Functional Analysis and Control System for the Thermosiphon Chiller Lukasz Zwalinski PH/DT/PO - Cooling

Introduction Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO liquid tank USA15 cavern Surface ATLAS ID Detector UX15 cavern Normal operation evap. R404a Cascade condenser Water condenser R23 Warm operation evap. Air condenser C6F14 brine circuit Normal operation C to C Warm operation C to C 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 20 th 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 requirements channel number J&E Hall Selected card number CERN 48 AI3x16AI 4 AO1x8AO 128 DI2x64DI 64 DO1x64DO I/O number Selected card number CERN 32 AI3x16AI 8 AO1x8AO 64 DI1x64DI 32 DO1x32DO

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

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

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

Status Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO SupplierCERN (Chiller) TaskStatusTaskStatus Electrical design for compressor panelDelivered Electrical design for compressor panel (verification) Accepted Electrical design for control cabinetUnknown ? 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)DeliveredFunctional analysis (verification)Accepted Instrumentation list (preparation)DeliveredInstrumentation 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 orderCompleted 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 list UNICOS object design Should start soon PLC software production PVSS software production Should start soon Mirror software testsNot started

Functional analysis organization Thermosiphon workshop §5 20 th 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 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 … EDMS

Process decomposition Thermosiphon workshop §5 20 th 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 CV59240 EV59246 CV59232 CV59233 F59505A F59505B F59505C F59505D COMP59502 CV59201 CV59202 CV59213 GT59263 COMP59112 CV59301 CV59302 GT59364 EV53003 EV53007 CV59326 CV59330 CV59331 CV59332 CV59333 CV59318 CV59314 R404 Chiller 1Chiller 2BrineWater R23 … Chiller System To be defined Has to be defined in next 2 weeks maximum

P&ID vs process decomposition Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO CV59235 Economizer HT Air Cooled Condenser Cascade Condenser R404 R23 Warm operation evaporator Economizer LT Normal operation evaporator

Chiller 1 – Option modes and operation states Thermosiphon workshop §5 20 th 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 is confirmed open, EV is closed. The chiller is using the Water Cooled Condenser and the manual changeover valves have been set for this condenser. A C 6 F 14 pump is confirmed as running. [2] Available for Warm Operation (ACC): The R404a compressor is not running, but is available to start. EV is confirmed open, EV 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 C 6 F 14 pump is confirmed as running. [3] Available for Normal Operation: Both compressors are available to start. A C 6 F 14 pump is confirmed as running and either EV or EV is open. [4] Warm Operation with Air Cooled Condenser ACC: The R404a compressor is running. EV is open,EV 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 is closed, EV is open. [6] Warm Operation with Water Cooled Condenser WCC: The R404a compressor is running. EV is open, EV 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 20 th October 2011 L.Zwalinski – PH/DT/PO T0 = Transition from any state to STOP A C 6 F 14 pump running = 0 EV AND EV = 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 6 F 14 pump must be confirmed as running Either EV or EV 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 C 6 F 14 pump must be confirmed as running Either EV or EV 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 C 6 F 14 pump must be confirmed as running Either EV or EV 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 C 6 F 14 brine temperature TT53101< o 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

R404 - compressor PCO operation states and transitions Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO 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 running T2 = ‘Starts per Hour’ timer is NOT running AND ‘Stop to Start’ timer is NOT running AND starter control panel switch is in the ‘ON’ position (AUTODI = 1, OFFDI = 0  OnSt) AND (EV or EV is open) AND C 6 F 14 Pump running. T3 = Chiller start command = Chiller.RunOrder T4 = PT {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 and EV is not open), or C 6 F 14 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 {R404a Compressor Discharge Pressure} <11.77 bara and the economiser is switched off

Summary logic description table example Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO Actuator Stopped [1] Waiting [2]Available [3]Run [4]Run Non Economized [5] Tripped [0] Comp59502OFF 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.Out O 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!) CV59201 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 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 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

Alarm parameters and recipes parameters Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO NameDescriptionMin ValueMax ValueDefault ValueUnitsAccess Level R404_CV59202_pl Loading Solenoid Pulse Length SecCommissioning R404_CV59201_pl Unloading Solenoid Pulse Length SecCommissioning R404_CV59213_pp Liquid Injection Solenoid Pulse Period SecCommissioning R404_CV59213_mpl Liquid Injection Solenoid Minimum Pulse Length SecCommissioning R404_CV59213_tTStart Discharge Temperature to Start Liquid Injection Control oCoCTechnician R404_CV59213_tTStop Discharge Temperature to Stop Liquid Injection Control oCoCTechnician R404_Spare01Not Used R404_MS59263_sr Speed Reduction every 30s when System Limiting 1205%Commissioning R404_CV59201_pn Number of pulses every 30s when Motor Current Limiting 1155-Commissioning

Computed variables Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO NameDescriptionUnitCalculation Range R404-ODP Oil Differential Pressure barPT – PT R404-OFPD Oil Filter Pressure Drop barPT – PT R404- DSH Discharge Superheat KSee notes below R404_LS1 Limit System Condition Level 1 BOOL R404_LP_LS1 OR R404_HP_LS1 OR R404_LS2 Limit System Condition Level 2 BOOL R404_LP_LS2 OR R404_HP_LS2 OR Description: Discharge Temperature (Saturated)(K) (T sat ) is calculated from this equation: T sat = A + (B x (LnP)) + (C x ((LnP)^2)) + (D x ((LnP)^3)) Discharge Superheat = Discharge Temperature (Actual)(K) – Discharge Temperature (Saturated)(K) Range Dead band 0.085K Tsat is available and archived in PVSS Where A = B = C = D = P = PT {R404a Compressor Discharge Pressure} (bara) T sat = Tsat59207 Then: R404-DSH = TT T sat Definition:

Summary and what’s next? Thermosiphon workshop §5 20 th October 2011 L.Zwalinski – PH/DT/PO Chiller Functional Analysis and I/O List accepted on Hardware Ethernet IP tests in progress. In 2 weeks time I’ll start preparation of UNICOS object list