EPICC FOR WASTEWATER RECYCLE

AND REDUCTION PROJECT

(QG2 AND QG3&4)
VENDOR/ SUBCONTRACTOR DOCUMENT NO VP-THI-QG29-118:

REVISION: C3

DOCUMENT TITLE: CONTROL PHILOSOPHY (QG2)

Page 1/16

CONTROL PHILOSOPHY (QG2)

C3

29th Feb.
2016

C2

SJK

SAFI

CJL

FOR APPROVAL

16 Oct.
2015

SJK

SAFI

CJL

FOR APPROVAL

C1

25th Sep.
2015

SJK

SAFI

CJL

FOR APPROVAL

Revision

Date

Originated

Checked

Approved

Description

th

CONTROL PHILOSOPHY FOR MBR CHILLER PACKAGE

1. READY TO START CONDITION

2. STOP OF COMPRESSOR.
3. SUPERHEAT CONTROL FOR EXPANSION VALVE
4. CAPACITY CONTROL FOR COMPRESSOR
5. OIL PUMP CONTROL
6. WATER PUMP CONTROL

READY TO START CONDITIONS OF C-101 COMPRESSOR (I-01 INTERLOCK)

Basic operating concept
This interlock is for permissive to start compressor. If all of below causes are satisfied
operator can start compressor by push start button at local site.
MBR Chiller package should be operated and started at job site due to for safety reason.
Remote operation for compressor will not be allowed.
Each MBR Chiller package is operated individually. It doesnt connect each other to control
total cooling capacity.
Signal for ready to start will be repeated to ITR PLC(by client) when occurred in THI chiller
PLC.
Signal for compressor running feedback should be send from ITR PLC(client scope) to THI
chiller PLC
Value for compressor current feedback should be send from ITR PLC(scope) to THI chiller
PLC
Causes (All causes in AND logic) :
1) Not activated of Suction pressure(29PY-87I402A) low (2.74 barg)
2) Not activated of Discharge pressure(29PY-87I405A) high (13 barg)
3) Not activated of Chilled return temperature(29TY-87I407A) low (23)
4) Compressor capacity position(29ZY-87I401A) is less than 5%
5) Compressor NOT running (29XL-87I403A)
6) Trip of compressor interlock(I-02) NOT active
7) Stop button on LCP(29HS-87I406A) NOT pushed
8) Stop signal from DCS(29HS-87I413A) NOT active
9) level(29LC-87I402A) low low trip(18%) NOT active
10) Water pump running (one of two 29XL , two of three 59XL),Signal from client PLC to THI
Chiller PLC.

Actions :
1) Activate ready to start lamp on LCP
2) Activate ready to start lamp on DCS

Note :
1) Compressor can be started only at local job site by pushing compressor start button
when ready to start lamp is ON

TRIP OF C-101 COMPRESSOR (I-02 INTERLOCK)

Basic operating concept
This interlock is for trip of compressor as per below descriptions.
Signal for not available /trip will be repeated to ITR PLC(client scope) when occurred in
THI chiller PLC
Signal for compressor fault feedback should be sent from ITR PLC(client scope) to THI chiller
PLC.
Signal for emergency stop will be repeated to ITR PLC (client scope) when occurred in chiller
PLC.

Causes (All causes in OR logic) :

1) Suction pressure(29PY-87I402A) low low trip(1.93 barg) active (Note 3)
2) Discharge pressure(29PY-87I405A) high high trip(15 barg) active
3) Oil level(29LC-87I402A) low low trip(18%) active
4) Oil supply Diff. pressure(29PDY-87I401A) low low trip(0.5 barg) active (Note 3)
5) Discharge temperature(29TY-87I410A) high high trip(110) active
6) Oil supply temperature(29TY-87I404A) high high trip(80) active
7) Suction superheat temperature(29UY-87I403A) low low trip(0) active
8) Compressor stop button(29HS-87I406A) active
9) Chilled water temperature(29TY-87I407A) low low trip(20) active
10) Compressor run feedback(29XL-87I403A) from MCC was NOT activated within 15sec.
11) Compressor stop command from DCS(29HS-87I413A) active
12) Compressor emergency stop bottom (29HS-87I407A) active.

Actions :
1) Trip compressor motor

2) Activate Common trip lamp on LCP (Note 1,2)

3) Activate Common trip signal on DCS
4) Activated emergency stop signal will be repeated in ITR PLC(client scope)

Note :
(1)Push reset button for alarm reset and recover Ready to start condition if all trip
conditions (causes) disappeared
(2) If there is still any trip condition, common trip lamp remain ON even if reset button is
pushed.
(3) This alarm & trip to be overridden before start-up even of alarm&trip condition is
generated.
(4) To check lamp in chiller PLC manually, use lamp test button.

SUPERHEAT CONTROL FOR CV-01 EXPANSION VALVE (I-03 INTERLOCK)

Basic operating concept
This interlock is for control expansion valve using superheat.
The temperature difference between boiling temperature and heat gained vapour
temperature is called superheat
If the superheat is low as below 1 K (Kelvin) , it means that the vapour can be condensed to
liquid. To avoid any liquid carry over to compressor suction , optimum superheat value to
be maintained during compressor operation.
Expansion valve opening signal will be repeated to ITR PLC(client scope) by Modbus
communication.
Control for expansion valve should be done at THI chiller PLC automatically to protect
compressor.
Manual operating is not possible for expansion valve.
Due to safety reason remote valve control will not be provided

Causes 1 (All causes are AND logic) :

1) Compressor is running(29XL-87I403A)
2) Calculated superheat(29UY-87I401A) is lower than set value(5)

Actions 1 :
1) Decrease open degree of control valve(CV-01)

Causes 2 (All causes are AND logic) :

1) Compressor is running(29XL-87I403A)
2)

Calculated superheat(29UY-87I401A) is higher than set value(5)

Actions 2 :
1) Increase open degree of control valve(29FV-87I402A)

Note :
1) Control valve position to return to zero position (0%) immediately when compressor is
stopped
2) Superheat can be calculated by following formula
TY=Ta Ts
Where,
TY : superheat (K or )
Ta : actual temperature read from 29TY-87I408A ()
Ts : saturation temperature () corresponding pressure (actual pressure read from PI05)

CAPACITY CONTROL FOR C-101 COMPRESSOR (I-04 INTERLOCK)

Basic operating concept
This interlock is to control compressor capacity.
Screw compressor are capacity regulated (hydraulically) in so far that oil is added or
removed from the capacity slide cylinder. This takes place with four solenoids valves , which
are controlled by capacity regulator , so that the slide moves towards max. or min. capacity ,
according to demand.
Operator can select mode of compressor capacity control in both chilled water temperature
and suction pressure
In mode of chilled water temperature, The compressor capacity regulation going to be ,
depending on the difference between the desired chilled water temperature set value and
the actual one.
In mode of suction pressure , The compressor capacity regulation going to be , depending
on the difference between the desired suction pressure set value and the actual one.
Remote capacity control will not be provided
Remote auto/manual selection will not be provided.
Signal for capacity control selection mode (chilled water temperature/suction pressre) will
be repeated to ITR PLC (client scope) from chiller PLC.
Signal for auto/manual selection mode will be repeated to ITR PLC(client scope) from chiller
PLC.
Signal for load will be repeated to ITR PLC (client scope) from chiller PLC.
Signal for unload will be repeated to ITR PLC (client scope)from chiller PLC.

Causes 1 (All causes in AND logic) : Capacity Decrease Control

1) Compressor running(29XL-87I403A) active
2) Capacity control switch(29HS-87I402A) is in AUTO position active
3) Capacity control mode(29HS-87I401A) is in chilled water temp. mode

4) Chilled water temperature(29TY-87I407A) is lower than Set value(26) minus low

gap(0.5)
Actions 1 :
1) Energize DECREASE solenoid(29XY-87I402A/ 29XY-87I404A)
2) De-energize INCREASE solenoid(29XY-87I401A/ 29XY-87I403A)

Causes 2 (All cause in AND logic) : Capacity Increase Control

1) Compressor running(29XL-87I403A) active
2) Capacity control switch(29HS-87I402A) is in AUTO position active
3) Capacity control mode(29HS-87I401A) is in chilled water temp. mode
4) Chilled water temperature(29TY-87I407A) is higher than Set value(26) plus high
gap(0.5)

Actions 2 :
1) Energize INCREASE solenoid (29XY-87I401A/ 29XY-87I403A)
2) De-energize DECREASE solenoid (29XY-87I402A/ 29XY-87I404A)

Causes 3 (All causes in AND logic) : Capacity Decrease Control

1) Compressor running(29XL-87I403A) active
2) Capacity control switch(29HS-87I402A) is in AUTO position active
3) Capacity control mode(29HS-87I401A) is in suction pressure mode
4) Suction pressure(29PY-87I402A) is lower than Set value(4.44 barg) minus low gap(0.1
barg)

Actions 3 :

1) Energize DECREASE solenoid(29XY-87I402A/ 29XY-87I404A)

2) De-energize INCREASE solenoid(29XY-87I401A/ 29XY-87I403A)
Causes 4 (All cause in AND logic) : Capacity Increase Control
1) Compressor running active(29XL-87I403A)
2) Capacity control switch(29HS-87I402A) is in AUTO position active
3) Capacity control mode(29HS-87I401A) is in suction pressure mode
4) Suction pressure(29PY-87I402A) is higher than Set value(4.44 barg) plus high
gap(0.1barg)

Actions 4 :
1)

Energize INCREASE solenoid(29XY-87I401A/ 29XY-87I403A)

2)

De-energize DECREASE solenoid(29XY-87I402A/ 29XY-87I404A)

Causes 5 (All causes in AND logic) : Capacity decrease control

1) Compressor running active(29XL-87I403A)
2) Capacity control switch(29HS-87I402A) is in MANUAL position active
3) Push unload button(29HS-87I404A)

Actions 5 :
1)

Energize DECREASE solenoid(29XY-87I402A/ 29XY-87I404A)

2)

De-energize INCREASE solenoid(29XY-87I401A/ 29XY-87I403A)

Causes 6 (All causes in AND logic) : Capacity Increase control

1) Compressor running active(29XL-87I403A)
2) Capacity control switch(29HS-87I402A) is in MANUAL position active
3) Push load button(29HS-87I403A)

Actions 6 :
1) Energize INCREASE solenoid(29XY-87I401A/ 29XY-87I403A)
2) De-energize DECREASE solenoid(29XY-87I402A/ 29XY-87I404A)

Note :
1) Set value of chilled water temperature and Suction pressure high/low gap can only be
changed in THI PLC.
2) If either DECREASE solenoid or INCREASE solenoid is energized at capacity control switch
in AUTO , solenoid ON delay time (1 sec.) & OFF delay time (4 sec.) to be implemented
in THI PLC logic

P-101 OIL PUMP CONTROL (I-05 INTERLOCK)

Basic operating concept
This interlock is for control of oil pump.
Lub oil pump to be started at job site.
Signal for auto/manual selection mode will be repeated to ITR PLC (client scope) from THI
chiller PLC.
Signal for pump running feedback should be send from ITR PLC(client scope) to chiller PLC

Causes 1 (All causes in AND logic) : Auto oil pump start control
1)

Oil pump selection switch(29HS-87I410A) is AUTO

2)

Compressor Running signal(29XL-87I403A) activate

3)

Oil pump run feedback(29XL-87I404A) from MCC activated within 15sec.

Actions 1 :
1)

Start oil pump

2)

Oil pump running lamp(29XL-87I404A) activate on LCP

3)

Oil pump running signal(29XL-87I404A) acticate to DCS

Causes 2 (All causes in AND logic) : Manual oil pump start control
1)

Oil pump selection switch(29HS-87I410A) is MANUAL

2)

Oil pump start button(29HS-87I411A) pushed

3)

Oil pump run feedback(29XL-87I404A) from MCC activated within 15sec.

Actions 2 :
1)

Start oil pump

2)

Oil pump running lamp(29XL-87I404A) activate on LCP

3)

Oil pump running signal(29XL-87I404A) acticate to DCS

Causes 3 (All causes in AND logic) : Manual oil pump stop control
1)

Oil pump selection switch(29HS-87I410A) is MANUAL

2)

Oil pump stop button(29HS-87I412A) pushed

3)

Oil pump run feedback(29XL-87I404A) from MCC not activated within 15sec.

Actions 2 :
1)

Stop oil pump

2)

Oil pump running lamp(29XL-87I404A) not activate on LCP

3)

Oil pump running signal(29XL-87I404A) not activate to DCS

P-101 WATER PUMP CONTROL (I-06 INTERLOCK), all below to be implemented and controlled
directly in client PLC

Causes 1 (All causes in AND logic) : Water pump start control

1)

Not activated of water tank level(29LC-87I401) low (30%)

2)

Water pump start button(HS-01A/B, HS-01A/B/C) active.

Actions 1 :
1)

Start water pump (29-Y8725-P12A/B, 59-Y8733-P12A/B/C)

Causes 2 (All causes in AND logic) : Water pump stop control

1)

Activated of water tank level(29LC-87I401) low low (15%)

2)

Water pump stop button(HS-01A/B, HS-01A/B/C) active.

Actions 2 :
1)

Stop water pump (29-Y8725-P12A/B, 59-Y8733-P12A/B/C)

STOP FOR COMPRESSOR (I-07 INTERLOCK)

Basic operating concept
This interlock is for stop compressor manually.
Signal for stop will be send to ITR PLC when occurred in chiller PLC

Causes (All causes in OR logic) :

1)

Compressor stop button active

2)

Compressor stop command form DCS active

Actions :
1)

Trip compressor motor