Compressor System Control Logic

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FERMILAB
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MTF Helium Refrigerator

Compressor System Control Logic (Phase I Upgrade)
Doc. No. RCU-98-031

Rev. No. 5
Date: July 19, 2006
Page 1 of 26
f
FERMILAB
Technical Division

Compressor System Control Logic
(Phase I Upgrade)
Author: Ruben Carcagno

Reviewed by:
Date: 12/10/98
Date:
FERMILAB
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Approved by:
Date:
Doc. No. RCU-98-031

Rev. No. 5
Date: July 19, 2006
Page 2 of 26
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Date: July 19, 2006
Page 3 of 26
TABLE OF CONTENTS
INTRODUCTION..........................................................................................................................................3
EQUIPMENT DESCRIPTION.....................................................................................................................4
COMPRESSOR START/STOP LOGIC......................................................................................................5
COMPRESSOR SHUTDWON INTERLOCK LOGIC.............................................................................8
MOTOR CONTACTOR PROTECTION..................................................................................................11
COMPRESSOR LOAD AND UNLOAD LOGIC.....................................................................................12
GAS MANAGEMENT SYSTEM...............................................................................................................15
SUB-ATMOSPHERIC SUCTION PROTECTION..................................................................................................16
SOLENOID VALVES...................................................................................................................................20
BROKEN TRANSMITTER ALARMS......................................................................................................23
APPENDIX A: SYMBOLS DEFINITION FOR LOGIC DIAGRAMS..................................................24
APPENDIX B: COMPRESSOR SYSTEM COLD BOX SYSTEM CONTROL INTERFACE........25
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Rev. No. 5
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INTRODUCTION
This document describes the control logic for the compressor system controls upgrade
(Phase I) of the MTF helium refrigerator. Phase I is intended to duplicate the existing
functionality of the control console in the new PLC-based control system. For details
about Phase I scope, please refer to RCU-98-022.
The basis for this document is the original compressor system control logic documented
in RCU-98-10, plus discussions with operators to identify obsolete aspects of the original
logic. These obsolete aspects have been eliminated for the upgrade logic. There are a few
changes described in this document intended to enhance safety and troubleshooting.
Deviations from the original logic and other comments can be found in the Upgrade
Notes section.
In addition, we contacted the compressor manufacturer (Sullair) to obtain information
about current compressor control strategies. We were referred to their supplier (Logix
Industrial Refrigeration Controls) and we consulted with them. Logix provided us with
their Compressor Control System Operations Manual so we could verify that our controls
upgrade basis is consistent with their approach.
For additional details, please refer to the following documents:
Operators Manual 1500 Watt Helium Refrigerator for Fermi/LBL,
from Helix Process Systems dated March 1978. Available in hardcopies
only.
Upgrade compressor system P&ID drawing (1670-ME-304962)
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Rev. No. 5
Date: July 19, 2006
Page 5 of 26
EQUIPMENT DESCRIPTION
The process compressor is a two-stage system on a separate skid approximately 35 by 8
by 10 high and weighs approximately 45,000 pounds. The skid consists of two open
drive Sullair screw compressors, oil cooling systems, oil separation system, gas
management valving, motor controls, and a local instrument cabinet.
TABLE 1: General Specifications
(This table is copied from the CTI Operators Manual)
Motor Power Supply
Control Power Supply
Control Power Requirement
Oil Capacity First Stage Compressor package
Oil Capacity Second Stage Compressor package
Oil Type
Compressor Package Weight
First Stage Compressor Motor
First Stage Compressor Motor Full Load Amps
First Stage Compressor Motor Locked Rotor Amperage
Second Stage Compressor Motor
Second Stage Compressor Motor Full Load Amps
Second Stage Compressor Motor Locked Rotor Amperage
Oil Cooler and Aftercooler Coolant
Coolant Inlet Temperature
460V, 3 phase, 60 Hertz

115V, 1 phase, 60 Hertz
600VA
100 gallons
150 gallons
UCON LB165
48,000 lbs.
200 hp
225 Amps
1339 Amps
1000 hp
1135 Amps
5400 amps
50% ethylene glycol
85 F
Model and Serial Number

First-stage Model C25LB704-26
Second-stage Model C25LA704-37
Serial No. 29247 FGG
TABLE 2: Operating Limitations
(This table is copied from the CTI Operators Manual)
Description
Design Discharge Pressure (Maximum)
Operating Differential Pressure (Maximum)
Suction Pressure (Maximum)
Oil Pressure (Maximum)
Oil Pressure (Minimum)
Oil Temperature (Maximum)
Discharge Temperature (Maximum)
Compressor Speed (Maximum)
Oil Filter Pressure Drop (Maximum)
First Stage
Compressor
150 psig
164 psig (typo?)
80 psig
80 psi
40 psi
125 F
225 F
3550 rpm
35 psi
Second Stage
Compressor
300 psig
314 psi
80 psig
80 psi
40 psi
125 F
225 F
3550 rpm
35 psi
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COMPRESSOR START/STOP LOGIC

The commands to start and stop the first and second stage compressor motors are
software pushbuttons accessible from operator display screens. There are no local or
hardwired start/stop pushbuttons.
The START request is a momentary signal latched by the motor running feedback coming
from the motor contactors closed auxiliary contact. Once issued, the STOP request
remains active until the operator pushes the RESET pushbutton.
There is a single Emergency Stop (E-Stop) hardwired circuit with two pushbuttons: one
located in the compressor room and another located in the control room. The E-Stop
circuit de-energizes both compressor motor control centers by removing power to the
480V circuit breaker (see electrical schematics for additional details.) Once this breaker is
open, a Fermilab electrician has to be called to close it. For this reason, a 110VAC power
switch was installed in the compressor control cabinet. This is to allow people to work on
equipment without having to worry that someone in the control room will start/stop
equipment. This switch is for 110 VAC going to motors contactors, not for 110 VAC for
PLC or 24 VDC power supply.
A number of conditions must be satisfied before the START request can actually start the
compressor motor. Figures 1 and 2 show the details of the START/STOP logic for the
first and second stage compressors. Table 3 and Figures 3 and 4 show the details of the
shutdown interlock logic.
UPGRADE NOTES:
1. The original system had three E-Stop circuits: one for the first stage motor, one for
the second stage motor, and one for both first- and second-stage motor control
centers. We decided to eliminate the individual E-stop circuits, and have only one
for both motors (at circuit breaker #3). A 110 VAC switch was also installed in the
control cabinet to allow people to work safely on equipment without worrying that
motors will start/stop by others or by the PLC.
2. In the original system, the anti-recycle timers had been set to their minimum delay
for unknown reasons. We restored these timers to the recommended settings of 20
minutes. The oil pressure differential timer was measured to be 16 seconds. We set
this timer to 10 seconds.
3. With the upgrade, the PLC includes the 480V motorized circuit breaker closed
auxiliary contact signal (1MCB-A and 2MCB-A). The compressor motor START
permissive includes now the condition that the corresponding 480V MCB has to be
closed.
4. Pressure and temperature switches provided input for interlock logic in the original
system. With some exceptions such as the motor overload and the motor winding
temperature, we decided to replace these switches by setpoints on the analog signal
from a sensor measuring the corresponding process variable. This change
significantly reduced the number of field devices and their associated wiring, and
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also provides additional information for the operator (e.g., the system now provides
continuous gas suction and discharge temperature indication instead of just a
shutdown temperature switch that gives no warning before shutdown.) For
additional details, see RCU-98-19.
5. The original system was designed to work outdoors and it was equipped with
heaters that had been disabled. Since the compressor system is working indoors
and the heaters are no longer required, we decided to remove them. This change
simplifies the electrical system.
6. Auxiliary oil pumps for the first and second stage compressor were added to the
original system and were started manually after a long shutdown and a couple of
minutes before starting the compressors. With the upgrade, these pumps can be
started remotely from the operator interface.
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F IG U R E 1 : F IR S T S T A G E C O M P R E S S O R S T A R T /S T O P L O G IC
F ir s t S t a g e C o m p r e s s o r
S a fe ty In te r lo c k in g
201M
A2
S e c o n d S ta g e M o to r
R u n n in g
S to p R e q u e s t
R eset
ES
A
C o m p re s s o r R o o m
E m e r g e n c y S to p P B
ES
B
O R
C o n tr o l R o o m
E m e rg e n c y S to p P B
F ir s t S ta g e
C o m p re s s o r
M o to r R u n /S to p
Com m and
( P L C O u tp u t)
A
1M C B
A
4 8 0 V M o to r iz e d C irc u it
B re a k e r C lo s e d C o n ta c t
S ta rt R e q u e s t
PO
1 s
S lid e V a lv e
M in im u m P o s itio n
ZSL
200
M o to r
R u n n in g
101M
A2
7
CR
PO
20m
F IG U R E 2 : S E C O N D S T A G E C O M P R E S S O R S T A R T /S T O P L O G IC
S e c o n d S ta g e C o m p re s s o r
S a fe t y In te r lo c k in g
S to p R e q u e s t
R eset
ES
A
S
R
C o m p re s s o r R o o m
E m e r g e n c y S to p P B
ES
B
O R
C o n tr o l R o o m
E m e rg e n c y S to p P B
A
2M C B
A
4 8 0 V M o to r iz e d C ir c u it
B r e a k e r C lo s e d C o n ta c t
S ta r t R e q u e s t
ZSL
201
201M
A2
PO
1 s
S lid e V a lv e
M o to r
R u n n in g
A
PO
20m
S
R
S e c o n d S ta g e
C o m p re s s o r
M o to r R u n /S to p
C om m and
(P L C O u tp u t)
8
CR
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COMPRESSOR SHUTDWON INTERLOCK LOGIC

A number of conditions must be satisfied for the compressors to start or continue running.
If any one of these conditions is not met, the compressor motor will be either prevented
from starting, or if it is running already it will be shutdown automatically. If the
compressors are allowed to continue running, equipment damage may result.
Table 3 summarizes the shutdown interlock conditions and setpoints. Figures 3 and 4
shows the details of the interlock logic for the first stage and second stage compressors
respectively.
TABLE 3: Shutdown interlock conditions
CONDITION
Low Suction Pressure
High Discharge Pressure
High Discharge Temperature
Motor Overload
High Motor Winding Temperature
High Oil Temperature
Oil Pressure Differential
Instrument Air Low Pressure
First Stage Safety Shutdown
Second Stage Safety Shutdown
Broken Transmitter
High Motor Current
FIRST STAGE
SECOND STAGE
PT201 < 14 psia for at least 30

minutes
PT205 > 75 psia
TT201 > 210 F
OLS200 > 480 A
TS206 > 248 F
TT203 > 125 F
PDS204 < 25 psid (after 20
seconds of motor running
signal)
PT209 < 75 psia
X
PT201, PT205, TT201, PT209,
TT203
IT200 > 250 A
PT206 < 14 psia for at least 2

minutes
PT210 > 260 psia
TT205 > 210 F
OLS201 > 1150 A
TS202 > 248 F
TT208 > 125 F
PDS209 < 25 psid (after 20
seconds of motor running signal)
PT209 < 75 psia
X
PT206, PT210, TT205, PT209,
TT208
IT201 > 1000 A
UPGRADE NOTES:
1. PS206, PS209, TS200, PS205, PS210, TS201, TS205, TS203 and TS208 have been
replaced by settings on analog signal provided by PT206, PT209, TT200, PT205,
PT210, TT201, TT205, TT203 and TT208 respectively.
2. All units are now expressed in psia or psid
3. The original system included a shutdown interlock on low suction temperature.
This interlock has been removed because the compressor system has been moved
far away from the coldbox and a condition of low suction temperature is not
expected to exist.
4. An interlock on cold box vacuum had been added to the system. We decided to
remove this interlock because it was intended to prevent cold gas from reaching the
first stage suction when the compressor system was installed close to the cold box.
5. A permissive on N2 vent valve open limit switch had been added to the system. We
decided to eliminate this interlock because it is no longer relevant due to process
equipment changes (this signal had been jumpered)
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6. An interlock on sub-atmospheric first stage suction pressure has been added (see
Gas Management section)
7. The instrument air low pressure setting has been lowered from 83.7 psia to 75
psia . This is because of the lower pressure differential rating of new 24 VDC
solenoids (75 psid) compared to the original 110 VAC solenoids (150 psid). In
addition, a transmitter (PT209) to allow trending has replaced the switch PS209.
We still need to find out what is the lowest admisible air supply pressure to operate
pneumatic valves. After this information is obtained, PT209 shutdown setting may
be lowered.
8. Timers for PDS204 and PDS209 were measured to be 16 seconds. We are going to
set them at 20 sec.
9. The implementation of the interlock logic includes first-fault indication. This is the
initiating event that caused the interlock condition.
10. Once the interlock condition is set, it will remain set until the operator pushes the
RESET pushbutton in the operator interface.
11. Broken transmitter interlocks have been added for analog transmitters. See section
on Broken Transmitter Alarms. Switches are wired in the Normally Closed (NC)
position, so any electrical problems in the loop such as an open circuit will cause a
shutdown.
12. The shutdown setpoint on 2nd stage discharge (260 psia) could be too conservative,
but operators never run the system that high in discharge pressure. There is a skid
relief valve set at 300 psia, so the shutdown setpoint should never exceed this value.
13. To avoid nuisance shutdowns during compressor system startup, we changed the
logic to trip the second stage compressor when the suction pressure remains
subatmospheric for more than 2 minutes. Initially, shutdown as soon as the suction
pressure went subatmospheric.
14. Following the February 2006 fire in IB1A, a current interlock for each helium
compressor motor was instituted: 250 A for first stage, 1000 A for second stage.
This interlock is software-based, programmed into the PLC. A subsequent startup
in July 2006 found that the first stage setpoint was too low. The inrush current is
higher than estimated, and the compressor tripped off shortly after startup when
the interlock timer expired. The setpoint was then raised to 300 A.
15. The settings for the new overload switches put into service during the May 2006
maintenance shutdown are as follows: OLS200 (first stage) has a 2.5 A setpoint
and uses time dial setting 3, OLS201 (second stage) has a 3 A setpoint and uses
time dial setting 2.
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Date: July 19, 2006
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F IG U R E 3 : F IR S T S T A G E C O M P R E S S O R S A F E T Y IN T E R L O C K IN G L O G IC
PT
201
S u c tio n
P re s s u re
< 1 4 p s ia
PT
205
D is c h a rg e
P re s s u re
> 7 5 p s ia
TT
201
D is c h a r g e
T e m p e ra tu r e
O LS
200
M o to r O v e r lo a d
(C u rre n t > 4 8 0 A )
N O T E : S w it c h e s a r e w ir e d in t h e N . C .
p o s itio n , th e r e fo r e u n d e r n o r m a l
c o n d it io n s t h e ir o u t p u t is " T r u e " o r
" H ig h "
> 210 F
TS
206
H ig h M o to r W in d in g
T e m p e ra tu r e ( > 2 4 8 F )
TT
203
H ig h O il
T e m p e ra tu r e
101M
A2
D I
30 m
O R
> 125 F
R eset
M o to r
R u n n in g
PD S
204
L o w O il
P re s s u re
D iffe r e n tia l
( < 2 5 p s i)
PT
209
In s tr u m e n t A ir
L o w P re s s u re
F irs t S ta g e C o m p re s s o r
S a fe ty In te r lo c k
D I
20 s
< 75 psi
S e c o n d S ta g e S a fe ty
In te rlo c k
B r o k e n T r a n s m it te r ( P T 2 0 1 ,
PT205, TT201, or PT209)
IT
200
High Motor
Current
> 300 A
F IG U R E 4 : S E C O N D S T A G E C O M P R E S S O R S A F E T Y IN T E R L O C K IN G L O G IC
S u c tio n
P re s s u re
PT
210
D is c h a rg e
P re s s u re
> 2 6 0 p s ia
TT
205
D is c h a r g e
T e m p e ra tu r e
> 210 F
O LS
201
M o to r O v e rlo a d
(C u rre n t > 1 1 5 0 A )
TS
202
H ig h M o to r W in d in g
T e m p e r a tu re ( > 2 4 8 F )
TS
208
H ig h O il
T e m p e ra tu re
201
M
M o to r
R u n n in g
N O T E : S w it c h e s a r e w ir e d in t h e
N .C . p o s itio n , t h e r e f o r e u n d e r
n o r m a l c o n d itio n s th e ir o u t p u t is
" T r u e " o r " H ig h "
O R
> 125 F
R eset
PDS
209
L o w O il
P re s s u re
D iffe r e n tia l
( < 2 5 p s i)
PT
209
In s tru m e n t A ir
L o w P re s s u re
DI
20 s
< 7 5 p s ia
F irs t S ta g e S a fe ty
In te r lo c k
B ro k e n tr a n s m itte r ( P T 2 0 6 ,
PT210, TT205, or PT209)
IT
201
D I
2 m in
< 14
p s ia
PT
206
High Motor
Current
> 1000 A
S a fe ty In te rlo c k
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Motor Contactor Protection

As part of lesson learned from prior safety related incidents, we decided to incorporate
logic in the upgrade to prevent fires or other damage should the motor contactor become
stuck between the open and close position. To this end, both motor contactor auxiliary
contacts are wired to the PLC. These auxiliary contacts are limit switches that provide
indication of contactor in the open position and contactor in the close position
respectively. Both switches are OFF (or OPEN) at the same time only while the contactor
is travelling. At all other times, one is OFF (or OPEN) and the other is ON (or CLOSED).
Thus, the logic to detect whether the contactor has become stuck while traveling from
one position to the other is simply to check that both auxiliary contacts do not remain
OFF (or OPEN) longer than for a pre-specified amount of time (arbitrarily taken to be 2
seconds). If both contacts remain OFF (or OPEN) after this time has elapsed, the PLC
sends a signal to open the 480V motorized circuit breaker, thus removing power from the
MCC and avoiding arcs or other conditions that may damage the equipment. Since the
480V motorized circuit breaker CLOSE limit switch is part of the motor
START/STOP logic (see figures 1 and 2), the command to run the compressor motor
will also be turned off. Figures 5 and 6 shows the details of this logic.
F IG U R E 5 : F ir s t S ta g e M o to r C o n ta c to r P r o te c tio n
101M
A2
M o to r C o n ta c to r in
" C L O S E D " p o s itio n
101M
A1
" O P E N " p o s itio n
1M CB
A
O pen 480V
M o to r iz e d C ir c u it
B re a k e r
DI
2 s
4
CR
4 8 0 V M o to riz e d C irc u it
B re a k e r "C L O S E D "
p o s itio n
F I G U R E 6 : S e c o n d S ta g e M o to r C o n ta c to r P r o te c tio n
201M
A2
" C L O S E D " p o s itio n
201M
A1
" O P E N " p o s itio n
2M CB
A
4 8 0 V M o to riz e d C irc u it
B re a k e r "C L O S E D "
p o s itio n
DI
2 s
O pen 480V
M o to r iz e d C ir c u it
B re a k e r
6
CR
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COMPRESSOR LOAD AND UNLOAD LOGIC

An electrical actuator replaces the original slide valve actuator in both stages.This
electrical actuator contains a motor and a gear reduction mechanism to drive the slide
valve. Limit switches actuated by cams establish the maximum and minimum capacity
positions for the slide valve. As part of the upgrade, a potentiometer will be added to the
actuator to provide continuous indication of slide valve position.
The original system included an option for automatic load/unload of the system based on
the refrigerator operating mode and several pressure switches. Operators no longer use
this option. Loading and unloading are always performed manually by pushing the
corresponding buttons in the control console. However, the original system included logic
to automatically unload the compressor in case of overpressure or overcurrent conditions.
If this action is not sufficient to lower the current and/or pressure, then the compressor
will shutdown when the shutdown setpoints are reached. We decided to preserve this
logic to avoid unnecessary compressor system shutdown, particularly when the system is
running unattended.
For the upgrade, we decided to eliminate all pressure switches associated with the
original automatic load/unload operation. Phase I will only include manual load/unload
capabilities from the operator interface plus automatic unload in case of overcurrent or
overpressure conditions. Automatic load/unload control strategies will be added later and
performed by software as part of the Phase II upgrade.
The control logic drives the slide valve to the minimum position at shutdown. In addition,
the control logic prevents the compressor from loading during the initial ten seconds of
running.
Figures 7 and 8 show the unload/load logic for the first stage compressor, and figures 9
and 10 show the unload/load logic for the second stage compressor.
UPGRADE NOTES:
1. Operators never run the system in AUTO load or unload. They manually load or
unload the system, using the motor current indicator as a feedback signal.
Typically, they like to run the first stage motor at 150-180 Amps, and the second
stage motor at 480-800 Amps. The upgraded system includes a potentiometer to
provide slide valve position feedback.
2. The original system included logic to automatically unload the compressor in case
of overcurrent or overpressure conditions (under either MANUAL or AUTO load
or unload). We decided to preserve this logic for the Phase I to avoid unnecessary
shutdown when the system is running unattended.
3. Automatic load and unload controls will be added as part of the Phase II upgrade.
It will be a software upgrade module for the overall gas management control
automation.
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4. The system had an old style slide valve actuator in the second stage, and a new style
actuator in the first stage. We decided to replace the old style by the new style, so
the upgraded system will have the same style actuator in both stages.
F IG U R E 7 : F IR S T S T A G E C O M P R E S S O R U N L O A D L O G IC
S lid e V a lv e
ZSL
200
F irs t S ta g e L o a d
C om m and
101M
A2
M a n u a l c o m p re s s o r u n lo a d
U n lo a d
R equest
F irs t S ta g e
U n lo a d
C om m and
10
C R
A u to m a tic a lly u n lo a d s c o m p r e s s o r w h e n m o to r s to p s
M o to r
R u n n in g
O R
D I
10s
IS
200
F irs t S ta g e M o to r
O v e rc u rre n t (N C )
PT
205
F irs t S ta g e
D is c h a r g e
P re s s u re
A
O R
> 5 5 p s ia
PO
180S
F ir s t S ta g e C o m p re s s o r
L o a d In h ib it
P re v e n ts lo a d in g c o m p r e s s o r
fo r 1 8 0 s e c o n d s a fte r a n
o v e r c u rre n t o r o v e r lo a d
c o n d itio n
F IG U R E 8 : F IR S T S T A G E C O M P R E S S O R L O A D L O G IC
ZSH
200
S lid e V a lv e
M a x im u m P o s itio n
F ir s t S ta g e U n lo a d
C om m and
A
F ir s t S ta g e C o m p r e s s o r
L o a d In h ib it
Load
R equest
M a n u a l c o m p re s s o r lo a d
F irs t S ta g e
Load
C om m and
9
CR
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F IG U R E 9 : S E C O N D S T A G E C O M P R E S S O R U N L O A D L O G IC
S lid e V a lv e
ZSL
201
Load Com m and
U n lo a d
R equest
201M
A2
M o to r
R u n n in g
M a n u a l c o m p re s s o r u n lo a d
U n lo a d
C om m and
12
C R
A u to m a tic a lly u n lo a d s c o m p r e s s o r w h e n m o to r s to p s
O R
D I
10s
IS
201
S e c o n d S ta g e M o to r
O v e rc u rre n t (N C )
PT
210
D is c h a r g e
P re s s u re
A
O R
> 2 8 0 p s ia
PO
180S
L o a d In h ib it
P r e v e n t s lo a d in g c o m p r e s s o r
fo r 1 8 0 s e c o n d s a fte r a n
o v e rc u rre n t o r o v e rlo a d
c o n d itio n
F IG U R E 1 0 : S E C O N D S T A G E C O M P R E S S O R L O A D L O G IC
ZSH
201
S lid e V a lv e
M a x im u m P o s itio n
U n lo a d C o m m a n d
S e c o n d S ta g e C o m p r e s s o r
L o a d In h ib it
Load
R equest
M a n u a l c o m p re s s o r lo a d
Load
C om m and
11
C R
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Rev. No. 5
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Page 16 of 26
Gas Management System

The function of the gas management system is to: (a) regulate the compressor discharge
pressure, (b) to provide makeup gas to the compressor, and (c) control the capacity of the
cold box by by-passing high pressure gas the low side.
At initial startup the second stage compressor suction pressure will drop rapidly, PCV221
will open diverting discharge gas into the suction line. Valve PCV221 is set to control the
intermediate pressure at 3.2 atm (PIC203 in the main control panel is set at 47 psia). As
the pressure continues to fall valve PCV211 opens to supply make up gas from the buffer
tank E1 (PIC202 in the main control panel will be set to approximately 44 psia).
As the intermediate pressure increases PCV211 will start to close and will be fully closed
at 3.2 atm.
When the first stage starts the suction pressure will drop, PCV210 will then open to raise
the pressure to 1 atm (PIC201 in the main control panel will be set to 15 psia). As the
discharge pressure of the second stage exceeds 219 psia or the set point of PIC200,
PCV204 opens bleeding high-pressure gas into the tank.
When both compressors are running fully loaded the intermediate pressure will be in
excess of 47 psia. If the intermediate pressure starts to fall below this set point, PCV221
will open, and thereby maintain intermediate pressure.
During operation of the liquefier, PCV215 will be open, then PCV214 and then finally
PCV200, allowing high-pressure gas to flow into the cold box. Initially during cooldown
the high-pressure discharge of the compressor will be maintained by PCV204. When the
coldbox reaches steady state conditions, PCV204 will be closed and PCV210 will supply
makeup gas required for liquefaction.
The gas management system has two operating modes: makeup and recirculation. A
software switch in the operator interface (originally a hardware switch LS200) selects
these modes. Figures 12 and 13 show a simplified process flow diagram for both modes
of operation of the gas management system. In the recirculation mode, makeup from the
gas storage system is disabled so that the discharge pressure and refrigeration capacity
fall until the load is matched. During shutdown the output of PIC201 will automatically
switch back to control PCV210 when the main refrigerator supply valve (PCV200) is
closed.
For more details, please see the technical note Compressor Skid Gas Management
System, RCU-98-032, August 19, 1998 by R. Rabehl. This note describes in detail the
as-built gas management system and the upgraded gas management system.
For details about PID tuning, please see the technical note MTF Compressor Skid PID
Loop Tuning Procedure, November 17, 1998 by R. Rabehl.
FERMILAB
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Doc. No. RCU-98-031

Rev. No. 5
Date: July 19, 2006
Page 17 of 26
Sub-atmospheric suction protection

In the original CTI system, only the second stage suction was protected against subatmospheric suction. If the second stage suction is below 1 atm, pressure switch PS206
was made and the compressor would trip. However, there was no equivalent protection
for first stage sub-atmospheric suction. This could be a problem, because air can be
pulled into the system and introduce contamination.
Protection against sub-atmospheric suction is particularly important for unattended
operation, where large amounts of contamination can be introduced into the system.
Eventually, the refrigerator will shutdown due to contamination-induced failure.
Recovery from this condition can be time-consuming and equipment damage may result.
Therefore, we would like to include as part of this upgrade a condition to protect against
sub-atmospheric compressor suction conditions.
One scenario leading to potential sub-atmospheric first stage suction is depletion of gas
inventory while the system is running in Makeup mode. The buffer tank pressure
decreases, and after a point PIC201 will no longer able to maintain first stage suction
pressure at its setpoint of 1 psi above atmosphere (15.7 psia). To avoid this condition, we
are going to include PLC logic to automatically switch to Recirculation mode when the
first stage suction pressure remains below 14 psia for at least 15 minutes. The timer is
included to prevent switchover during normal short-term compressor suction oscillations.
Figure 11 shows the details of this logic.
If the condition persists after switching over, there will be a shutdown condition for the
first stage compressor suction running below atmospheric (see Figure 3), just like there is
for the second stage (see Figure 4). However, switching first to Recirculation mode
should normally prevent reaching the shutdown condition.
F IG U R E 1 1 : F IR S T S T A G E C O M P R E S S O R S U C T IO N P R O T E C T IO N
PT
201
S u c tio n
P re s s u re
< 1 4 p s ia
DI
15 m
A
G a s M a n a g e m e n t in
"M a k e u p " m o d e
S w itc h to
" R e c ir c u la tio n "
M ode
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Date: July 19, 2006
Page 18 of 26
UPGRADE NOTES:
1. Operators run the gas management system normally in the Makeup mode
(LS200 ON).
2. A switch had been added to the system to use PIC202 to control PCV1406 instead
of PCV211. PCV1406 brings gas to the medium pressure line from HX-1400.
Operators normally run the system with this switch ON, so PCV211 is normally
closed, PIC202 is put in MANUAL and its output is used to control PCV1406. This
valve is usually controlled to be 100% open or closed, so the PID functionality and
variable output is not really required. The upgraded system eliminates the switch,
PIC202 is used exclusively to control PCV211, and an OPEN/CLOSE command
will control PCV1406.
3. Operators like to run the system with PIC203 controlling PCV221 at 20 to 25%
open.
4. Operators run the system with a setpoint range for PIC200 between 150 psi and
220 psi, about 38 psia for PIC203, and 1 psi above atmosphere (15.7 psia) for
PIC201.
5. The original system had been modified to add a manual valve in the pneumatic line
joining PCV226 and PCV207. The original intent of this seems to be to allow
PCV206 to open to bleed gas into the first stage suction if valve PCV204 is open
fully and the discharge side pressure continues to climb. Since the manual valve is
always closed, this logic has been disabled. The upgraded system will remove this
pneumatic line and install a standard solenoid for valves PCV206 and PCV204. If
a two-tier control stragegy for discharge pressure is needed, it will be done in
software as part of the Phase II upgrade.
6. The original system was designed so LS200 will automatically switch from makeup
to recirculation mode when the dewar liquid level reaches a predetermined
setpoint. This logic did not work very well because of noisy dewar liquid level
signal, so it had been disabled. LS200 was only actuated manually by the operator.
The Phase I upgrade will not include any automatic switching between makeup
and recirculation mode, but Phase II may include this automation.
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Page 19 of 26
FIGURE 12:
G AS M AN AG EM ENT SYSTEM - M AKEU P M O D E

( c o n s ta n t d is c h a rg e p r e s s u r e )
G AS STO RAG E
PCV
205
S P : 1 5 p s ia
PCV
210
S P : 4 4 p s ia
P IC
201
S P : 2 1 9 p s ia
PCV
211
P IC
202
PCV
204
P IC
200
PCV
206
S P : 4 7 p s ia
P IC
203
PCV
221
PT
206
PT
201
F ir s t
S ta g e
PT
203
S econd
S ta g e
F ro m
H X -1 4 0 0
PCV
1406
S
PCV
215
PDS
202
PCV
214
C O LD BO X
S
PDS
200
PDS
201
PCV
200
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Rev. No. 5
Date: July 19, 2006
Page 20 of 26
FIGURE 13:
G A S M A N A G E M E N T S Y S T E M - R E C IR C U L A T IO N M O D E
( d i s c h a r g e p r e s s u r e a d ju s t s t o l o a d )
G AS STO RAG E
PCV
205
PCV
210
S P : 1 5 p s ia
S P : 4 4 p s ia
P IC
201
P IC
202
S P : 2 1 9 p s ia
PCV
211
PCV
204
P IC
200
PCV
206
S P : 4 7 p s ia
P IC
203
PCV
221
PT
206
PT
201
F ir s t
S ta g e
PT
203
S econd
S ta g e
F ro m
H X -1 4 0 0
PCV
1406
S
PCV
215
PDS
202
PCV
214
C O LD BO X
S
PDS
200
PDS
201
PCV
200
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Doc. No. RCU-98-031

Rev. No. 5
Date: July 19, 2006
Page 21 of 26
Solenoid Valves
The compressor system isolation valves PCV215, PCV 214, and PCV200 are N.C.
valves. These valves open by energizing their corresponding 3-way solenoid valves
PCV212, PCV224, and PCV201. When the solenoid valves open, instrument air is
supplied to the isolation valves and these valves will open. When the solenoid valves
close, air is exhausted from the isolation valves and these valves will close. There are
certain permissives that must be satisfied before the solenoid valves can open. Figure 14
shows this logic.
PCV215 and PCV215 are equipped with limit switches to signal that these valves are
fully open.
PCV214 (MP Valve) limit switch is used to energize a 5TI relay (CR290), which is used
as one of several permissives to open T1 and T2 turbines inlet valves in the cold box.
This limit switch is also used to activate a pilot lamp to indicate that PCV214 is fully
open.
PCV215 (LP Valve) limit switch is used to activate a pilot lamp to indicate that this valve
is fully open.
UPGRADE NOTES:
1. The PCV214 solenoid (PCV224) had been disabled, and the pneumatic line
connected directly to PCV214 for unkown reasons. As a result, PCV214 no longer
closed but operators still needed to push the OPEN button to satisfy permissives to
open PCV200. A consequence of bypassing the solenoid is that PCV214 open
permissives based on pressure differential (PDS200 and PDS201) were no longer
effective. The upgrade will restore the functionality of the PCV214 solenoid and its
open permissives, as it was originally intended. According to R. Barger, this is
important to prevent damage to turbines.
2. The permisive on cold box instrument air supply OK has been removed. This seems
to be an unnecessary interface between the cold box and the compressor system.
FERMILAB
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Page 22 of 26
F I G U R E 1 4 : S o le n o id s P C V 2 1 2 , P C V 2 2 4 , a n d P C V 2 0 1
101M
A2
201M
A2
F ir s t S ta g e
C o m p re s s o r
R u n n in g
C o m p re s s o r
R u n n in g
A
PDS
202
D iffe r e n tia l P a c r o s s
P C V 215 < 5 psi
PC V215 O pen
R equest
PC V
212
A ir to P C V 2 1 5
( o p e n s o le n o id
PC V212)
S
R
101M
A2
201M
A2
F ir s t S ta g e C o m p re s s o r
R u n n in g
C o m p re s s o r R u n n in g
PDS
200
PC V214 < 5 psi
PDS
201
PC V214 < 15 psi
PC V214 O pen
R equest
A ir to P C V 2 1 4
PC V224)
PC V
224
A ir to P C V 2 0 0
PC V201)
PC V
201
S
R
101M
A2
201M
A2
F ir s t S ta g e
C o m p r e s s o r R u n n in g
C o m p re s s o r R u n n in g
PCV
224
A ir to P C V 2 1 4
PCV
212
A ir to P C V 2 1 5
PC V200 O pen
R equest
S
R
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Page 23 of 26
F I G U R E 1 5 : S o le n o id s P C V 2 2 2 , P C V 2 2 3 , P C V 2 2 6 , P C V 2 2 7 , a n d P C V 2 2 5
201M
A2
C o m p re s s o r
R u n n in g
A ir to P C V 2 1 1
PC V222)
PC V
222
A ir to P C V 2 2 1
PC V223)
PC V
223
A ir to P C V 2 0 4
PC V226)
PC V
226
A ir to F C V 2 0 4
PCV227)
PCV
227
A ir to P C V 2 0 5
PCV225)
PCV
225
F I G U R E 1 6 : S o le n o id s P C V 2 0 8 a n d P C V 2 0 7
101M
A2
F ir s t S ta g e
C o m p re s s o r
R u n n in g
"M a k e u p " M o d e
(L S 2 0 0 O N )
101M
A2
F ir s t S ta g e
C o m p re s s o r
R u n n in g
" R e c ir c u la tio n " M o d e
(L S 2 0 0 O F F )
A ir to P C V 2 1 0
PC V208)
A ir to P C V 2 0 6
PCV207)
PCV
208
PCV
207
UPGRADE NOTES:
1. Solenoid PCV227 (air to FCV204, the interstage isolation valve) has been
hardwired to CR-204 (the second stage motor start relay) according to hand-written
notes. In the original CTI system, it was wired to the 5TI output Y22. However, the
original 5TI program does not contain logic for Y22. R. Barger explained that this
valve was originally included by CTI to prevent second stage compressor backspin
after shutdown, so they wanted to make sure it closed immediately after shutdown.
It was still not effective to prevent backspin, so a check valve was added to the
system later. With the check valve addition, FCV204 is not as critical, so we decided
to wire it to the PLC and replace the hardwired logic by PLC logic. The current 5TI
program version does include logic for Y22, but it does not seem to be related to
PCV227. We need to verify where is Y22 wired to during the disassembly.
2. Solenoid PCV226 was added to the system and solenoid PCV207 was changed to a
standard 3-way solenoid. See RCU-98-032 for details.
3. Manual valves have replaced the three solenoids for the buffer tank (EV-240 to
242) because they are used for maintenance only.
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Broken Transmitter Alarms

Analog transmitters are used to shutdown equipment when the corresponding process
variables reach a critical alarm setpoint. However, if the transmitter is broken the
equipment may continue running unprotected. Therefore, it is important to identify
conditions indicative of a broken transmitter and shutdown equipment before an
undetected dangerous condition exists.
All analog transmitters operate in the range of 4 to 20 mA. A transmitter signal between 0
an 4 mA is therefore indicative of either a broken transmitter or a problem in the
electrical loop. The PLC analog input cards convert the analog input to a digital value
between 0 and 32,000. Therefore, any digital value in the range 0 to 6400 (corresponding
to the 0 to 4 mA range) is indicative of a broken transmitter. The strategy to detect a
broken transmitter is to check the raw digital value, and if it is between 0 and 6400 issue
an alarm. When the alarm is for transmitters associated with shutdown conditions, the
equipment will be automatically shutdown because it is not acceptable to run with broken
critical transmitters.
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Rev. No. 5
Date: July 19, 2006
Page 25 of 26
APPENDIX A: Symbols Definition for Logic Diagrams

Logic diagrams were produces according to the ANSI/ISA-S5.2 standard, Binary Logic
Diagrams for Process Operations. Please refer to the standard for additional details.
S Y M B O L D E F IN IT IO N F O R B IN A R Y L O G IC D IA G R A M S (A N S I/IS A -S 5 .2 )
IN P U T
S ta te m e n t
o f In p u t
In it ia t in g in s t r u m e n t o r d e v ic e
n u m b e r, if k n o w n
D*
O U TPU T
* O u tp u t D s h a ll n o t b e
s h o w n if it is n o t u s e d
S ta te m e n t
o f O u tp u t
M E M O R Y : S re p re s e tn s s e t m e m o ry a n d R
re p re s e n ts re s e t m e m o ry . L o g ic o u tp u t C e x is ts
a s s o o n a s lo g ic in p u t A e x is ts . C c o n tin u e s to
e x is t, re g a rd le s s o f th e s u b s e q u e n t s ta te o f A ,
in til th e m e m o ry is r e s e t, i.e ., te r m in a te d b y
lo g ic in p u t B e x is tin g . C r e m a in s te rm in a te d
re g a rd le s s o f th e s u b s e q u e n t s ta te o f B , u n til A
c a u s e s th e m e m o ry to b e s e t. L o g ic o u tp u t D , if
u s e d , e x is ts w h e n C d o e s n o t e x is t, a n d D d o e s
n o t e x is t w h e n C e x is ts .
In p u t- O v e r r id e O p tio n : If In p u ts A a n d B e x is t
s im u lta n e o u s ly , a n d if it is d e s ire d to h a v e A
o v e rrid e B , th e n S s h o u ld b e e n c irc le d ; if B is to
o v e rrid e A , th e R s h o u ld b e e n c irc le d .
O p e r a te d in s tru m e n t o r d e v ic e
n u m b e r, if k n o w n
A
B
A
B
O R
A N D : lo g ic o u tp u t D
e x is ts if a n d o n ly if
a ll lo g ic in p u ts A , B ,
a n d C e x is t
DI
t
T IM E R D e la y In it i a t io n o f o u t p u t : t h e c o n t i n u o u s
e x is te n c e o f lo g ic in p u t A fo r tim e t c a u s e s lo g ic
o u tp u t B to e x is t w h e n t e x p ire s . B te r m in a te s
w h e n A te rm in a te s .
DT
t
T IM E R D e la y T e r m i n a t io n o f o u t p u t : t h e e x is t e n c e
o f lo g ic in p u t A c a u s e s lo g ic o u tp u t B to e x is t
im m e d ia te ly . B te r m in a te s w h e n A h a s
te r m in a te d a n d h a s n o t a g a in e x is te d fo r tim e t.
PO
t
T IM E R P u ls e
A , re g a r d le s s
lo g ic o u tp u t B
tim e t a n d th e
O R : lo g ic o u tp u t D
o n e o r m o re lo g ic
in p u ts A , B , a n d C
e x is t
N O T : lo g ic o u tp u t B
lo g ic in p u t A d o e s
n o t e x is t
O u tp u t: th e e x is te n c e o f lo g ic in p u t
o f its s u b s e q u e n t s ta te , c a u s e s
to e x is t im m e d ia te ly . B e x is ts fo r
n te rm in a te s .
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Rev. No. 5
Date: July 19, 2006
Page 26 of 26
APPENDIX B: Compressor System Cold Box System Control Interface

Control Signals from Compressor System to Cold Box System:
1.
2.
3.
4.
5.
First Stage ON (wire 101M-A2 signal to X5 5TI input)

Second Stage ON (wire 201M-A2 signal to X21 5TI input)
PCV214 Fully Open (wire PCV214 limit switch ZSH214 signal to X26 5TI input )
PCV200 Open Command (Output to solenoid valve PCV201)
PCV215 Fully Open (wire PCV215 limit switch ZSH215 signal to X27 5TI input)
Control Signals from Cold Box System to Compressor System:

None
UPGRADE NOTES:
1. The 5TI signals are 110 VAC, so auxiliary control relays to switch 110 VAC may be
needed to provide these signals.
2. We decided to eliminate the cold box vacuum signal to the compressor system. This
signal (wired to X49) would trip the compressor if the cold box vacuum is bad. The
5TI program was modified to accommodate this logic. The purpose of this seems to
be to prevent cold gas from running through the compressors, which was more
critical when the compressors were close to the cold box.
3. We also decided to eliminate the N2 vent valve limit switch signal. The compressors
were prevented from starting if this valve was closed (again, this logic was added to
the 5TI system). This condition is no longer relevant, and the signal had been
jumpered.

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MTF Helium Refrigerator

Doc. No. RCU-98-031

MTF Helium Refrigerator

Author: Ruben Carcagno

MTF Helium Refrigerator