1. 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

2. 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

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

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

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

6. 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

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

8. 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

9. 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

10. 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

11. 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

12. Brine Circuit regulations
1) CIP1301x pump speed control:
MV: dP over the pump
SP: 5.0 bara
2) PCV way bypass valve control:
MV: chiller return temperature TT1308
SP: Brine temperature set point – 0.5
3) EH 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

13. 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

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

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

16. 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 is closed [GH53003 = 0], EV 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 is closed [GL = 1], EV is open [GH59267 = 1], EV 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 is closed [GH53003 = 0], EV 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 is open [GH59266 = 1], EV is closed [GL59267 = 1], EV 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 {C6F14 ‘Warm Operation’ Evaporator} or EV {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 is closed [GL59266 = 1], EV is open [GH59267 = 1], EV is closed [GL59268 = 1].
[4] Warm Operation with Air Cooled Condenser ACC: The R404a compressor {COMP-59502} is running. EV is open [GH53003 = 1], EV 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 is closed [GL = 1], EV is open [GH53007 = 1].
[6] Warm Operation with Water Cooled Condenser WCC: The R404a compressor {COMP-59502} is running. EV is open [GH53003 = 1], EV 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 OC to 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 oC 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 will not open if the upstream ‘brine’ temperature is below -22°C.
Control Logic for ATLAS thermosiphon chiller brine and water circuit

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

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

19. 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

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

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

22. 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 {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

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

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

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

26. 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
Brine cooling speed checked.
Brine pump performance checked.
Chiller performance checked EDMS 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
Control Logic for ATLAS thermosiphon chiller brine and water circuit

27. 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

28. 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

29. Welcome panel

30. Main panel
Log in

31. Main panel
Log in
Push navigation buttons

32. Main panel
State indication

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

34. PVSS main panel
Local mode indication

35. Chiller Stepper

36. Chiller Alarms
Double click
Double click

37. Chiller Alarms List

38. Chiller input/output temp. terend

39. R404 compressor panel

40. R404 stepper panel

41. R404 alarm panel

42. R404 Economiser High Temperature panel

43. R404 Warm Operation Evaporator panel

44. R404 Cascade Condenser panel

45. R404 Air Cooled Condeser panel

46. R23 Compressor panel

47. R23 Stepper panel

48. R23 Alarms panel

49. R23 Economiser Low Temperature panel

50. R23 Normal Operation Evaporator panel

51. R23 NOE Alarms panel