1. CO2 progress and issues on the control system Lukasz Zwalinski – PH/DT 09.02.2009

2. Requirements for test stand: 32 Analog Inputs 4 Analog Outputs 32 Digital Inputs 32 Digital Outputs SCADA system with long term logging Requirements for CO2 test stand L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

3. There will be one PCO with 3 option modes driven by allowance table Plant operation L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010 StopStand-ByRun Stopx10 Stand-By1x1 Run11x Switch between modes is executed manually by the operator request. Start interlock: all requests are blocked when ON SI1 – NO Option Mode Selected Temporary Stop interlock: sends OFF request to the object when ON TS1 – NO 24V PS01 Status OK; [10s delay] Full Stop interlock: sends OFF request to the object & waits acknowledge when ON FS1 – NO Process Stop Button OK OR NO Process Stop OK; [2s delay] FS2 – HPC Pressure Switch Low =1 OR Pressure Switch High =1 [5s delay] FS3 – Pump Thermal Switch TSL1101 [5s delay] Configuration logic: FeedBackON = True IF CO2 PCO (Run Order & One of the option modes selected) FeedBackOFF = False IF NO CO2 PCO (Run Order & One of the option modes selected) CO 2 PCO

4. Plant operation L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010 2 Start up 1 CO 2 PCO T1 Cool down loop Safety position 3 0 Cool down accumulator T2 T0 Start up request Cool down request Cool down accumulator request In option mode Stand-By we can distinguish stepper with 4 steps associated Safety positionIt is preparation step before plant start up. All objects are switched off. Start upAccumulator is heated up to 27C. When TRUE loop should be filled with liquid and then pump might be switched on. Cool down loopOnce liquid circulation is achieved chiller might be switched on. Accumulator is still kept at high pressure and the condenser will sub-cool the liquid. This is important to assure that CO2 is out of the 2-phase region flowing sub-cooled liquid in to the pump. Cool down accumulatorstarting the accumulator cooling spiral Transition conditions: T0 = Not Run Order OR Not Option Mode Stand-by T1 = Run Order & Option Mode Stand-by & liquid circulation is achieved  Pump ON & FT1901 > xx T2 = Run Order & Option Mode Stand-by & TT1110 – 30C < TTsat(calculated from PT1104)

5. Accumulator Control PT1103 Acc. T sp PID MV SP EH1104 Out High limit Out Low limit Low limit High limit 0% Dynamically calculated f(R th ) 0 ÷ 100 % PID Out Low limit Out High limit MV SP P sat (Tsp) CV1104 Low limit High limit Dynamically calculated f(sub-cool) 0 ÷ -100 % 0% OutO IF > 0 Then EH ON ELSE OFF IF < 0 Then CV ON ELSE OFF Analog Digital Object Analog Object PWM 0 ÷100% PWM 0 ÷100% L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

6. Accumulator Control calculated every 5s Thermal resistance: CO2_B158_PC1104minRth50 mK/W CO2_B158_PC1104maxRth75 mK/W CO2_B158_ PC1104OutHmin25 % CO2_B158_ PC1104OutHmax100 % subcool = T sat (PT1103) – TT1110 Sub cooling: CO2_B158_PC1401scH5 K CO2_B158_PC1401scL3 K CO2_B158_ PC1401OutLmin-10 % CO2_B158_ PC1401OutLmax-100 % L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

7. Interlocks Pump_ST1IF TT1101 > ? o C Then Pump OFF Pump_ST2IF CB_Pump_OK = FALSE Then Pump OFF HPC_ST1IF TT1110 < -55 o C Then HPC OFF HPC_ST2IF (PSL OR PSH) = TRUE Then HPC OFF HPC_ST3IF CB_HPC_OK = FALSE Then HPC OFF EHHPC_ST1IF CB_EHHPC_OK = FALSE Then EHHPC OFF EHHPC_ST2IF HPC.OffST = TRUE Then EHHPC OFF ???? EH1101_ST1IF CB_EH_OK = FALSE Then Heater OFF EH1101_ST2IF TT1101 > threshold Then Heater OFF EH1102_ST1IF CB_EH_OK = FALSE Then Heater OFF EH1102_ST2IF TT1102 > threshold Then Heater OFF EH1102_ST3IF TS = 1 Then Heater OFF EH1903_ST1IF CB_EH_OK = FALSE Then Heater OFF EH1903_ST2IF TT11## > threshold Then Heater OFF L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

8. logic L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010 STOP Safty position Start-upCool down loop Cool down accumulator Run EH1101 Pump oil bathOFF Reg TT1101 SP= EH1102 DumperOFF Reg TT1102 SP = EH1104 AccumulatorOFF Reg PT1103 SP=27C OFF EH1301 ChillerOFF ON EH1903 after supply/return HXOFF IF TT1103 -20C ≤ Tsat(PT1105) AND Manual On Request = True THEN EH1903 = ON EH1903.AuPosR (Positon request = power) (hrequested - h3) * Øm CV1104OFF Reg PT1103 SP= PumpOFF IF TT1110 – 3C < TTsat(calculated from PT1104) THEN ON ChillerOFF IF TT1110 ≥ -55C Then Chiller = ON Else Chiller = OFF

9. Enthalpy control Øm = Qexperimet / (h5 - h4) 5 6 1 4 2 3 Enthalpy (kJ/kg) Qheater = (hrequested - h3) * Øm It is not possible directly control the enthalpy in a PID loop. The enthalpy must be derived from measured pressure and temperature and always be present in the liquid phase which means that measured temperature should be at least 2C lower than calculated Tsat. IF TT1103 -2C ≤ Tsat(PT1105) THEN enthalpy calculation ON The enthalpy of point 3 can also be in the 2-phase area The PLC is calculating enthalpy of a point 2 from measured temperature (TT1103) and pressure (PT1105). Tsat = B / [ln(P)-A]-C A = 10.77 B = -1956 C = 271.04 L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

10. UNICOS user interface L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010

11. Software preparation SCADA server Logic Generator Instance Generator Specyfication SIEMENS PLC UNICOS project creation: 1 – Exel specyfication preparation 2 – PLC hardware configuration 3 – PLC & PVSS instance generation 4 – Process logic programation 5 – Code compilation 6 – Loading to PLC 7 – Commisionig & operation All generated files will be kept in Subversion Version Control (SVN) service. L.Zwalinski – PH/DT CO2 test stand control system 10.02.2010