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P and S Automation Limited

Provision Refrigeration Compressor Control System Manual


P & S Contract 2144P

P & S Automation Limited. Project: Provision Refrigeration Compressors Control System Manual Contract 2144P November 2009

Table of Contents: 1.
1.1

Introduction .............................................................................................................................3
Operation Notes ..........................................................................................................................................3

2.
2.1 2.2 2.3 2.4

Overview and Description ......................................................................................................3


Operating Philosophy..................................................................................................................................3 Alarms.........................................................................................................................................................3 Sea Water Pumps ........................................................................................................................................3 H.T. Compressors .......................................................................................................................................4 2.4.1 Hand Operation ...........................................................................................................................................4 2.4.2 Auto Operation............................................................................................................................................4 2.4.3 Condenser Control Valve Operation. ..........................................................................................................5 2.5 L.T. Compressors........................................................................................................................................6 2.6 Subcooling Operation. ................................................................................................................................7

3. 4.
4.1 4.2 4.3

PLC Program Notes ................................................................................................................7 HMI Operation ........................................................................................................................9


Home Page ..................................................................................................................................................9 Compressor Screens ..................................................................................................................................10 Settings Pages ...........................................................................................................................................14

5. 6.

Appendix 1. Alarm List......................................................................................................28 Appendix 2. - Settings ...........................................................................................................30

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1.

Introduction

This system is to control two off Sabroe CMO26 & two of TCMO28 compressors. The original Siemens control PLC has been replaced with a new Mitsubishi control PLC and HMI in November 2009. 1.1 Operation Notes After a compressor has tripped out on a fault condition, switch the control selector switch back to Stop, then press the Mute button to accept the fault. Press the Alarm button on the HMI to show the alarm list to see what alarm has tripped the compressor. If the fault is one that has to be reset externally (e.g. KP15 Temperature) then once it has been reset press the mute again, the alarm will now clear (shown on the alarm list as no symbol to the left of the alarm). To make changes in the HMI there is a requirement to first Login. To Login press the Login button (1st function key) then enter 8786 and press the enter key, the Login will stay active for 30 minutes then automatically log out.

2.

Overview and Description

2.1 Operating Philosophy The system controls 4 refrigeration compressors. No.1 & 2 are on the H.T. circuit and No.3 & 4 are on the L.T. circuit. Each compressor has an associated sea water pump. 2.2 Alarms There are 40 alarms installed into the system, the complete alarm list is detailed in appendix 1. When an alarm occurs, the Common Alarm output relay is energised, the running lamp for the pump or compressor associated with the alarm will flash. The alarm will show on the HMI in the alarm banner on the home page and in the alarm list. To accept the alarm press the mute button on the panel or the Ack button on the HMI. 2.3 Sea Water Pumps Each of the 4 sea water pumps is controlled as detailed below: When the front panel selector switch is set to Off the SW pump will not run. When the front panel selector switch is set to Hand the pump will start and continue to run provided the Common Emergency Stop and Pump Overload are not active.

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When the front panel selector switch is set to Auto the pump will start 30 second before the compressor starts and then continue to run until 15 seconds (set by adjustable SW Pump Stop Delay timer) after the compressor has stopped. If the Emergency Stop is activated the pump will stop. If the Thermal Overload is activated the pump will stop, the running light will flash and the Common Alarm relay will de-energise. 2.4 H.T. Compressors 2.4.1 Hand Operation Providing the compressor is OK to Run (no shutdown alarms present see appendix 1.), the sea water pump is running and the emergency stop is not active, if the control selector switch is set too 33% the compressor will start and continue to run. The running lamp will illuminate and the Running relay will energise, this will energise the Running Lamp on the Cold Room control panel. The HT Liquid Solenoid will energise. After a 60 second delay (Adjustable Oil Return Delay) the Oil return Solenoid will energise. If the selector switch is set to 50% the 50% solenoid will energise after a 1 second delay. If the selector switch is set to 67% the 50 % & 67% solenoid will energise after a 1 second delay. If the selector switch is set to 100% the 50%, 67% & 100% solenoid will energise after a 1 second delay. When the switch is set to off, the compressor will stop and the solenoid valves will de-energise. If any of the shutdowns occur the compressor will stop, the running lamp will flash and the common alarm relay will de-energise. The individual Compressor Fault relay will de-energise (this is relayed too the Cold Room Control panel). 2.4.2 Auto Operation The S.W. pump should be in Auto. There should not be any alarms present. Turn the Compressor Selection switch (1 or 2) to the compressor to be run. Turn the Control Selector Switch to Auto a 10 minute timer will start (Start Delay Timer), after 9 minutes (30 seconds less then the Start Delay Timer) the sea water pump will start to run. After a further 30 seconds the compressor will start to run.

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The running lamp will illuminate and the Running relay will energise, this will energise the Running Lamp on the Cold Room control panel. The HT Liquid Solenoid will energise. After a 60 second delay (Adjustable Oil Return Delay) the Oil return Solenoid will energise. If the Suction pressure is greater then the Set Point plus the Hysterisis the Step Up timer will start (60 Seconds), once timed out the 50% loading valve will energise. While the Suction Pressure is within the window Set Point minus Hysterisis (40 PSI) to Set Point plus Hysterisis (50 PSI) the loading valve status will remain steady. If while at 50 % loading the Suction pressure is greater then the Set Point plus the Hysterisis the Step Up timer will start (60 Seconds), if this times out the 67% loading valve will energise as well as the 50% valve. If while at 67 % loading the Suction pressure is greater then the Set Point plus the Hysterisis the Step Up timer will start (60 Seconds), if this times out the 100% loading valve will energise as well as the 67 & 50% valves. The process will reverse if the Suction pressure is less then the Set Point Minus the Hysterisis but the Step Down time is much shorter at 5 seconds. If when at 33% loading (no loading valves energised), the Suction pressure is less then the Set Point Minus the Hysterisis for the Step Down time (5 seconds) the compressor will stop and the sea water pump will stop after a further 15 seconds. While the compressor is stopped and in Auto if the Suction Pressure rises above the Set Point plus Hysterisis the start timer will start (Start Delay Timer), after 9 minutes (30 seconds less then the Start Delay Timer) the sea water pump will start to run. After a further 30 seconds the compressor will start to run and load up/down as detailed above. When the switch is set to off, the compressor will stop and the solenoid valves will de-energise. If any of the shutdowns occur the compressor will stop, the running lamp will flash and the common alarm relay will de-energise. The individual Compressor Fault relay will de-energise (this is relayed too the Cold Room Control panel). 2.4.3 Condenser Control Valve Operation. The Motorised Valve will be Closed (down) while the compressor is stopped, the close signal remains on and therefore it is important that the limit switches within the valve actuator are set correctly.

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When the compressor starts the valve is given an Open (Up) signal for 30 seconds (adjustable), once the 30 seconds has timed out the valve will then move to try to maintain the Discharge pressure at the Set Point (247 PSI). It does this by Closing (Down) to increase pressure and Opening (Up) to decrease pressure. The controller action is described below. The controller checks the values on a cyclic basis, the period of this cycle is set by the I-Param time (3 seconds). Each time it checks the values: It works out if the error is High or Low. It then works out the size of the error. It works out if the error is greater then the Large Error Inhibit value. It works out if the error is greater or less then the error during the last cycle. Based on the answers to these checks it then operates the valve as below: If the error is high, it needs to reduce pressure so will mainly be Opening (Up) the valve, if the error is low, it needs to increase pressure so will mainly be Closing (Down) the valve. The P-Parameter is divided by the size of the error and multiplied by 10, this value is then used in the Pause timer. Hence a small error gives a long pause time and a large error gives a short pause time. The output will then pulse on for 1 second (Impulse timer) and off for the length of time due to the size of the error (P-Parameter / error (PSI) x 10 = time in 0.1 sec e.g. a P-Param of 40 and an error of 10PSI = 40/10 x 10 = 40 = 4 seconds). If the error is greater then the Large Error Inhibit value (20 PSI) then the above will always be true, if the error is less then 20 then the D parameter can come into play. If the error in one sample is less then the error in the previous sample (i.e. the process is starting to get closer to the set point) then the valve will pulse in the other direction to reduce the amount of overshoot that occurs. The D parameter (set at 100) will operate a pause timer for a pulse in the other direction as described for the normal operation above. 2.5 L.T. Compressors The L.T. compressors work in the same way as the H.T with the following differences: The Suction set point is lower (15 PSI) When temperature input KP77 is set the additional Cooling valve will be energised.

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2.6 Subcooling Operation. When the selector switch is set to Sub Cooling or Compound, the subcooling valves will energise a time delay (0 seconds) after the following statement is true: If compressor 1 or 2 is running, and compressor 3 or 4 is running When the statement is false the valves will de-energise.

3.

PLC Program Notes

All used devices (memory tags, timers, data words) have a comment to advise what they do. HMI will act as a transparent conduit to the PLC. The enables the HMI to carry on working while also looking at / changing the program. The program is structured as detailed below: Rung 0 to 184 - Set default values to adjustable values When the PLC is set to Run (normal mode), during the 1st scan the default settng values are loaded into the various data words. Rung 184 to 297 Read in Analogue Values This program area reads in the analogue values. The raw values are 0 for 4mA and 4000 for 20mA. Rung 303 to 580 Scale Analogue Values The analogue values are scaled by carrying out a division and then a subtraction to scale the inputs to the real engineering units. Note pressure is in PSI, current in Amps. Rung 585 to 721 Map in Digital Inputs The digital inputs (X**) are mapped into memory tags (M**) these memory tags are used within the program, thus if a switch works the opposite way to expected then the input can be inverted once in this area. Rung 723 to 1050 Check for Alarm Values from Analogue Values The analogue inputs are compared to alarm limit values, the output tags from these checks are used in the Alarm handling section. Rung 1077 to 3080 Alarm Handler All the alarm handling software is in this area, there are 40 alarms within the system. 3074 to 5200 Compressor No.1 All the software for controlling compressor No.1 is within this area 5204 to 7298 Compressor No.2 All the software for controlling compressor No.2 is within this area 7302 to 9452 Compressor No.3 All the software for controlling compressor No.3 is within this area 9456 to 11566 Compressor No.3

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All the software for controlling compressor No.3 is within this area 11570 to 11588 Liquid Valve Controls 11606 to 11 636 Sub Cooling Operation 11656 to 11834 Map Outputs Out The memory tags for each digital output are mapped out to the output in this area.

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4.

HMI Operation

The HMI is used to view internal operation values, alarms and also to change settings. 4.1 Home Page This is the Home Page it can be accessed at any time by pressing the Home button

OGIN

PREV

NEXT

SETTING LOGOU

It shows which compressors are set to run in Auto and prompts the 4 function keys to press to access the values for each compressor, i,e, to select compressor 2 press the button labelled PREV. The Banner area at the top displays the last active alarm. -

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4.2 Compressor Screens The screens below are the same for each compressor, for this manual we have only showed the screens for Compressor 1. This is the first compressor screen. All the function keys will work as labelled. If an alarm occurs the word ALARM will flash in the top right hand corner, to go to the Alarm page press the ALARM button. -

OGIN

PREV

NEXT

SETTING LOGOU

To go to the next page for compressor No.1 press the NEXT button.

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The 2nd compressor screen is shown below. The valves will change to solid black when they are energised.

OGIN

PREV

NEXT

SETTING LOGOU

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The 3rd compressor screen is shown below: The control requirement is shown on the left hand side. Man means in Manual Control, when in manual control the amount of load required will be shown by the appropriate valve being filled in black. When in Auto the word Man will be replaced by the word Auto. The right hand side shows the status of the output valves. These will be filled with black when they are active.

OGIN

PREV

NEXT

SETTING LOGOU

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The last compressor page is shown below, this details the status of the sea water pump. The NEXT button will not work on this page.

OGIN

PREV

NEXT

SETTING LOGOU

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4.3 Settings Pages The Setting screen can be accessed by pressing the SETTING button from any of the compressor pages.

OGIN

PREV

NEXT

SETTING LOGOU

Before settings can be changed you must first LOGIN. Press the LOGIN button.

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Input the Password (which is 8786), Then press the ENTER button.

OGIN

PREV

NEXT

SETTING LOGOU

-If the password is entered correctly it will show the screen below.

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OGIN

PREV

NEXT

SETTING LOGOU

-Press the NEXT button to scroll through the setting screens.

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OGIN

PREV

NEXT

SETTING LOGOU

The 1st screen details the current alarm setpoint (limit) and the step down (time delay) for each compressor.

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To change any values on the settings screen use the ARROW keys to move the CURSER to the value to be changed.

OGIN

PREV

NEXT

SETTING LOGOU

Use the numeric keys to enter the new value, then press the ENTER key to enter the value.

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The next setting screen shows the suction Setpoint and Hysterisis, the hysterisis is added to either side of the setpoint.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting page shows the suction alarm (setpoint) and delay (step down) values.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting screen shows the HT and LT Step Up/Down and Start / Stop delays.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting screen shows the Sub Cooling valve operation delay.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting screen shows the Discharge pressure Alarm/Warning/Setpoint levels, alarm/warning and Oil Return Valve operation delays.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting screen shows the control valve settings,: The P-Parameter is the gain setting, the higher this value the slower the operation will be. The I-Parameter sets the update sample time in seconds (dont set above 10) The IMPLUSE time is the length of each pulse (nominally 1 second) The Pause and Valve times are not used and should be left as they are. The Open > Start setting is the time that the control valve is told to open when the compressor starts. After this time the valve will start to control to the Setpoint.

OGIN

PREV

NEXT

SETTING LOGOU

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The next setting screen has additional control valve settings. The D parameter is similar to the P-Param on the previous screen, but this sets the amount of correction that is given when the process value starts to improve towards the setpoint, this is to reduce overshoot. The higher the value the more action is given. The LRG ERR INH this sets a window either side of the set point when the process value is outside this window the D-Param is inhibited.

OGIN

PREV

NEXT

SETTING LOGOU

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This is the last setting page. The settings shown is the Run On time for the sea water pump after the compressor is stopped.

OGIN

PREV

NEXT

SETTING LOGOU

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This is the Alarm List screen, it is accessed by pressing the Alarm button.

OGIN

PREV

NEXT

SETTING LOGOU

Press the TIME button to give time and date of the alarm. The Plus button will change the size of the font. Press the ACK button on the HMI or the MUTE button on the main panel to accept the alarms. A $ sign to the left of the alarm means that it has not been accepted. A sign to the left of the alarm means that it has been accepted but it is still active (not been cleared).

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5.
Alarm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Appendix 1. Alarm List


Description Compressor1 High Current Compressor1 High Disc.Pressure W Compressor1 High Disc.Pressure A Compressor2 High Current Compressor2 High Disc.Pressure W Compressor2 High Disc.Pressure A Compressor3 High Current Compressor3 High Disc.Pressure W Compressor3 High Disc.Pressure A Compressor4 High Current Compressor4 High Disc.Pressure W Compressor4 High Disc.Pressure A HT Low Suction Pressure LT Low Suction Pressure Compressor1 H-L Oil Compressor1 Oil Pressure Compressor1 Oil Temp. Compressor2 H-L Oil Compressor2 Oil Pressure Compressor2 Oil Temp. Compressor3 H-L Oil Compressor3 Oil Pressure Compressor3 Oil Temp. Compressor4 H-L Oil Compressor4 Oil Pressure Compressor4 Oil Temp. Compressor1 Overload Compressor1 Fail to Start Compressor2 Overload Compressor2 Fail to Start Compressor3 Overload Compressor3 Fail to Start Compressor4 Overload Compressor4 Fail to Start Compressor Shutdown N N Y N N Y N N Y N N Y N N Y Y Y Y Y Y Y Y Y Y Y Y Y N Y N Y N Y N

The list of alarms is detailed below:

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35 36 37 38 39 40 41

S.W. Pump 1 Overload S.W. Pump 2 Overload S.W. Pump 3 Overload S.W. Pump 4 Overload Spare Spare Pressure in Safety Line

Y Y Y Y N N N

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6.

Appendix 2. - Settings

The adjustable settings and their default values are listed below: These values can be changed by the HMI, however if the PLC is stopped (either by the Reset / Stop / Run switch or by powering down). When it restarts these default values are re-loaded.
Plus (High Temp Compressor Motor Current Setpoint Delay Comp.1 60A 2 Sec Comp.2 60A 2 Sec Minus (Low Temp) Comp.3 60A 2 Sec Comp.4 60A 2 Sec

Suction Control Suction Pressure Warning Low Press. Compressor Set Point Hysterisis Set Point Delay Step Up Step Down Start Delay Stop Delay Sub Cooling Delay

Plus (High Temp 45 PSI 5 PSI 30 PSI 5 Sec 60 Sec 5 Sec 600 Sec 1 Sec 0 Sec Plus (High Temp

Minus (Low Temp) 15 PSI 5 PSI 6 PSI 0 Sec 60 Sec 5 Sec 600 Sec 0 Sec N/A Minus (Low Temp) Comp.3 295 PSI 280 PSI 5 Sec 247 PSI 1 PSI 40 100 3 Sec 20 PSI 1 Sec 1 Sec 60 Sec Comp.4 295 PSI 280 PSI 5 Sec 247 PSI 1 PSI 40 100 3 Sec 20 PSI 1 Sec 1 Sec 60 Sec

Condenser Alarm Discharge Pressure Warning Delay Set Point Hysterisis Gain (P) Gain (D) Control Valve Sample Time (I) Pulse Time Pause Time Valve Close Time

Comp.1 295 PSI 280 PSI 5 Sec 247 PSI 1 PSI 40 100 3 Sec 1 Sec 1 Sec 60 Sec

Comp.2 295 PSI 280 PSI 5 Sec 247 PSI 1 PSI 40 100 3 Sec 20 PSI 1 Sec 1 Sec 60 Sec

Large Error Inh (D) 20 PSI

47-49, Cutlers Road, Saltcoates Ind. Est, South Woodham Ferrers, Chelmsford Essex Tel: 01245 322777 Fax: 01245 322776

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P & S Automation Limited. Project: Provision Refrigeration Compressors Control System Manual Contract 2144P November 2009

V/V Open > Start Comp. Oil Return Delay

30 Sec 60 Sec

30 Sec 60 Sec

30 Sec 60 Sec

30 Sec 60 Sec

Plus (High Temp Pumps Pre Start Time Stop Delay Comp.1 30 Sec 15 Sec Comp.2 30 Sec 15 Sec

Minus (Low Temp) Comp.3 30 Sec 15 Sec Comp.4 30 Sec 15 Sec

47-49, Cutlers Road, Saltcoates Ind. Est, South Woodham Ferrers, Chelmsford Essex Tel: 01245 322777 Fax: 01245 322776

Refer-Compressor-Manual-iss1.doc

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Email:
enquiries@PandSautomation.com Website: www.PandSautomation.com