Chiller control system Lukasz Zwalinski – PH/DT

Automatic call of operators in case of failure or alarm Failure diagnostic tools User friendly man-to-machine interface Long term data storage Full automatic remote control through the CERN TN Schneider PLC and I/O Maintain the PLC by CERN team Project requirements L.Zwalinski – PH/DT/PO General requirements: Ensure stable long, safe and automatic operation without presence of the operators Provide safe shut-down and automatic restart procedures in case of failure Automatic adjustment of the cooling power to the actual load (between 20%-100%) Enable possibility of fast changes on control system by CERN personel Control system conforming CERN standards To fulfill this requirements CERN will provide: CERN’s standard for PLC and SCADA UNICOS framework (UNified Industrial COntrol System) SCADA system with long term logging (PVSS 3.8)

Split of the responsibilities 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&ID 3.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 block Limit of the supplier Logic Generator Instance Generator Software production Collaboration of Supplier and CERN CERN limit General Control System Requirement

L.Zwalinski – PH/DT/PO Electrical control and pneumatic cabinets For maintenance reason it shall be possible to disconnect independently each one of the chillers from the electrical supply during nominal operation without interfering with the normal operation. Electrical cabinet 50% spare space for additional equipment Control and pneumatic cabinet 30% spare channels cabled to terminal block 50% spare space for additional equipment One electrical cabinet for each chiller and one for the brain circuit Electrical schematics have to be prepared in: Microsoft Visio, Tracelec or AUTOCAD All equipment, cables and wires in the cabinets shall be labeled All the equipment and the instrumentation shall be labeled with the tag code provided by CERN Justification of sizing cables and protection devices have to be prepared in TR-Ciel software CERN provide the color code for the internal wiring Emergency stop button has to be present on each cabinet with feedback signal to the PLC Feedback signals form each CB and TS should be connected to the PLC Supplier has to ensure that in case of PLC failure the basic protection against damage in particular compressors must be provided by the hard wired interlocks. The status of the hard wired interlock has to be available in the PLC. Max 2m from floor level

L.Zwalinski – PH/DT/PO Summary Before manufacturing the electrical and control cabinets all the electrical drawings and the layout have to be approved by CERN in writing. Detailed control, electrical and instrumentation requirements can be found in Annex 5: Control and Regulation Annex 6: Instrumentation Annex 7: Electricity

L.Zwalinski – PH/DT/PO System architecture - option with 1 CPU Chiller system Chiller 1Chiller 2 CVxxx COP EHxxx PVxxx ONE PLC solution CVxxx COP EHxxx PVxxx Brine Pump1 Pump2 In example: in case of failure or maintenance this part is deactivated

System architecture - option with 1 CPUSystem architecture - option with 1 CPU and backplane extension L.Zwalinski – PH/DT/PO Ring topology M340 with Multi-Port Module BrineThermosiphon ETHERNET IP surface Brine OWS DIP Distributed I/|O Chiller 2 back plane extension CPU + I/O cardsI/O cards Chiller 1Water I/O cards back plane extension 1 CPU and backplane extension: + 1 PVSS data server + no need to build up software communication + simple !