Control Logic for ATLAS Thermosiphon chiller brine and

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 1

Control for ATLAS thermosiphon chiller, brine and water system ■ Standard CERN UNICOS control system Ø Ø ■ Control layer: 1 PLC Schneider Premium located in SX 1 SCADA Layer: 1 Win. CC-OA Project located in CCR External communications Ø Ø Ø 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 2

Control for ATLAS thermosiphon chiller, brine and water system ■ Documentation All control logic is described in Functional Analysis: Ø Ø Water and Brine system EDMS #1216919 Ø Functional analysis C 6 F 14 Chiller No 1 EDMS #1165941 Ø Brine and water circuit I/O commissioning tests EDMS #1323221 Ø Specification of control interface between Thermosiphon 60 k. W - Chiller Cooling Control System and ATLAS Detector Control System EDMS #1541750 Ø Specification of CCC alarms for the Thermosiphon 60 k. W Chiller, Brine and Water system EDMS #1355443 Control Logic for ATLAS thermosiphon chiller brine and water circuit 3

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

Brine and Water circuit decomposition SX 1 Water Brine Pump 1 CIP 1301 R FI 1301 ON FI 1301 R PV 1302 Pump 2 CIP 1302 R FI 1302 ON FI 1302 R PV 1304 EH 1301 ON EH 1301 R PV 1301 PV 1801 EH 1301 PCV 1303 Pump 1 CIP 1501 R Pump 2 EH 1301 ON EH 1301 R PV 1301 PV 1801 EH 1301 PCV 1303 Chiiller 1 EDMS 1165951 Chiiller 2 CIP 1501 R Tap. Water EDMS Xxxxxx? ? PV 1901 Control Logic for ATLAS thermosiphon chiller brine and water circuit 5

Chiller P&ID vs process decomposition Air Cooled Condenser Economizer HT CV 59235 Economizer LT Cascade Condenser Normal operation evaporator Warm operation evaporator R 404 R 23 Chiller is very complex machine! Control Logic for ATLAS Thermosiphon circuit 6

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

Overall Chiller Brine and Water commands - decomposition System operation states: STOP OPERATION MAINTENACE BRINE WATER Chiller 1 OFF ON Maint. OFF Man. ON Maint. SX 1 master PCO: • CSMA_SX 1_Air. Flow_AL • CSMA_SX 1_230 VAC_FS • CSMA_SX 1_24 VDC_FS • CSMA_SX 1_PLC_R_FS • CSMA_SX 1_EMS_FS • CSMA_SX 1_Air. P_FS In consequence => all water, brine and chiller system will STOP!! Control Logic for ATLAS thermosiphon chiller brine and water circuit 8

Water Circuit in SH 1 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 9

Water Circuit regulations Regulations: 1. Tap water inlet valve control (PV 1901) based on water system pressure (PT 1901) • SET to OPEN if PT 1901 < t. L • RESET to CLOSE if PT 1901 > t. H 2. Chiller water inlet control valve (PCV 1531) - controlled on R 404 compressor 1 discharge pressure, however at the 2 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 In consequence => chiller shall run in Warm Mode • No flow etc. Alarms which stop individual pump: CSMA_WP 1_No. Flow_FS CSMA_WP 1_HT_FS CSMA_WP 1_Com_FS CSMA_WP 1_CB_FS CSMA_WP 1_EMS_FS etc. In consequence => second pump will start automatically Control Logic for ATLAS thermosiphon chiller brine and water circuit 10

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 11

Brine Circuit regulations Regulations: 1) CIP 1301 x pump speed control: 5 4 o MV: d. P over the pump o SP: 5. 0 bara 2) PCV 1304 3 way bypass valve control: o MV: chiller return temperature TT 1308 o SP: Brine temperature set point – 0. 5 1 3) EH 1301 - Brine dummy load (40 k. W heater) control: 2 3 o MV: brine temperature before TS condenser TT 1109 o SP: Brine temperature set point arrives from TS PLC. 4) PCV 1303 Brine, condenser by-pass valve control: always fully OPEN 5) PV 801 & PV 1802 keep tank pressure inside 2 -3 bara “window” Control Logic for ATLAS thermosiphon chiller brine and water circuit 12

Brine Circuit Alarms CSMA_B_Llevel_AL CSMA_B_PT 1303_AL CSMA_B_HP_AL CSMA_B_LP_AL CSMA_B_HT_AL CSMA_B_MSec_FS CSMA_B_Leak_AL CSMA_B_MV 1305_SI Too low C 6 F 14 level - LT 1301 Brine pressure PT 1303 too high PT 1301 OR PT 1302 too high Brine pressure before filters too low Any Brine TT except TT 1310 too high NOT Msec_OK Brine leak rate too high Manual outlet valve closed FS FS FS AL SI CSMA_B_EH 1301_nfl_TS Brine heater No Flow Alarm TS CSMA_B_EH 1301 HT_ST CSMA_B_CB_ST CSMA_B_Triac_ST CSMA_B_TS_ST Heater temperature exceeded NOT CB_EH 1301_OK NOT EH 1301 OK NOT TS 1301 TS TS CSMA_BP 1_FI 1301_FS CSMA_BP 1_FI 1301 C_FS CSMA_BP 1_HT_FS CSMA_BP 1_HP_FS CSMA_BP 1_LP_FS CSMA_BP 1_GS_FS CSMA_BP 1_EMS_FS CSMA_BP 1_CB_FS CSMA_BP 1_HP_AL CSMA_BP 1_PDT 1301_AL FI 1301 not OK FI 1301 command problem NOT CIP 1301 PTC NOT PS 1301 Pump low pressure alarm Valve closed alarm Emergency Stop Button Alarm Circuit Breaker Tripped Pump 1 high pressure exceeded Pump 1 differential pressure exceeded FS FS FS Stop all the Brine system Only for information Brine system start is not allowed STOP EH 1301 Stop Pump 1 and start Pump 2 Control Logic for ATLAS thermosiphon chiller brine and water circuit 13

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

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

Chiller stepper [0] Stopped: Both compressors are switched off, either by the operator or by the switches on the individual compressor starters [R 404 a Compressor AUTODI = 0 and OFFDI = 1 and R 23 Compressor AUTODI = 0 and OFFDI = 1], all outputs are off including EV 53003 DO {C 6 F 14 ‘Warm Operation’ Evaporator} and EV 53007 DO {C 6 F 14 ‘Normal Operation’ Evaporator}. [1] Available for Warm Operation (WCC): The R 404 a compressor {COMP-59502} is not running, but is available to start, (see Operation State Definition for each compressor). EV-53003 is closed [GH 53003 = 0], EV-53007 is closed [GL 53007 = 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 [GL 59266 = 1], EV-59267 is open [GH 59267 = 1], EV-59268 is closed [GL 59268 = 1]. A C 6 F 14 pump is confirmed as running During ‘Normal Operation’, the chiller will pulldown the C 6 F 14 ‘brine’ temperature from -22. 00 OC 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 36 k. W and 180 k. W. However, {V-53007} will not open until R 23 suction pressure reaches a normal operating level. When the chiller operates in “Warm Operation” mode the R 23 circuit will not be required. During “Warm Operation” the chiller will pulldown the ‘brine’ temperature from 0. 0 o. C to -20. 81 o. C 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 10 k. W and 50 k. W. Nonetheless, V-053003 will not open if the upstream ‘brine’ temperature is below -22°C. [2] Available for Warm Operation (ACC): The R 404 a compressor {COMP-59502} is not running, but is available to start (see Operation State Definition for each compressor). EV-53003 is closed [GH 53003 = 0], EV-53007 is closed [GL 53007 = 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 [GH 59266 = 1], EV -59267 is closed [GL 59267 = 1], EV-59268 is open [GH 59268 = 1]. 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. (see Operation State Definition for each compressor). A C 6 F 14 pump is confirmed as running and both EV-53003 {C 6 F 14 ‘Warm Operation’ Evaporator} or EV-53007 {C 6 F 14 ‘Normal Operation’ Evaporator} are closed [GH 53003 = 0, and GH 53007 = 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 [GL 59266 = 1], EV-59267 is open [GH 59267 = 1], EV-59268 is closed [GL 59268 = 1]. [4] Warm Operation with Air Cooled Condenser ACC: The R 404 a compressor {COMP-59502} is running. EV-53003 is open [GH 53003 = 1], EV-53007 is closed [GL 53007 = 1], The R 23 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 [GL 53003 = 1], EV-53007 is open [GH 53007 = 1]. [6] Warm Operation with Water Cooled Condenser WCC: The R 404 a compressor {COMP-59502} is running. EV-53003 is open [GH 53003 = 1], EV-53007 is closed [GL 53007 = 1], The R 23 compressor {COMP-59512} is not required, so its status is ignored. Water Cooled Condenser is running. Control Logic for ATLAS thermosiphon chiller brine and water circuit 16

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

Chiller R 404 circuit Control Logic for ATLAS thermosiphon chiller brine and water circuit 18

Chiller R 404 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 (EV 53007 OR EV 53003 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 R 404 a 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 R 404 a Compressor Speed Controller if selected to auto, or by the local ‘soft’ buttons on the HMI if selected to manual. However, IF Ch 1_R 404_PT 59207 {R 404 a Compressor Discharge Pressure} <11. 77 bara OR R 404 a Compressor Speed < 85% then the economiser is switched off. Control Logic for ATLAS thermosiphon chiller brine and water circuit 19

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

Chiller R 23 circuit Control Logic for ATLAS thermosiphon chiller brine and water circuit 21

Chiller R 23 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 EV 53007 is open (GH 53007 = 1, Off. St) OR C 6 F 14 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. C 6 F 14 brine flow is >= 10. 0 kg/s and not T 0. [4] Start Inhibit: The compressor is not running, it is available, it has been commanded to start but is prevented because Ch 1_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 R 23 Compressor Speed Controller if selected to auto OR the compressor has been selected to ‘Manual’ on the local HMI or Win. CC 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 R 23 Compressor Speed Controller, but Ch 1_R 23_PT 59336 {R 23 Compressor Suction Pressure} >2. 5 bara OR the economiser is switched off OR brine temperature Ch 1_Ch_TT 53102 > -45 o. C. Control Logic for ATLAS thermosiphon chiller brine and water circuit 22

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

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

LHC Logging – active since 10. 2014 Brine temperature TT 1305 Control Logic for ATLAS thermosiphon chiller brine and water circuit 25

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: ■ ■ ■ Ø ‘Thermosiphon Chiller commissioning procedure’ EDMS 1535476 Control Logic for ATLAS thermosiphon chiller brine and water circuit 26

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 27

Backup slides Touch screen application for the Thermosiphon 60 k. W Chiller as an example ■ Brine and Water touch screen application is not presented in this ppt ■ Control Logic for ATLAS Thermosiphon circuit 28