Ritendra Bhattacharya March 34 2020 45K Cold Box Controls Software Review 2 Charge March 34 2020 2 Are the process requirements clearly defined and approved by the appropriate stakeholders ID: 776100
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Slide1
4.5 K Software Requirements
Ritendra BhattacharyaMarch 3-4, 2020
4.5K Cold Box Controls Software Review
Slide22
Charge
March 3-4, 2020
2
.
Are
the process requirements clearly defined and approved by the appropriate stakeholders?
Slide3Outline
IntroductionControl Philosophy as software specificationReview and Approval of Control PhilosophyList of Reference DocumentsUse for Code DevelopmentResponse to review charge question
3
March 3-4, 2020
Slide44
Introduction
March 3-4, 2020
The requirements for the 4.5K software development is defined in the Control Philosophy document.
Control philosophy is developed and maintained by
sub-contractor AIR LIQUIDE ADVANCED TECHNOLOGIES US. LLC
. [Reference: C1303-NT-400
]
Thereafter, this document is revised based on the comments from JLAB and SLAC.
Currently, we are using control philosophy version 5 as our specification for the 4.5K control software development effort.
Slide55
Control Philosophy as Software Specification
March 3-4, 2020
Control philosophy explains how the 4.5K cold box will operate in automatic as well as manual operation.
Control philosophy includes specification for
PID Control Loops
Control Sequences
Alarms
Trips
Interlocks
Calculations
Instrument
ranges and calibration table
PID gain Values
Slide66
PID Control Loops - Table
March 3-4, 2020
Description
Control Loop
Actuators
Process Value
Set Point
Action
Warm End Controls
HP Flow
TIC-22400
PV-22400 and PV-22402
Min(TP-22505,TT-22201) – TP-22101
0.0 K
Direct
LN2
LIC-22520
PV-22520
LT-22510
70%
Indirect
80K Bed A
TIC-22418A
EH-22418A
MAX [TP-22418AA1 / AA2 / AB1 / AB2]
350 K
Indirect
80K Bed B
TIC-22418B
EH-22418B
MAX [TP-22418BA1 / BA2 / BB1 / BB2]
350 K
Indirect
4
Slide77
PID Control Loops - Table
March 3-4, 2020
Description
Control Loop
Actuators
Process Value
Set Point
Action
Turbine Controls
Bearing
PIC-22405
PV-22405
PT-22405
12 atm
Indirect
T1 Spped
SIC-22432
PV-22432
ST-22433
TIC-22432.Out X Attenuator
Indirect
T1 Discharge TT
TIC-22432
SIC-22432.SP Calculation
TD-22332
34 K
Direct
T2 Spped
SIC-22452
PV-22452
ST-22453
TIC-22452.Out X Attenuator
Indirect
T2 Discharge TT
TIC-22452
SIC-22452.SP Calculation
TD-22352
13 K
Direct
T3 Spped
SIC-22472
PV-22472
ST-22473
TIC-22472.Out X Attenuator
Indirect
T3 Discharge TT
TIC-22472
SIC-22472.SP Calculation
TD-22372
6.5 K
Direct
T4 Spped
SIC-22482
PV-22482
ST-22483
TIC-22482.Out X Attenuator
Indirect
20K Discharge TT
TIC-22482
SIC-22482.SP Calculation
TD-22466
18.5 K
Indirect
T1 Brake
PIC-22436
EV-22436
PT-22436
- 5.0 atm if EIC OFF
- EIC-22436 if ON
Indirect
T1 Efficiency
EIC-22436
PIC-22436.SP Calculation
Calculated tip spped/ spouting velocity
0.65
Direct
T2 Brake
PIC-22456
EV-22456
PT-22456
- 5.0
atm
if EIC OFF
- EIC-22456.Out if ON
Indirect
T2 Efficiency
EIC-22456
PIC-22456.SP Calculation
Calculated tip spped/ spouting velocity
0.64
Direct
T3 Brake
PIC-22476
EV-22476
PT-22476
- 5.0 atm if EIC OFF
- EIC-22476.Out if ON
Indirect
T3 Efficiency
EIC-22476
PIC-22476.SP Calculation
Calculated tip spped/ spouting velocity
0.64
Direct
T4 Brake
PIC-22486
EV-22486
PT-22486
- 5.0 atm if EIC OFF
- EIC-22486.Out if ON
Indirect
T4 Efficiency
EIC-22486
PIC-22486.SP Calculation
Calculated tip spped/ spouting velocity
0.62
Direct
17
Slide88
PID Control Loops - Table
March 3-4, 2020
DescriptionControl LoopActuatorsProcess ValueSet PointActionCold End Controls20K BedTIC22465EH-22465MAX [TP-22465 A1/ A2/ A3/ B1 /B2/B3]350 KIndirect T4 Discharge PTPIC-22485PV-22485PT-223933.0 atmIndirect20K Discharge TTTIC-22485PIC-22485 MIN OutTD-2246618.0 KIndirectT4 Discharge PTPIC-22393PV-22393PT-223933.25 atmDirectDewar PressurePIC-22194PV-22194PT-310051.5 atmDirectDewar OverpressurePIC-31020PV-31020PT-310051.7 atmDirectDewar LevelLIC-31000EHTR-31000LT-3100090%Direct Subcooler LevelLIC-22930PV-22390LT-22195A (SC Probe)50%IndirectT4 Discharge PTPIC22390LIC-22390 MAX OutPT-223932.8 atmDirectSubcooler PTPIC-22193PV-22193PT-221951.05 atmDirectSubcooler LevelLIC-22195APV-22195LT-22195A (SC Probe)70%DirectSubcooler LevelLIC-22195BEHTR-22195LT-22195A (SC Probe)90%Direct Coldend bypassTIC-22389PV-22389TD-22386Calculation with TD-22466Direct 13
DescriptionControl LoopActuatorsProcess ValueSet PointActionWarm Shield (35K) and Cold Shield (5K) ControlWS Pressure DropDPIC-22441PV-22441PT-22245-PT-222492.5 atmIndirectWS Pressure DropDPIC-22242PV-22242PT-22245-PT-222491 atmDirect CS Return TTTIC-22392PV-22392TT-221918.0 KDirectT4 Discharge PTPIC-22392TIC-22392 MAX OutPT-223932.9 atmDirectCS ReturnPIC-22191PV-22191PT-221912.3 atmDirect 5 Primary Supply (4.5 K) ControlT4 Discharge PTPIC-22391PV-22391PT-223932.7 atmDirect 1
TOTAL: 40 PID Control Loops
Slide99
Control Sequences
March 3-4, 2020
Automated Control SequencesCold Box Vacuum (Upper and Lower)Turbine 1Turbine 2Turbine 3Turbine 4Cool down LHe Dewar ConnectionWarm Shield Cold ShieldPrimary Supply Manual OperationCold Box warmupAdsorber regenerationCold box preparation before cool downCold box isolationStart/Stop of automatic sequence
State 1
State 2
Task - 1
Task - 2
Transition Condition
Task - 3
Task - 4
Slide1010
Example: Vacuum Sequence - Start
March 3-4, 2020
Tag Description:
Operator start order
Roughing pump, VP-23610
Diffusion Pump, EH-23610
Chamber Vacuum, PT-23610
Roughing pump vacuum, PT-23618
Pump ready, TSH23611
ON/OFF Valves
Gate Valve, PV-23611
Chamber Roughing Valve, PV-23616
DP Roughing
Valve,
PV-23614
Gate valve opening, ZSH23611
Slide1111
Alarms
March 3-4, 2020
Control philosophy provides overall 83 alarms for the operator.
The areas of 4K cold box alarm are
Pressures at Warm lines
Cold embrittlement at warm lines
80 K and 20K
Adsorbers
Differential temperatures at heat exchangers
LN2 phase separator
Cold box cold end
LHe
Subcooler
Turbines 1, 2, 3 and 4
Vacuum skid
General
Set points for alarm activation and reset are different to prevent alarm blinking.
Some of the alarms are conditioned in a way so that they are activated only in a specified ‘state’.
Slide1212
Trips
March 3-4, 2020
Control philosophy has described overall
100 trips.
The areas of trips are
Differential
temperatures at heat exchangers
(Ex: High
temperature difference on HX-12 cold end if
Δ
T >
50
K)
Turbines
1, 2, 3 and 4
(Ex: T1
inlet pressure high if PT>
19.46
atm
)
Vacuum skid
(Ex: No running feedback for diffusion pump)
Utility (Air pressure failure)
Trip actions
Cool down sequence trip
Turbine 1 / 2 / 3 / 4 sequence trip
Vacuum sequence trip
Cool down sequence trip shut down entire cold box except for vacuum sequence.
Operator action is required to start up the sequences.
Slide1313
Interlock
March 3-4, 2020
The purpose of interlock is to prevent automated sequence trips.
Overall 56 interlocks are developed. These are acting on valves and heaters elements.
Interlocks covers following area
Warm Inlet Valves
LN2 Phase Separator
Cool down line valves
80K
Adsorbers
20K
adsorber
Cold End and
LHe
Subcooler
Dewar
Turbines
Vacuum skid
Interlock overrides auto and manual actions. Operator reset is required to return back to the state before interlock.
A subset of all interlocks is categorized as temporary. Operator reset action is not required for temporary interlocks.
Slide1414
Calculations
March 3-4, 2020
Calculation covers flow conversion, turbine efficiency calculation and turbine attenuator set up.
HEPAK® property data is used for density calculation for flow calculation if the supply temperature is below 7 K. Ideal gas density has been calculated if the supply temperature is above 7 K.
Turbine attenuators are used to reduce the turbine speed set point in case turbine parameters approaches to the UNSAFE or OFF-DESIGN condition.
Turbine isentropic efficiency is dependent on ratio of tip speed (U) and the spouting velocity (C0). The ratio U/C0 is actively calculated based on design parameter and helium properties from
HEPAK
®.
Slide1515
Review and Approval of Control Philosophy
March 3-4, 2020
Control philosophy has been prepared by ALATUS.
Control philosophy has been jointly reviewed by JLAB and SLAC after final design review with a dedicated meeting during Sept 27-28, 2018 at Houston.
Currently control philosophy is approved for developing the PLC and HMI codes.
During the process of code development, control philosophy has been revised to better describe the findings.
The last revision is originated from the bench testing of the PLC code performed during December 16-19, 2019 participated by ALATUS and SLAC.
It is expected to have future revision during onsite commissioning and performance testing of 4.5K cold box.
Slide1616
List of References – Electrical
March 3-4, 2020
Drawing number
Enclosure ID
Drawing name
As-Built Status
As-Installed Redline available
79221-1000
CX-4K-CBX-PLC
4K COLD BOX SYSTEM CONTROL & TERMINATION ENCLOSURE DETAILS
Approved
79221-1001
4K COLD BOX SYSTEM 24VDC INSTRUMENT POWER SUPPLY ASSEMBLY
Approved
79221-1002
4K COLD BOX SYSTEM CONTROLS TERMINATION DETAILS 24VDC POWER SUPPLY SOURCE
Approved
79221-1003
4K COLD BOX SYSTEM PLC CHASSIS ASSEMBLY
Approved
79221-1004
4K COLD BOX SYSTEM PLC ETHERNET CONNECTIONS
Approved
79221-1005
4K COLD BOX SYSTEM PLC MODULE TERMINATION DETAIL DIGITAL INPUT
YES
79221-1006
4K COLD BOX SYSTEM PLC MODULE TERMINATION DETAIL RELAY OUTPUT
YES
79221-1007
4K COLD BOX SYSTEM PLC MODULE TERMINATION DETAIL ANALOG INPUT SINGLE ENDED CURR.
YES
79221-1008
4K COLD BOX SYSTEM PLC MODULE TERMINATION DETAIL ANALOG OUTPUT
Approved
79221-1009
4K COLD BOX SYSTEM TEMPERATURE DIODE INPUT
Approved
79221-1010
CX-MCB-20K-ADS-HTR-CTRL
4K COLD BOX SYSTEM 20K HEATER CONTROLLER
Approved
79221-1011
CX-MCB-SC-HTR-CTRL
4K COLD BOX SYSTEM SUBCOOLER HEATER CONTROLLER
Approved
79221-1012
CX-MCB-80K-ADS-Z-HTR-CTRL
4K COLD BOX SYSTEM 80K ADSORBER HEATER CONTROLLER
Approved
79221-1013
CX-MCB-LTTI-TEST-HTR-CTRL
4K COLD BOX SYSTEM LTTI TEST HEATER
Approved
79221-1016
CX-YMCB-VAC-RP-CTRL
4K COLD BOX SYSTEM ROUGHING PUMP CONTROLS ENCLOSURE, WIRING AND LAYOUT
Approved
79221-1017
CX-YMCB-VAC-DP-CTRL
4K COLD BOX SYSTEM DIFFUSION PUMP CONTROLS ENCLOSURE, WIRING AND LAYOUT
YES
79720-1002
CX-LHD-HTR-CTRL
4K COLD BOX SYSTEM LHe DEWAR HEATER CONTROLLER DETAILS & SCHEMATIC
Approved
79720-1003
CX-LHD-INSTR-ENCL
4K COLD BOX SYSTEM 10kL LHe DEWAR INSTRUMENT ENCLOSURE
Approved
71200-2925
SHIELD TEST LOAD HEATER CONTROLLER
Approved
71200-2926
4K TEST LOAD HEATER CONTROLLER
Approved
Slide1717
List of References - Design
March 3-4, 2020
Number
Description
Status
79221-0001
Main 4.5K Cold Box
Test P&ID
Approved
79221-0002
Main 4.5K Cold Box P&ID
Approved
79720-0001
LHe
Storage Dewar System
Approved
C1303 A 120
4.5K Cold Boxes P&IDs set
Approved
C1303 LT 101
Mechanical & Instrumentation List
Approved
C1303-LT-103
Turbines Mechanical & Instrumentation List
Approved
79120-C6003
LCLS-II General Software Specification
Approved
C1303 NT 101
Process Calculations Including TS Diagrams
Approved
C1303 NT 701
Interfaces
Hazop
Approved
C1303 NT 751
Reliability Plan
Approved
C1303 NT 401B
Vacuum Logic
Approved
C1303 A 110
Process Flow Diagram
Approved
Slide1818
Use for Code Development
March 3-4, 2020
Control philosophy has served as the guiding specification to develop PLC codesThe PLC code has been developed and fully bench tested at JLAB.Plans for integration of developed codes has been prepared along with the overall commissioning plan.
Refer presentation by R. Norton
Refer my last presentation
Slide1919
Response to Charge
March 3-4, 2020
2
.
Are
the process requirements clearly defined and approved by the appropriate stakeholders?
YES, the requirement are clearly defined and approved.
Redlines originated from as-installed condition are available since the installation is ongoing.
Slide2020
March 3-4, 2020
THANK YOU FOR KIND ATTENTION