘soft key’ start button on the HMI or manual start via PCO faceplate and can vary its speed according to the local ‘soft keys’ Manual Speed Increase & Manual Speed Decrease. [7] 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 R23 Compressor Speed Controller, but Ch1_R23_PT59336 {R23 Compressor Suction Pressure} >2.5 bara OR the economiser is switched off OR brine temperature Ch1_Ch_TT53102 > -45oC. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Chiller low temperature stage Alarms Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit CCC Alarms Control Logic for ATLAS thermosiphon chiller brine and water circuit

LHC Logging – active since 10.2014 Brine temperature TT1305 Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit System tests: Alarm thresholds tuning. PID parameters tuning. Orifice brine flowmeter and scale calibration. Several brine issues solved EDMS 1498362. Brine cooling speed checked. Brine pump performance checked. Chiller performance checked EDMS 1554017 v.1 Chiller test performed large number of times in different configurations. This has indicated need of significant control methods modifications requested by J&E Hall. Water system operation tests completed. Failure modes (Alarms) for Brine & Water are verified. Failure modes (Alarms) for Chiller, verified but result on power cut is not yet satisfactory. And much more. Please see also: ‘Thermosiphon Chiller commissioning procedure’ EDMS 1535476 Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS thermosiphon chiller brine and water circuit Conclusions: System is fully operational. All communication channels but DSS are active Still some control changes required due to the chiller modifications minor/major? Not clear for the moment. Is there anything on Chiller, Brine or Water side that can damage the detector? No as far as I can imagine for the upcoming test. Control Logic for ATLAS thermosiphon chiller brine and water circuit

Control Logic for ATLAS Thermosiphon circuit Backup slides Touch screen application for the Thermosiphon 60kW Chiller as an example Brine and Water touch screen application is not presented in this ppt Control Logic for ATLAS Thermosiphon circuit

Welcome panel

Main panel Log in

Main panel Log in Push navigation buttons

Main panel State indication

Double click action Double click available after log in Local mode indication Double click available after log in

PVSS main panel Local mode indication

Chiller Stepper

Chiller Alarms Double click Double click

Chiller Alarms List

Chiller input/output temp. terend

R404 compressor panel

R404 stepper panel

R404 alarm panel

R404 Economiser High Temperature panel

R404 Warm Operation Evaporator panel

R404 Cascade Condenser panel

R404 Air Cooled Condeser panel

R23 Compressor panel

R23 Stepper panel

R23 Alarms panel

R23 Economiser Low Temperature panel

R23 Normal Operation Evaporator panel

R23 NOE Alarms panel