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Control System for CO2 Test Stand: Requirements and Operation Overview

This document outlines the requirements and operational guidelines for a CO2 test stand control system created by Lukasz Zwalinski. It details the necessary features, including 32 analog inputs and 32 digital outputs, as well as the SCADA system for long-term logging. The document describes operational modes for plant control, interlocks for safety, and the configuration logic for dynamic calculations related to enthalpy based on pressure and temperature measurements. The software requirements for the UNICOS project are also summarized.

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Control System for CO2 Test Stand: Requirements and Operation Overview

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  1. CO2progress and issues on the control system Lukasz Zwalinski – PH/DT 09.02.2009

  2. Requirements for CO2 test stand Requirements for test stand: • 32 Analog Inputs • 4 Analog Outputs • 32 Digital Inputs • 32 Digital Outputs • SCADA system with long term logging L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  3. Plant operation CO2PCO There will be one PCO with 3 option modes driven by allowance table 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) L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  4. CO2PCO Safety position 0 Start up request Start up 1 T1 T0 Cool down request Cool down loop 2 T2 T0 Cool down accumulator request Cool down accumulator 3 T0 Plant operation In option mode Stand-By we can distinguish stepper with 4 steps associated 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) L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  5. Dynamically calculated f(Rth) 0 ÷ 100 % Analog Digital Object High limit PID Out High limit EH1104 PWM MV OutO 0÷100% SP Out Low limit Low limit 0% IF > 0 Then EH ON ELSE OFF IF < 0 Then CV ON ELSE OFF PT1103 Acc. Tsp Psat(Tsp) 0% Analog Object Out High limit High limit PID CV1104 MV PWM OutO 0÷100% SP Out Low limit Low limit Dynamically calculated f(sub-cool) 0 ÷ -100 % Accumulator Control L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  6. Accumulator Control Sub cooling: Thermal resistance: subcool = Tsat(PT1103) – TT1110 calculated every 5s L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  7. Interlocks L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  8. logic L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  9. 2 3 5 6 4 1 Enthalpy (kJ/kg) Enthalpy control Øm = Qexperimet / (h5 - h4) Qheater = (hrequested - h3) * Øm Tsat = B / [ln(P)-A]-C A = 10.77 B = -1956 C = 271.04 • 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). L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  10. UNICOS user interface L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

  11. Software preparation UNICOS project creation:1 – Exel specyfication preparation 2 – PLC hardware configuration3 – PLC & PVSS instance generation4 – Process logic programation5 – Code compilation 6 – Loadingto PLC7 – Commisionig & operation Specyfication SCADA server Instance Generator SIEMENS PLC Logic Generator All generated files will be kept in Subversion Version Control (SVN) service. L.Zwalinski – PH/DTCO2 test stand control system 10.02.2010

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