Controls and Safeties

Controls and Safeties

Chapter Objective This chapter describes the operational controls of the machine and
the safeties provided.

Control Panel The control panel consists of the following components :

. Programmable Logic Controller (PLC).

. Operator interface.
. Power and control circuit for pumps.
. Panel mounted instruments.
. Terminal blocks for field connection

Capacity Control The cooling capacity of the machine is the total heat extracted
from the chilled water. The chilled water fl-ow rate to the machine is
kept Constant. Hence the capacity is proportional to the difference
in the temperatures of the inlet and outlet chilled water. Load
changes are reflected in the rise or fall of the temperature of the
inlet chilled water. As the inlet chilled water temperature rises or
falls the. outlet chilled water temperature tends to follow the same
pattern. A RTD sensor in the outlet chilled water senses this
change in temperature. This signal is fed to the PLC. An inbuilt
software PID control loop processes this signal with respect to the
chilled water set point. A control output signal of 4 to 20 rnA is sent
to the I/P co-nverter. The I/P converter converts the 4 to 20 rnA
electrical signal to a 0.2 to 1 kg/cm2g pneumatic signal. This
pneumatic signal controls the position of the steam control valve.
As the load increases the steam control valve opens, as the loac!
reduces the steam control valve closes, and thus regulates the
quantity of steam entering the machine.

BLOCK DIAGRAM:

C) VAM

EEEEEERE
PT100 TEMP. SENSOR PLC I to p STEAM CONTF`C)L
CONVERTEF` VALVE

L-cut differential : Sometimes the !ciad may fall sharply due to which chilled water
temperature will start dropping. When tlie chjlled watr3r outlet
temperature drops below the chilled water out set point minus L-
cut differential set point, the refrigerant piimp is switched off and
Steam control valve shuts off fully (0 amps). This safety prevents
further temperatijre clrop of the chilled water. The refrigerant pump
and steam control valve will restart after the Chilled water outlet
temperature iises abo`/e th.e CHW out set point minus L..cut
differential plus the hysterisis.

Safeties Safety devices are provided to protect the machine from abnormal
conditions and safeguard i{ from damage and ensure continued
availability.

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 -=-rTTh~.-.T.*xpe_4malr7TH ` +1

Controls and Safeties

Safety devices are -

Machine mounted safeties located on the machine,
Panel mounted safeties in the control panel, and
Field lnterfocks passing signals from the field to the machine.

Machine mounted . Chilled water flow transmitter :

safeties Connected across orifice plate mounted on CHW inlet
piping.
. Chilled water Differential Pressure (DP) transmitter :
Connected between the inlet and outlet chilled water
nozzles.
. Refrigerant level electrodes :
Mounted in the refrigerant level box.
. Temperature sensors mounted at various locations to display
temperatures.
Panel mounted . Refrigerant level controller.
safeties . Absorbent pump overload relay / AC Drive.
. Ftefrigerant pump overload relay.
. Purge pump overload relay.

Field Interlocks . Chilled water pump interlock.

. Chilled water pump starvstop permissive contact.
. Cooling water pump/ butterfly valve start/stop permissive contact.

Vacuum Dis Vacuum Transmitter is mounted on the purge tank assembly. By

suitably opening the isolation valves, the vacuum on the shell side
& tank side can be seen on the operator panel. '

Safef Functions: The safety functions of the machine protect it against abnormal
conditions. The various safety funclions are
Thermal shock protection.
Antifreeze protection.
Cavitation protection of refrigerant pump.
Motor protection

Thermal sh To protect the machine from thermal shock, the steam control
valve is opened gradually for first 10 minutes after machine start
prtyffiqu: up, when the Generator temperature is less than 70°C. After the
slow opening diiration is over, the control is switched over to
chilled water tempel.atui.e modulation aiitomatically.

In case if the chilled water outlet temperature is already below the

set point, then the slow opening is bypassed and the control is
through the PID

Antifreeze lf the chilled water outlet temperature drops below the antifreeze
; protection: set point, the machine trips and the `TOTAL SHUTDOWN. alarm
sequence is carried out. The alarm will be reset only after the
chillecl water outlet temperature rises above the ar,ti freeze set
point plus the hysterisis set point.
Chilled water pump If cliilled water flow is very low ctr is absent freezing can take place
interlock : immediately. Chilled water flow is essential for machine operation.

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OFF / TRIP status. The machine after giving the start permissive
walls for 10 seconds for the feedback. In case the feedback cloes

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 Coiiti.ols and

waits for 10 seconds for the feedback. In case the feedback does
not arrive then the machine immediately goes to 'TOTAL SHUT
DOWN' alarm sequence. If the chilled water pump stops/trips
during operation also , the `TOTAL SHUTDOWN' alarm sequence
is carried out.

Chilled water flow If the chilled water flow drops below 500/o Of the rated value, the
`TOTAL SHUTDOWN' alarrri sequence is carried out.
transmitter :

Chilled water DP If the chilled water flow drops below 50°/o of the rated value, the
`TOTAL SHUTDOWN' alarm sequence is carried out.
transmitter :

DURING ANY OF THE ABOVE SAFETIES COOLING WATER

FLOW TO M/C MUST STOP IMMEDATELY OTHERWISE
FREEZING MAY OCCUR INSPITE OF M/C TRIPPING.DURING
THESE SAFETIES STEAM CONTROL VALVE CLOSES FULLY(0
AMPS).

`' i:..
Chilled water flow ooling water flow should be stopped immediately when the chilled
ater flow stops/ goes below tha set point of DP transmitter/Flow
low/No flow
transmitter. So th€ cooling water pump should be started through
interlock with
the start permissive of cooling water pump only. If the cooling
cooling water flow water pumps are not dedicated to the chiller then the pneumatically
controlled auto shut off valve should be used for stopping/starting
the cooling water flow to the machine through the permissive .
contacts only.
Cooling water low If the cooling water inlet temperature drops below the cooling
water low temperature set point, the `DILUTION CYCLE' alarm
temperature safety
sequence is carried out and tlie machine goes into dilution cycle
immediately. The alarm can be reset only when the cooling water
inlet temperature rises above the cooling water low temperature
set point plus hysterisis set value. During initial slartup till
generator temperature reaches to 70°C this safety is bypassed.
However 30min after startup this safety will be in operation
irrespective of generator temperature.

If the concentrated absorbent solution returning to the a.bsorber

from the generator is excessively cooled, it crystallizes in the heat
exchanger and the operation of the machine can be affected.
Crystallization occurs either when the concentration of the

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prevent the machine from crystamzing.

Steam control valve

modulation on :;:t:I?,:aaT,o8nol:tLogercaot:::::rra:Loant:soncc:::!::,:dn~::aTseo:aL,:u,aTt::
by the PLC. The PLC always tries to keep the Pre set safe
crystallization
distance between the crystallization temperature and stron8~`
prevention safety solution temperature of low temperature heat exchanger outlet. If
the distance is less than the pre set safe distance then the PLC
modulates the steam control valve so that the strong solution
temperature will never reach crystallization temperature. If the
distance is less than safe distance steam control valve operates
only on crystallization control signal and capacity control signal is
overruled.

J722 IFFCO
 Controls and Safeties

Absorber level lf the absorber level goes below first safety limit (25% of sight
safety glass) AE2 then the auto blow down solenoid valve will open to
transfer refrigerant to absorber to build the absorber level again. If
the absorber level goes further below (0% of sight glass) AE3, the
steam control valve closes fully. When the level in absorber rises
back to 50% of sight glass AE1, auto blow down valve will shut,
SCV valve will open and mac'hine will come back in to operation
automatically. AE4 is reference electrode.

NOTE wriEN THE REFRIGERANT puMp is iN `OFFi CONDITION,

THERE WILL NOT BE ANY SUPPLY TO THE AUTO BLOW
DOWN SOLENOID VALVE AND THE ABOVE SAFETY IS NOT
APPLICABLE.
Valve control on When the generator temperature exceeds the trip set point minus
Generator differential, the steam control valves close immediately (Both the

a
• . i-- . `
temperature valves close simultaneously). This prevents further increase in LiBr
concentration. The valve control is returned to the chilled water
temperature control loop .when the generator temperature drops
below the set point minus the hysterisis set value.

Generator high If the GENEF`ATOR temperature exceeds the GENERATOR high

temperature safety temperature set point, the `DILUTION CYCLE' alarm sequence is
carried out and the machine goes into dilution cycle immediately.
GENERATOR high temperature alarm can be reset only \^/hen the
GENERATOR temperature drops below the set point minus the
hysterisis set value

The set points mentioned in above descriptions are nominal set

points and may vary to some extent if machine parameters are
different from literature parameters.

Cavitation If the refrigerant level in the evaporator pan falls excessively, the
protection of pressure in the refrigerant pump suction drops below the
saturation pressure of the refrigerant and the refrigerant pump
rfuerant pump. starts to cavitate. To ensure minimum acceptable suction pressure
the level of refrigerant is not allowed to fall below a certain level.
This is done by means of three level electrodes, RE1, F`E2, RE3,
and a level relay, 33RL.
The three electrodes are mounted in the refrigerant level
box assembly on the lower shell (Evaporator side). REl electrode
js the smallest in length and RE3 is the longest. The level is
maintained between REl and RE2. RE3 acts as a reference
electrode. When the level reaches RE1, the pump starts arid when
the level goes below RE2, the pump stops and restarts only when
the level reaches REl again. When the level goes below RE2, a
delay of 10 seconds is provided before the pump !s switched off.
Motor rotection
safeties

Absorbent pump lf the absorbent pump niotor draws more than its rated current,
overload relay this overload relay trips and the 'TOTAL SHUTDOWN' alarm
sequence is carried out. The alarm is reset by resetting the
overload relay.

Refrigerant pump If the refrigerant pump motor draws more than its rated current,
•{his overload relay trips ,ind the `DILUTION CYCLE' alarm
overload relay

`J722 1FI..(.O
 Controls aiid Safeties

sequence is carried out. Resetting the overload relay resets the

alarm.

Purge pump If the purge pump motor draws more than its rated current, this
overload relay overload relay trips. Resetting the overload relay resets the alarm.

Simultaneous mode During simultaneous coolingTheating mode, PID loop functions on

operation cooling water outlet instead of chilled water outlet temp, all other
control logic remaining same as cooling mode. In case there is no
sensor provided in cooling water outlet, chilled water outlet sensor
shall be removed from its place and put in cooling water outlet line
before switching over to simultaneous mode.

After running the in/c in simultaneous mode, when the changeover

{o cooling mode is required the sensor shall be again physically put
in chilled water outlet position.

Alarm Log Currently activated alarm(s) will be displayed, in the "alarm log"
Window with date and time. The alarm log shall not include the
power failure alarms.
Alarm se uences : There are three alarm sequences which activate when the fault
conditions occur
. Dilution cycle alarm sequence.
. Total shutdown alarm sequence.
.Power failure alarm sequence.
Dilution cycle alarm This alarm sequence protects the machine from crystallisation.
sequence.
Fault conditions which activate this alarm sequence are -

. Generator Temperature high.

. All temperature sensor errors except chilled water outlet
temperature sensor.
. Cooling water inlet temperature low.
The alarm action is as follows

a . Refrigerant pump trip/ not respon.ding.

•
•
Steam control valve closes immediately.
Refrigerant pump and cooling wa.ter±±jp]p. stops after 4
minutes.
• Absorbent pump keeps running for 20 minutes after which it
stops.
• The cooling water pump stops or shut-off valve closes after 4
minutes.

lf tr,e operator.does not acknowledge the fault within 20 minutes,

the machine stops completely.

Note: lf the refrigerant pump trips/not responds during dilution

cycle then after reset, it will run for the balance time of the 4
minutes after I.eset.

Total Shutdown Tliis alarm sequence protects the machine from freezing ot the
Alarm Sequence evaporator or any other damage.

Fault conditions which activate this ?larm sequence are -

.'7=2 II.`FCO
 Controls and Safeties

Chilled water flow transmitter trip.

Chilled water D.P. transmitter trip.
Chilled water pump interlock trip.
Chilled water outlet temperature sensor fault.
Antifreeze trip.
Absorbent pump over current trip / AC Drive trip.
Absorbent pump contactor / AC Drive not responding.
The alarm action is as follows

• Steam control valve closes immediately.

• Cooling water pump/shut off valve closes immediately.
• Refrigerant pump and absorbent pump stops.

After the fault(s) is reset the machine goes into dilution cycle. If the
'0 machine is not restarted during the dilution cycle, the machine
stol)s completely after the dilution cycle is over.

-es,/ Power failure Alarm Suppose machine power fails during normal running/dilution cycle
of the machine, then upon power resumption the machine shall go
and resumption
to dilution cycle automatically. An alarm sound will occur till it gets
sequence reset by the operator.

During vacuum pump trip, Chilled inlet temp sensor error only
alarm will sound and the machine keeps running.

Control of De-super To cater to the cooling load, two nos. of Steam driven Vapour
heating station Absorption Machines (1000 TR) will be required. The chilled water
will be available from the Absorption Machines at 9 °C and will be
Cooling water Valve
circulated through cooling coils, over which inlet air to the gas
turbines will flow. In this process, air (122.6 kg/s) will be cooled
from 40 °C, 45% F`H to 15 °C, 100% RH before entering the
turbine. Differential Pressure transmitter will be provided across

a the prefilter (05-DPT-02), mist eliminator (05-DPT-03), louvers (05-

DPT-04), fine filters (05-DPT05) and also at the inlet and outlet of
the air duct while entering and leaving the filter house (05-DPT-06)

I-:LJ and across the cooling coil (05-DPT01 ). On the other hand, chilled
water will get heated to 19 °C and will be returned to the
Absorption Machines. Three chilled water pumps (two operating
and 1 standby) each of 300 m3/hr, 30 in h.ead will be provided.
Pressure transmitters (01-PT-01,02,03) are provided for individual
pumps to measure the pressure at the pump discharge side. The
standby pumps of the process systems of Vapour Absorption
Machine will be started on auto start mode as per the requirement
ancl also when any of the pump fails the other standby pump will
start autcjmatically.

As the ambient conditions change fi-om time to lime, the cooling

loacl wlll be variable. Therefore, the system will have three way
control valves (05-TCV-01,02) across the cooling coil circuit and
also Temperature elemen.is (05-TE-01,02) will be provided at the
inlet and outlet of the air cluct. The temperature element (05-TE-
02) will sense the temperature of air entering t'ne gas turbine. It will
send signals to the Temperature Controller which will modulate the
three way .control valve (05-TCV-01,02). Whenever the

J722 [l..FC`O
 Controls and Safeties

temperature of air, after passing over the cooling coil, drops below
the design temperature of 15 °C, the three way control valve (05-
TCV-01,02) will operate such that chilled water (at 9 °C) to the
cooling coil will be partly bypassed until the air temperature returns
to 15 OC.

Consequently, the temperature of chilled water returning from the

cooling coil to the Absorption Machines will be lower than 19 °C. |n
turn, the heat energy required by the Absorption Machines to chill
the water to 9 °C will be lesser. To facilitate this, the PLC which
records the temperature of chilled water leaving the Absorption
Machines will send signal to a steam flow control valve. Whenever
the temperature of chilled water leaving the Absorption Machines
drops below the design temperature of 9 °C, the steam flow control
valve will throttle until the chilled water temperature is restored.
Also, when the temperature of chilled water leaving the Absorption
Machines rises above the design temperature of 9 °C, the steam
flow control valve will open until the chilled water temperature is.
restored to 9 °C. A flow element will be provided for individual
Vapour Absorption Machine to sense the chilled water flow and the
signal will be transmitted to the PLC through a flow transmitter and
displayed on the Panel screen.

A Flow transmitter with orifice will be provided before the

Desuperheating Station to measure the steam flow required at
various condition. The pressure transmitter (03-PT-01,02) and
Temperature elements (03-TE-01,02) will be provided before and
after the Desuperheating Station to measure the pressure alld
temperature of the steam at the inlet and outlet of the
Desuperheating Station. All these data shall be transmitted to the
PLC and displayed on the Panel screen.

Steam will condense in the Absorption Machines and will be

collected in a condensate tank. Two pumps (1 operating and 1
standby) each of 25 m3/hr, 48 in head will transfer the steam
condensate to the deaerator. The condensate tank will be provided
with Level switches (04-LS-01,02,03) to measure the condensate
level in the tank. When the steam condensate reaches the higher
level limit (04-LS-02) then the pump will start to pump the
condensate to the deaerator and as soon as the steam
condensate reaches the lower level limit (04-LS-01) the pump will
stop. Additionally, two pumps (1 operating and 1 standby) each of
2.2 m3/hr, 50m head will transfer part of the steam condensate to
the Desuperheating Station. The quantity of steam condensate to
be sprayed in the Desuperheating Station will be controlled with
the temperature element (03-TE-03) provided at the outlet of the
Desuperheating Station in the main steam header (Saturated). The
temperature element (03~TE-03) will sense the steam temperature
at the outlet of the Desuperheating Station and send signal to the
Temperature Controller which will regulate the water flow control
valve (03-WCV-01). If the degree of superheat is more in the
incoming steam to the Desuperheating Station this will reflect in
the temperatLire of steam downstream to the Desuperheating
Station. The signal sent by the temperature element (03-TE-03)

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Absorption Machine.

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7
Controls and Safeties

An auto shut off valve shall be provided in the cooling water supply
line to each machine. This will ensure that the cooling water supply
will be switched off jf the chilled water pumps stop.

Chilled Water Pump ln the chilled water circuit, the individual pump capacity selection is
Change-over based on the chilled water flow required for individual Vapor
Absorption Machine. There will be three chilled pump out of which
two will be working and one will be standby. When both the Vapor
Absorption Machine is working any two pumps will start operating.
While the system is operating and the pressure limits of any pump
goes below or above the set points limit which is set for individual
pump then the functioning pump will stop and the standby will start
to operate. Once the pump starts to deliver full capacity then the
System will be said to start working at full load condition.

Similarly, when any one of the Vapor Absorption Machine stops

working, then any one pump of the two should stop operating.

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