NL02!17!0464 Control Philosophy

VUNGTAU VIETNAM BREWERY – COOLING PLANT
Control philosophy
Vung Tau Vietnam Brewery – Control Philosophy
REVISION HISTORY
Revision Date Description Author
0.0 16-04-2018 First Issue [DRAFT] ETK
0.1 08-06-2018 First revision ETK
Page i
CONTENTS
Revision History .............................................................................................................................................................................. i
Contents ........................................................................................................................................................................................ ii
1 Introduction .......................................................................................................................................................................... 1
Project Participants ................................................................................................................................................................2
Used References ....................................................................................................................................................................3
Development Software ..........................................................................................................................................................4
Main Components..................................................................................................................................................................5
1.4.1 Compressors ....................................................................................................................................................................5
1.4.2 Condensers ......................................................................................................................................................................5
1.4.3 Pumps ..............................................................................................................................................................................5
Simple Process Diagram .........................................................................................................................................................6
Network Layout......................................................................................................................................................................7
2 GENERAL FEATURES AND OPERATING STRATEGY .................................................................................................................................. 8

Introduction ...........................................................................................................................................................................8
Passwords ..............................................................................................................................................................................8
2.2.1 Levels ...............................................................................................................................................................................8
2.2.2 Access ..............................................................................................................................................................................8
2.2.3 Login ................................................................................................................................................................................8
Safety precautions .................................................................................................................................................................9
2.3.1 Ammonia Detection ........................................................................................................................................................9
2.3.2 Emergency Stop Buttons .................................................................................................................................................9
2.3.2.1 Alarms and Status ..................................................................................................................................................9
2.3.2.2 Position ..................................................................................................................................................................9
2.3.2.3 Reset ......................................................................................................................................................................9
2.3.3 Engine Room Ventilation Fans .........................................................................................................................................9
2.3.3.1 Mode ventilation fans ..........................................................................................................................................10
2.3.4 Ammonia Scrubber ........................................................................................................................................................10
2.3.5 Gutter pump ..................................................................................................................................................................10
2.3.5.1 Low level ..............................................................................................................................................................10
2.3.5.2 High level .............................................................................................................................................................10
2.3.5.3 High-high level .....................................................................................................................................................10
2.3.6 High pressure Switches .................................................................................................................................................10
2.3.7 Local Compressor Stops ................................................................................................................................................10
2.3.8 Isolating Switches ..........................................................................................................................................................11
2.3.9 Unisab III Compressor Control Units .............................................................................................................................11
2.3.10 PLC Control System .......................................................................................................................................................11
2.3.11 Block-In Valves ..............................................................................................................................................................11
2.3.12 Safety valves on Vessels and Compressors ...................................................................................................................11
Visualization Structure and Operating Strategy ...................................................................................................................12
2.4.1 Screens ..........................................................................................................................................................................12
2.4.2 Visual elements .............................................................................................................................................................12
2.4.3 Auto and Manual Mode ................................................................................................................................................12
2.4.4 Alarms ...........................................................................................................................................................................12
2.4.5 Events ............................................................................................................................................................................13
2.4.6 Settings Screens ............................................................................................................................................................13
3 DETAILED DESCRIPTION AND INSTRUCTIONS ..................................................................................................................................... 13

MAIN SCREEN ..........................................................................................................................................................................13
3.1.1 Condensers ....................................................................................................................................................................13
3.1.1.1 Overview ..............................................................................................................................................................13
3.1.1.1.1 Sequence.........................................................................................................................................................14
3.1.1.1.2 PI Control ........................................................................................................................................................15
Page ii
3.1.1.1.3 Wet Bulb Temperature ...................................................................................................................................16

3.1.1.2 INDIVIDUAL VIEW .....................................................................................................................................................17
3.1.1.3 SETTINGS ................................................................................................................................................................17
3.1.1.4 SAFETY FUNCTIONS ...................................................................................................................................................17
3.1.2 AIRPURGER .......................................................................................................................................................................18
3.1.3 Water Treatment System ..............................................................................................................................................19
3.1.3.1 Bleed-off ..............................................................................................................................................................19
3.1.3.2 Corrosion anti-scaling ..........................................................................................................................................19
3.1.3.3 Biocide .................................................................................................................................................................19
3.1.4 Liquid Receiver ..............................................................................................................................................................20
3.1.4.1 Oil detection ........................................................................................................................................................20
4 Ammonia cooling systems ................................................................................................................................................... 21

Ammonia Freezing System ...................................................................................................................................................21
4.1.1 Economizer ....................................................................................................................................................................21
4.1.1.1 Level.....................................................................................................................................................................21
4.1.1.2 Pressure ...............................................................................................................................................................21
4.1.2 Separator .......................................................................................................................................................................21
4.1.2.1 Level.....................................................................................................................................................................21
4.1.2.2 Pressure ...............................................................................................................................................................22
4.1.3 Compressors ..................................................................................................................................................................22
4.1.3.1 Automatic operation............................................................................................................................................22
4.1.3.2 Manual Operation ...............................................................................................................................................23
4.1.3.3 MV motor start ....................................................................................................................................................23
4.1.3.3.1 Start-start timer ..............................................................................................................................................23
4.1.3.3.2 Stop-start timer...............................................................................................................................................23
4.1.3.4 Oil Cooling System ...............................................................................................................................................23
4.1.3.5 Winding protection ..............................................................................................................................................23
4.1.3.6 Bearing protection ...............................................................................................................................................24
4.1.4 Coolant Freezing System ...............................................................................................................................................25
4.1.4.1 Overview ..............................................................................................................................................................25
4.1.4.2 Compressor capacity table ..................................................................................................................................25
4.1.4.3 Cold level .............................................................................................................................................................26
4.1.4.4 Sequence .............................................................................................................................................................27
4.1.4.5 Flow control .........................................................................................................................................................28
4.1.4.5.1 Cascade flow control.......................................................................................................................................29
4.1.4.5.2 Primary coolant flow control ..........................................................................................................................30
4.1.4.5.3 Coolant valves .................................................................................................................................................30
4.1.4.5.4 Primary coolant pumps ...................................................................................................................................31
4.1.4.5.5 Distribution coolant pumps ............................................................................................................................32
4.1.4.6 Coolant quality control ........................................................................................................................................33
Ammonia Chilling System.....................................................................................................................................................34
4.2.1 Economizer ....................................................................................................................................................................34
4.2.1.1 Level.....................................................................................................................................................................34
4.2.1.2 Pressure ...............................................................................................................................................................34
4.2.2 Separator .......................................................................................................................................................................34
4.2.2.1 Level.....................................................................................................................................................................34
4.2.2.2 Pressure ...............................................................................................................................................................35
4.2.3 Compressors ..................................................................................................................................................................36
4.2.3.1 Automatic operation............................................................................................................................................36
4.2.3.2 Manual Operation ...............................................................................................................................................37
4.2.3.3 MV motor start ....................................................................................................................................................37
4.2.3.3.1 Start-start timer ..............................................................................................................................................37
4.2.3.3.2 Stop-start timer...............................................................................................................................................37
4.2.3.4 Oil Cooling System ...............................................................................................................................................37
Page iii
4.2.3.5 Winding protection ..............................................................................................................................................37

4.2.3.6 Bearing protection ...............................................................................................................................................37
4.2.4 Coolant Chilling System .................................................................................................................................................39
4.2.4.1 Overview ..............................................................................................................................................................39
4.2.4.2 Compressor capacity table ..................................................................................................................................39
4.2.4.3 Cold level .............................................................................................................................................................40
4.2.4.4 Sequence .............................................................................................................................................................41
4.2.4.5 Flow control .........................................................................................................................................................42
4.2.4.5.1 Cascade flow control.......................................................................................................................................43
4.2.4.5.2 Primary coolant flow controller ......................................................................................................................44
4.2.4.5.3 Distribution coolant pumps ............................................................................................................................46
4.2.4.6 Coolant quality control ........................................................................................................................................47
Make-up and Expansion Tank ..............................................................................................................................................48
4.3.1 Settings ..........................................................................................................................................................................48
4.3.2 Safety Functions ............................................................................................................................................................48
4.3.3 Drum Pump ...................................................................................................................................................................49
4.3.4 Filling Procedure ............................................................................................................................................................49
4.3.4.1 General ................................................................................................................................................................49
4.3.4.2 Mixing make up tank ...........................................................................................................................................49
4.3.4.3 Filling main system ..............................................................................................................................................49
5 Brewmax SC4U ................................................................................................................................................................... 50
Page iv
1 INTRODUCTION
This document will describe the control philosophy for the first phase of the new Greenfield cooling plant in Vung Tau, Vietnam.
Page 1
PROJECT PARTICIPANTS
Customer: Heineken Vietnam Brewery Limited Company

Visit Address: Vung Tau
Vietnam
Postal Address: ...
...
Vietnam
Phone: ...
Fax: ...
Customer Reference: ...
Principal: Johnson Controls

Visit Address: Pieter Zeemanweg 16
3316 GZ Dordrecht
The Netherlands
Postal Address: Postbus 399
3300 AJ Dordrecht
The Netherlands
Phone: +31 786305010
Fax: +31 786186980
E-Mail: Infonl.cg-eur@jci.com
Project Manager: Bastiaan Brouwer

Phone: +31 786305026
Mobile: +31 620968454
E-Mail: Bastiaan.brouwer@jci.com
Principal Reference: NL02/17:0464
Page 2
USED REFERENCES
Drawing
Issue Description Source
Number
2042001-01 B Engineering diagram ammonia evaporator coolant freezing system JCI
2042002-01 B Engineering diagram ammonia evaporator coolant chilling system JCI
2042003-01 B Engineering diagram ammonia compressor coolant freezing system JCI
2042004-01 B Engineering diagram ammonia compressor coolant chilling system JCI
2042005-01 B Engineering diagram evaporative condensers JCI
2042006-01 B Engineering diagram liquid receiver JCI
2042007-01 B Engineering diagram ammonia coolant freezing system JCI
2042007-02 A Engineering diagram ammonia coolant freezing system JCI
2042008-01 B Engineering diagram ammonia coolant chilling system JCI
2042008-02 A Engineering diagram ammonia coolant chilling system JCI
2042009-01 A Engineering diagram ventilation / safety provision cooling plant JCI
2042010-01 A Engineering diagram softened water supply JCI
2042011-01 A Engineering diagram boiled feed water supply JCI
0.1 NL02-17-0464 Cause and effect Rev.1 JCI
Date Description Location
Page 3
DEVELOPMENT SOFTWARE
The control software is written using the following development software:
Siemens SIMATIC TIA Portal V15
Development software for other systems in use is:
Danfoss MCT10 V3.27
Note that the above mentioned development software is necessary to maintain the software on the cooling
plant. Customer to check with its software department if this software is available on-site and if the version
numbers correspond with the minimum requirements.
Page 4
MAIN COMPONENTS
1.4.1 COMPRESSORS
Process
# Description Type Capacity Remark
Number
1 Compressor Sabroe SAB-233LME C 99.111.01 1477,7 [kW] Coolant Freezing System
2 Compressor Sabroe SAB-233LME C 99.112.01 1477,7 [kW] / Swing Compressor
1955,0 [kW]
3 Compressor Sabroe SAB-233LME C 99.113.01 1477,7 [kW] / Swing Compressor
1955,0 [kW]
4 Compressor Sabroe SAB-233LME C 99.114.01 1955,0 [kW] Coolant Chilling System
5 Compressor Sabroe SAB-233LME C 99.115.01 1955,0 [kW] Coolant Chilling System
1.4.2 CONDENSERS
Process Spray
# Description Type Fan Remark
Number Pump
1 Condenser Baltimore CXV-D876L A 95.111.01 2x DOL 1x FRQ
1.4.3 PUMPS
Process Electric
# Description Type Remark
Number Power
1 Pump P 95.111.01 5,5 [kW] Evaporative condensers
9 Pump P 95.120.01 ?,? [kW] Biocide
10 Pump P 95.120.02 ?,? [kW] Corrosion / Scaling
11 Pump KSB ETN 200-150-250 GG P 96.111.01 37 [kW] Coolant Freezing Primary
14 Pump KSB ETN 200-150-250 GG P 96.121.01 37 [kW] Coolant Chilling Primary
17 Pump KSB ETN 050-032-1601 GG P 96.151.01 4,0 [kW] Make-up
18 Pump LUTZ P 96.151.02 ?,? [kW] Drum
19 Pump KSB ETN 200-150-315 GG P121.111.01 75 [kW] Coolant Freezing Distribution
22 Pump KSB ETN 200-150-315 GG P121.121.01 75 [kW] Coolant Chilling Distribution
25 Pump KSB AMA Drainer 415 P307.100.01 1,6 [kW] Gutter pump
Page 5
A.99.29.01 A.99.27.01 A.99.26.01 A.99.25.01 A.99.28.01 A.95.10.01 A.95.11.01
EVC1 EVC2 EVC3 EVC4 EVC5 EVC6 EVC7
C.99.20.01 C.99.22.01 C.99.24.01 C.99.21.01 C.99.21.02 C.99.23.01 C.99.23.02 C.99.11.01 C.99.10.01 C.99.12.01
A.95.20.01
LIQ CMP1 CMP2 CMP3 CMP4 CMP5 CMP6 CMP7 CMP8 CMP9 CMP10
Figure 1: Simple process diagram

SIMPLE PROCESS DIAGRAM
A.97.12.01
ECO1
A.97.11.01 A.97.10.01
SEP1 SEP2
A.96.10.01 .02 .03 A.98.10.01 .02 .03

PHE1 PHE2 PHE3 CWC1 CWC2 CWC3
P.96.10.01
TT TT TT
.02 PROCESS WATER
RETURN
FT TT PT TT FT
.03 A.114.01.01 TT TT TT
TT TT TT
FT FT FT
TT
A.96.11.01 Expansion A.121.10.01

Tank
CWT
P.114.01.01
Make-Up
A.96.11.02 Tank
STT
.02 PT
CELLAR DAW PLANT
P.96.11.01 P.121.10.01 TT
FT
FT
.02 BREWHOUSE 1
WORT COOLER
TT PT
BREWHOUSE 2 BREWHOUSE 1
P.121.11.??
.03
.??
PACKAGING WORT COOLER
BREWHOUSE 2
TT
Page 6
NETWORK LAYOUT
Figure 2: Network layout
Page 7
2 GENERAL FEATURES AND OPERATING STRATEGY
INTRODUCTION
First the general features and operating strategy are explained. Hereafter is a detailed instruction on how to operate the plant. For
this instruction the print-outs of the actual screens are used to give you the most realistic information possible. Please note that the
numeric values in the screens displayed in this chapter do not represent the actual situation. However there was no solution for
getting a 100% identical picture. Also keep in mind that some of the texts are pop-up texts and are therefore only visible when
activated on the real Human Machine Interface (hereafter called “HMI”)..
PASSWORDS
In this paragraph a description of password levels valid for all screens in general is given. For operating the HMI there are four access
levels installed, protected by different passwords:
2.2.1 LEVELS
Level Persons Login Password Log-Out Time
0 Guest Everybody n/a n/a n/a
3 Operator Operators OPER 1234 5 [min]
5 Supervisor Shift Engineer / Supervisor / Utility Manager SUPER 2345 5 [min]
6 Engineer Automation Engineer ENG 1357 5 [min]
9 Expert JCI EXPERT **** 60 [min]
2.2.2 ACCESS
Supervisor
Operator
Engineer
Expert
Guest
Action
Navigation between screens
Acknowledge alarms and warnings
Change product specific set points
Change equipment mode from auto to manual and vice versa
Change equipment sequence
Change calculated / fixed set point condensers
Adjust control parameters (except warning and alarm levels)
Adjust warning and alarm settings
Empty warning and alarm buffer
Full authority
2.2.3 LOGIN
Basically there are two possibilities to work with the passwords:
- Go to the login screen and enter the password. This login ensures access to all settings corresponding to the level of the
password entered, and all lower levels.
- Go directly to a screen to operate a certain function or modify a certain parameter. If the function you want to operate is
restricted, the system will ask for the password. Once the correct password is entered, access is granted to all functions and
parameters corresponding to the level of password entered. When trying to change a setting protected by a higher level the
system will ask again for a password. Only entering of the password corresponding to that level will give access.
Page 8
SAFETY PRECAUTIONS
This part describes all safety related items for the cooling plant. All actions related to the safety and control items are described in
more detail in the Cause & Effect diagram.
2.3.1 AMMONIA DETECTION

The ammonia detection is not a part of the cooling plant. The safety panel E23-03 from the cooling plant has 3 hard-wired contacts
to the NH3 detection installation delivered by 3rd party. The purpose off the signals connected to the safety panel are:
• NH3 alarm 50ppm

• NH3 alarm 200ppm
• NH3 alarm 800ppm
All actions related to these contacts are described in more detail in the Cause & Effect diagram
2.3.2 EMERGENCY STOP BUTTONS

The cooling plant contains 14 emergency stop pushbuttons.
2.3.2.1 ALARMS AND STATUS

Emergency stop buttons are equipped with two NC contacts for the emergency loop circuit and one NO contact for status and alarm
to the HMI. If the status of an emergency stop button on the HMI is shown as gray this means “normal operation”, red means that
the emergency stop button activated (pressed). An alarm with TAG number is shown on the HMI.
2.3.2.2 POSITION
In total fourteen (14) (ZS 307.100.01 – ZS 307.100.14) emergency stop pushbuttons are placed in the field. Eight (8) (ZS 307.100.02-
09) at the entrance doors of the engine room (in and outside), two (2) (ZS 307.100.10/11) are placed on the roof near the condensers
and three (3) (ZS 307.100.12-14) are placed in the utility cooling room. One (1) ZS 307.100.01 is placed in the LV Room.
The emergency stop relay will switch off the total cooling plant. All field equipment will be made powerless. The power supply
towards the panels will be switched off.
2.3.2.3 RESET
After an emergency stop the installation can be reset operating as follow:
- Pull out the key button of the emergency stop.

- Activate the reset buttons on panel E 23-03 (Safety panel) this will reset the emergency stop relay.
- Reset the alarms with the reset button on panel E23-03 or the button on the HMI in the engine room
After this is done the cooling plant can be started up manually.
At an ammonia alarm 800ppm or emergency stop activation the complete system will shut down. All motors
of compressors, pumps, etc. will stop. Also the HMI will be made powerless.
In case of ammonia detection the ammonia scrubber will be active; in case of emergency stop the ammonia
scrubber will not be active.
2.3.3 ENGINE ROOM VENTILATION FANS

The engine room is equipped with 6 ventilation fans (M307.100.01 until M307.100.06) for temperature control purpose. The engine
room has 6 louvres for supply air from outside to the engine room. This will prevent an under pressure inside the engine room when
ventilation fans are running. The ventilation fans are temperature controlled by the average temperature of 2 temperature elements
(TE 307.100.01 and TE 307.100.02) in the engine room. The temperature control is based on a setpoint with an offset (adjustable on
HMI). If there is a release to start the ventilation fans first the louvres should be opened. The PLC activates hard-wired contacts for
the release of the louvre motors. When the louvres are opened they should give a feedback that they are open. Then the PLC starts
as many ventilation fans as feedback is received from the louvres.
Page 9
Example:
Receiving feedback for 4 louvres = 4 ventilation fans released for running.
For each louvre that not opened a warning is displayed on the HMI.
2.3.3.1 MODE VENTILATION FANS

In “Auto mode” the PLC starts or stops the ventilation fans if engine room temperature is above set point. The fans will stop when
the temperature is below set point minus difference.
- In case of ammonia alarm > 200ppm stop fan immediately.
- The fan will start again if the ammonia value is under 200ppm and the alarm is reset.
In “Manual mode” the PLC starts the exhaust fan that is in manual mode.
- In case of ammonia alarm > 200ppm stop fan immediately.
- The fan will start again if the ammonia value is under 200ppm and the alarm is reset.
In “Off mode” the exhaust fan stops or stays off.
2.3.4 AMMONIA SCRUBBER

On the roof near the evaporative condensers is an ammonia scrubber A307.0100.001 installed. In case of an ammonia alarm >200ppm
the scrubber will start. If the ammonia level comes is < 50ppm the scrubber will stop automatically. During the operation of the
scrubber fan M307.100.01 the water valve V307.100.01 is activated. Inside the scrubber air duct is a flow switch FS307.100.01
installed. If the scrubber fan is running and there is not enough airflow through the air duct a warning is displayed on the HMI in the
engine room.
It must be possible to activate the scrubber with a button on the HMI for service purpose only.
2.3.5 GUTTER PUMP

In the engine room is a pump pit for collecting water and ammonia after leakage of the cooling system. The pit contains a submerged
pump (P 307.100.01) and the outlet goes to the water drain. The pit also contains a drain to remove ammonia from the pit in case of
a huge ammonia leakage. The submerged pump is only manually operated.
2.3.5.1 LOW LEVEL

In case of a low level detect by LS 307.110.01 the pump will stop if started.
2.3.5.2 HIGH LEVEL

In case of a high level detect by LS 307.110.02 a warning is displayed and the operator needs to decide of the high level inside the pit
is coming from water or from ammonia. If the pit contains only water the operator needs to start the pump with the start button
near the pump pit. If the pump pit contains ammonia the drain for the ammonia should be used to remove the ammonia from the
pit. The ammonia needs to be stored in a safe places for people and environment.
2.3.5.3 HIGH-HIGH LEVEL

In case of a high-high level detect by LS 307.110.03 an alarm is displayed and the operator needs to decide of the high-high level
inside the pit is coming from water or from ammonia. If the pit contains only water the operator needs to start the pump with the
start button near the pump pit. If the pump pit contains ammonia the drain for the ammonia should be used to remove the ammonia
from the pit. The ammonia needs to be stored in a safe places for people and environment.
2.3.6 HIGH PRESSURE SWITCHES

All compressor units are provided with a high pressure switch (PS 99.***.01). In case of high pressure on this unit, it will switch off
the control current of the motor starter and lock. This is a hard-wired contact! Reset must be done locally on the pressure switch first
and afterwards on the particular Unisab III controller before you can reset the alarm on the HMI.
2.3.7 LOCAL COMPRESSOR STOPS

All compressor units are provided with a local push button on the Unisab (black color). In case the push button is activated, it will
switch off the control current of the motor starter and lock.
Reset must be done locally by pulling out the push button first and then reset on the particular Unisab III controller.
Page 10
2.3.8 ISOLATING SWITCHES

All pumps, fans and compressors are provided with an isolating (service-) switch. In case of maintenance on this part of the installation
the switch must be switched off and locked (LOTO). Each isolating switch contains a contact connected to the PLC for status and
alarm. If the isolating switch is in safe (Off) position a warning is displayed on the HMI.
2.3.9 UNISAB III COMPRESSOR CONTROL UNITS

Each compressor unit is equipped with a microprocessor controlled Unisab III compressor control unit. The control and
safeguarding of the compressor unit is incorporated in those units, except the general capacity control of the total installation
which will be regulated in PLC of the safety panel E23-03.
2.3.10 PLC CONTROL SYSTEM

To control the cooling plant a PLC Siemens S7-1500 is installed. The control and safeguarding of the cooling plant is incorporated in
this system. In case of low suction pressure PT 97.011.01 or PT 97.021.01 or high discharge pressure PT 95.120.09 it will switch off
the compressors.
2.3.11 BLOCK-IN VALVES

Block-in valves are dividing the system in several compartments. The block-in valves are closing in case all the compressors and
condensers are stopped (time delayed), at emergency stop or in case of ammonia alarm >800ppm (Direct). The following blocking
valves are installed:
Liquid receiver:
- V 95.100.02, V 95.100.03, V 95.100.04, and V 95.100.05.
Economizer coolant freezing:

- LV 97.112.01, PV 97.112.02, V 97.112.03 and V 97.112.04.
Economizer coolant chilling:

- LV 97.122.01, PV 97.122.02, V 97.122.03 and V 97.122.04.
Ammonia separator coolant freezing:

- LV 97.111.01.
Ammonia separator coolant chilling:

- LV 97.121.01.
Each block-in valve has an open and close position feedback switch for alarm purpose. If the applicable solenoid is activated or de-
activated and the position feedback is not valid within monitoring time an alarm is displayed on the HMI.
2.3.12 SAFETY VALVES ON VESSELS AND COMPRESSORS

To prevent that pressure in vessels and compressors will rise above the design pressure, safety valves with change-over valves are
installed.
Page 11
VISUALIZATION STRUCTURE AND OPERATING STRATEGY

After start-up the HMI will show the main screen of the visualization. The main screen gives an overview of the actual operating state
and conditions of the cooling plant. Linked to the main screen are the detailed screens of the individual components. By means of
these screens it is possible to view information in detail and to operate the installation. By pressing the corresponding button in the
main screen one will access that detailed screen from the main screen.
2.4.1 SCREENS
Furthermore there are several screens for:
- Compressors
- Condensers
- Coolant freezing system
- Coolant chilling system
- Make-up
- Trending
- Energy
- Events
- Alarms
- Ventilation
- System settings
- Control overview
2.4.2 VISUAL ELEMENTS

The equipment shown on the HMI must have status information in color or symbol.
Example:
Valve activated is color GREEN. Valve deactivated is color GREY
If a part of the cooling plant is in alarm or warning the applicable button to navigate to that part must have a border in the color RED
or ORANGE. If there is an item in manual mode the border will be the color BLUE. See example with alarm and warning below.
2.4.3 AUTO AND MANUAL MODE

The automatic / manual mode of the pumps and valves are displayed with a hand.
2.4.4 ALARMS
When there is an alarm, an alarm message will be shown in the second line of the screen, no matter which screen you are in. There
will also be a blue alarm indicator flashing in the top right corner as long there is an active alarm. In case of multiple active alarms
the most recent alarm message will be shown and the underlying alarms become visible, one by one, when acknowledging the alarm
on the display. When acknowledging an active alarm, the alarm message will disappear however the blue indicator will stay on until
the alarm has been reset.
To acknowledge an alarm press the ACK key on the HMI;

To reset an alarm press the separate RESET button.
Note that alarms can only be reset after the concerning problem has been rectified; so when the alarm is no longer active.
Page 12
In case of an alarm the horn (installed inside the engine room) will sound. This audio alarm will stop by acknowledging the alarm.
With a new alarm the horn will sound again. All alarms are registered in the alarm buffer.
If a system has an alarm or warning a color mark will appear around the applicable button of the system.
2.4.5 EVENTS
For warranty issues and customer checks all the operator actions needs to be traceable. Therefore all the changes of setpoint or
acknowledge of alarms (and alarms from user administration) will be saved as an event in a log file on the HMI. The software for
creating the event log is WinCC Audit. The log file is stored in CSV format.
2.4.6 SETTINGS SCREENS

In this manual there is an overview of all the settings screens. The setting screens contain all parameters that can be adjusted on the
HMI. Most of the settings are restricted to pass word level 6 minimum. Please consult JCI first before altering these settings. In the
instruction manual you will find a listing with “default settings after commissioning” to which can be returned in case of problems.
3 DETAILED DESCRIPTION AND INSTRUCTIONS
MAIN SCREEN
The main screen gives on overall view on the operating state and running conditions of the cooling plant. Note that the main screen
is only a display of information: nothing can be operated directly from this screen.
You can log on with the key and log off with the key with cross and the system will store the person who is logged on in the event
list. (The logged on person’s name appears in the right upper corner).
With the ACK button you can acknowledge the alarms.
Following information can be read from the screen:
- Status of individual fans and pumps on condensers (grey is off, green is on, red is failure, yellow is maintenance).
- Status of all compressors. (Grey is off, green is run, red is failure, yellow is not ready).
- Status of coolant freezing and coolant chilling coolers (yellow is in operation or grey is not used).
- Status of all pumps. (Grey is off, green is run, red is failure).
- Status of the ammonia blocking valves (green is open, grey is closed).
- Level liquid receiver
- Temperature separator ammonia.
- Level separator ammonia.
- Level economizer.
- Suction pressure economizer.
- Discharge pressure condensers.
- Ammonia detection indicators.
- Level coolant stratification tanks.
3.1.1 CONDENSERS
3.1.1.1 OVERVIEW
This screen gives an overview of the status of all condensers, liquid vessel, scaling and operating possibilities.
Following information can be read out on the screens:
- Actual discharge pressure PT 95.120.01.

- Wet bulb temperature MT 95.120.01.
- Ambient temperature TT 95.120.01.
- Water flow FQ 95.120.01
- Status of individual condenser fans (indicator).
- Status of individual condenser pumps (indicator).
- Status of individual heaters (indicator).
- Status and level of the liquid receiver A.95.100.01.
- Status of the air-purger A.95.100.07.
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- Status of the biocide pump (indicator).

- Status of the corrosion/scaling pump (indicator).
- Condenser sequence.
3.1.1.1.1 Sequence
There are four (for phase 1) evaporative condensers. Each condenser is equipped with 2 water spray pumps and 1 variable speed
fan. The sequence of the condensers in regulation can be set manually through the HMI. The condensers are controlled per
condenser, there is a sequence for 4 condensers.
Condenser pump standby:
Component N
See component conditions
conditions OK
Level in N
condenser OK Alarm on HMI
LA 95.xxx.01
Pump standby
Condenser standby: a condenser is standby whenever both spray pumps are standby.
Remarks:
- Only water pumps in operation results in approximately 5% of condenser capacity.
- Fan speed 1.500 rpm at 50Hz. Frequency controlled fans within 30-100% (15-50 Hz).
- Compressor start/stop causes major capacity (discharge pressure) changes within short time. For this reason the calculated
discharge pressure set point will be adjusted in time steps.
The rate of the regulation (by stepping up or down) will change automatically depending on the difference between the actual
discharge pressure and the calculated discharge pressure setpoint. With the stepping up and down time in combination with the
dead zone (i.e. dead band) the rate of regulation is changed.
stepping up
+ time
Then pulse up
discharge setpoint (°C)

discharge
dead zone
Pressure
(°C)
(°C)
PT 95.100.01
+ (if step 3 regulation down and fans running minimal) calculated time
or
Remark: Calculated time
stepping down Then pulse down
Page 14
Dead zone ± 2 °C in steps of 0.1 °C.

The calculated “stepping up / down” time will depend on the difference between the calculated discharge setpoint and the actual
discharge pressure. When the difference is getting bigger the regulation steps will follow quicker limited by a minimal and maximal
stepping time. Step time is adjustable in HMI.
pressure up
min.stepping up time (15 sec.)
pre define value

(°C)
KI04080-T-OPREGEL
max.stepping up time* calculated discharge
discharge setpoint (°C)
dead zone*
pressure
(°C) (°C) KI04080-PIT01-SPDZ
KI04080-PIT01 max.stepping down time*
KI04080-T-AFREGEL
pre define value

(°C)
min.stepping down time (20 sec.)

pressure down
If the condenser pump or fan that has to start by step regulation can’t start when the related condenser isn’t standby then an extra
“pulse regulate up” will be created to go to the next step in the sequence. So the "normal” step time will not be used in this
situation to avoid high discharge pressure.
- If a pump on the condenser is not in a standby state, the condenser will be stopped in automatic mode (i.e. protection against
dry running).
- Both condenser pumps will always run with an adjustable off-delay during a biocide dosage on the related condenser. Biocide
dosage is only possible if the condenser pumps are standby.
- Each component can be switched from automatic to manual through the HMI. If there is an object in manual, the total
automatic regulation will stay in regulation.
- When a particular condenser is not in a standby state, the next condenser will take over in the step regulation based on
discharge pressure.
3.1.1.1.2 PI Control
When regulation is in step (7), the speed of the fans is controlled by a PI controller between minimal and 100%. Maximum speed
can be changed on the HMI.
start when condenser

step 9 is reached
(calculated) discharge Speed control Speed controlled value

Pressure setpoint (°C) auto mode Speed (20 - 100%)
PI controller control
fans
P factor Basic & component

Conditions OK
I factor
Discharge Choice auto or
Pressure (°C) manual speed (%)
manual
PT 95.100.01
Page 15
3.1.1.1.3 Wet Bulb Temperature

Condenser capacity control is based on the pressure in the central discharge line compared to the discharge pressure setpoint. The
discharge pressure is limited between min/max +27 ºC and +36 ºC. The condenser regulation will use a calculated setpoint in the
automatic mode. This calculated setpoint is based on the wet bulb temperature. It is also possible to switch to semi-automatic
mode to run the condenser with a fixed set point. If there is a failure of the temperature or humidity transmitters the setpoint will
be fixed.
Discharge pressure set point (°C) (semi-

automatic)*
Choice auto or semi
auto
Twb Calculated discharge

set point (°C)
((0,8095 x Twb) + 10,87 ) °C Discharge pressure set
point (°C)
Discharge pressure set point is limited

Twb = temperature wet bulb between 27 and 36 (°C)
Remarks:
- Wet bulb temperature (Twb) is been determined by MT 95.120.01.
- Formula changed into the following:
Calculated discharge pressure set point = ((0,8095 x Twb) + 10,87)
(10,87 = constant adjustable value in software).
- As you can see we have not taken the number of (running / total) compressors into account as it
influences the outcome in a negative way.
This applied formula ensures at limited required condensing capacity the condensers will operate
in part load conditions.
This implies in practice it can be better energy wise to condensate a couple of degrees higher
(increase compressor power consumption), but running in part load on the condenser (decrease
condenser power consumption).
If the basic conditions are correct the condenser regulation will start when the first compressor cuts in (cooling on). Condenser
capacity will be regulated up or down in steps.
The following table describes these steps. From every single step the regulation can switch between up or down regulation until the
first step is reached or the final step is reached.
Page 16
sequence
Step 0▼ All pumps and fans stopped
Step 1▲▼ First condenser water pumps on
Step 2▲▼ Second condenser waters pump on
Step 3▲▼ Third condenser water pumps on
Step 4▲▼ Fourth condenser water pumps on
Step 5▲▼ First condenser fan low speed
Step 6▲▼ Second condenser fan low speed
Step 7▲▼ Third condenser fan low speed
Step 8▲▼ Fourth condenser fan low speed
Step 9▲▼ All fans speed regulation
Step 10 ▲ All fans running 100%
3.1.1.2 INDIVIDUAL VIEW

When pressing the individual condenser (A.95.111.01 - A.95.114.01) in the condenser main screen, the condenser screen appears.
One section of a condenser can be set to manual and the other section can be set to auto at the same time.
Operation
Pumps and fans can all be operated in the same way. By pressing the button “Mode A/M” a pop-up screen appears and in this screen
all manual/auto buttons are shown:
- Pressing the manual/automatic button will switch the component from manual to auto or auto to manual (in case of manual
mode a ‘hand’ icon will appear).
- Pressing the manual on/off button will put the component in manual to on or in manual to off, depending on running state at
switch-over (if it was running in auto it will stop, until you press the manual on/off button). The component is completely off
when switch automatic/manual is in manual position and switch manual on/off is in off position.
Note that dry operation of a section is permitted but definitely not recommended. Therefore a fan will start,
even when the corresponding water pump is not running.
Note that in case of power failure all “manual” selections will be stored but automatically set to “off”. The
components must be switched to “on” again manually.
“Automatic” selections will be remembered, but always the systems must be started up again manually. As
result of a power failure all systems will be switched to “off”.
3.1.1.3 SETTINGS
In this condenser settings screen one can change all condenser settings. You must be logged on before you can change anything.
3.1.1.4 SAFETY FUNCTIONS

Level switches LS 95.xxx.01 protect the pumps from dry operation due to too low water level in the pan sections.
- When the contact of this level switch is continuously interrupted for a period of 5 seconds the pump will be switched off
and an alarm is issued.
Page 17
Note that dry operation of the condenser (fans running while the corresponding circulation pump is not
running) is possible, but not preferable. At full speed the fan motors absorb app. 25% more power. When
setting a maximal current in the frequency converter software the fans will run on a maximum speed which
is lower than 1.500 rpm.
Dry operation is possible on one condenser section while the other section is operating wet.
Condenser fans are frequency controlled and are protected by a thermal overload relay.
3.1.2 AIRPURGER
To keep the system free of non-condensable gasses, an airpurger A95.120.01 is installed. The airpurger is a stand-alone condenser-
unit, it will condensate the ammonia gasses and collects the non-condensable gasses. When enough non-condensable gasses are
collected, the airpurger will blow off the non-condensable gasses. On each point where non condensable gasses will collect in the
system during operation a solenoid valve is placed to bring the gasses to the airpurger. Each condenser is equipped with two
solenoid valves for purging purpose (V95.11X.01/02) and the liquid receiver has one V95.100.01.
The airpurger has a 230 VAC supply, this supply is continuous active and switched off by emergency stop alarm and ammonia
detection HH alarm (800 ppm). The airpurger is activated by a potential free contact in the cooling control panel and gives a signal
to the PLC (DI) when the airpurger starts to blow off.
The airpurger system can be switched on and off on the HMI, initial setting is “on”.
Once a day a purge cycle will be performed automatically at an adjustable start time if at least one of the cooling systems is started.
This means that all solenoid purge valves will open for an adjustable time one after each other. If a condenser is not in operation,
the purge valves of this condenser are skipped in the sequence. When the airpurger blow-off valve is active, the cycle is paused.
The purge valve that is open at that time will remain open and the airpurger keeps running. When the blow-off valve is closed
again, the cycle continuous. The number of started purge cycles and the number of blow-off are counted and presented on the
HMI, with a reset possibility.
Also an air purging auto cycle can be started by pressing the “Start Auto Cycle” button on the HMI.
The circuit breaker inside the control panel contains a trip contact that is connected to the PLC. If the circuit breaker is tripped a
warning is displayed on the HMI.
Page 18
3.1.3 WATER TREATMENT SYSTEM

Each condenser is equipped with a water treatment system. This equipment controls the conductivity of the circulating water by
dosing chemicals and by controlling the bleed off flow. Furthermore the system takes care of the dosing of biocide, meant to prevent
the growth of algae and bacteria in the circulating water.
3.1.3.1 BLEED-OFF
The function of the circulating water is that a part of it will evaporate. As a result of this, the minerals concentration in the remaining
water will increase. Each condenser has a transmitter (CE 95.11x.01) that measures the conductivity of the circulating water, this
transmitter gives his signal to the PLC. When the conductivity (= concentration of dissolved minerals) reaches its high limit value the
bleed-off valves V.95.xxx.03 of the applicable condenser will be opened, bleeding off the highly concentrated water. The amount of
water that is bled off, is replenished by fresh make-up water. A mechanical float valve controls make-up water supply. When the
conductivity reaches its low limit value, the bleed-off valve is closed again. The opening time of the bleed-off valve is time limited
(adjustable on HMI). If the opening time is exceeded a warning is displayed on HMI. Bleed-off system is activated after an adjustable
time delay when the water pump of that condenser is in operation.
3.1.3.2 CORROSION ANTI-SCALING

Proportional to the supply of make-up water, measured by water meter FQ 95.120.01 (10 liter/pulse), a corrosion inhibitor (anti-
scaling) is dosed. This corrosion inhibitor makes it possible to operate with higher minerals concentrations in the circulating water,
compared to the situation without corrosion inhibitor, without the risk of corrosion and/or deposits. Operating with higher minerals
concentrations means less bleed off and therefore lower water consumption. The anti-scaling drum is equipped with a pump
P95.120.02 for injection of the anti-scaling in the water supply line to the condensers. The pulse from the water meter is used to
start the anti-scaling pump. Each pulse represents an amount of anti-scaling injected by the anti-scaling pump. The anti-scaling drum
contains a level transmitter LT95.120.02. If the level becomes under the warning setpoint (adjustable on HMI) a warning will be
displayed on the HMI. If the level reaches the alarm setpoint (adjustable on HMI) an alarm will be displayed on the HMI and the anti-
scaling pump is stopped.
3.1.3.3 BIOCIDE
Beside corrosion inhibitor the water treatment system also takes care of the dosing of a biocide, meant to kill all micro-organisms
that grow in the pan water. The biocide is dosed once or twice a week (timer based) with a relative large quantity per dosage in order
to reach a concentration that is sufficient to kill the microbiological activity. The timer is in the PLC, day, start time and duration of
biocide dosage is adjustable on the HMI.
The biocide system has one biocide supply pump P95.120.01 mounted on the biocide drum and each condenser has its own solenoid
valve V95.120.0x for dosing biocide tot the condenser. The dosing of biocide is a continue cycle, after dosing biocide in the first
condenser for a set time (adjustable on HMI), dosing in the second condenser will start and so on. The dosing pump can’t be operated
when all solenoids are closed. When the water pump of the condenser is not in operation during dosing biocide, it is forced on and
keeps running for an adjustable delay after dosing. When the water pump is not stand-by or running, dosing biocide for this condenser
is skipped. During and after dosing biocide the bleed-off of the applicable condenser will be blocked during an adjustable (HMI) time.
Water meter (CE 95.120.01) is located close to the condensers. Bleed off valves (V 95.***.03) and conductivity measuring cells (CE
95.***.03) are located on the condensers.
Containers for biocide and corrosion inhibitor, with built on dosing pump and level transmitters are located in the engine room.
Page 19
3.1.4 LIQUID RECEIVER

The liquid receiver receives its liquid from the evaporative condensers. Under normal conditions there should be always liquid in the
receiver. The liquid receiver is used for distribution of ammonia liquid to:
• Ammonia freezing system

• Ammonia chilling system
• Ammonia compressor oil cooling
A minimum level inside the liquid receiver is necessary for the oil cooling of the compressors. The liquid receiver is equipped with a
level transmitter LT95.100.01 for visualization and alarm purpose only. If the level inside the liquid receiver comes below low level
setpoint the valve to the freezing system V95.100.03 and the chilling system V95.100.04 will be de-energized and a warning will be
displayed on the HMI.
3.1.4.1 OIL DETECTION

The liquid receiver is equipped with a level-switch LS95.100.01 that is capable to detect oil level in refrigerant. If the level-switch
detects oil level in the liquid receiver a timer starts running (with a delay of 30s) and a warning is displayed on the HMI. The timer
will run until the oil level inside the liquid receiver is below the switching point of the level-switch (oil removed by service technician).
Each time that the timer start counting the counter value will be raised with 1 to determine how many times oil is removed. The time
between start and stop, the start time and date, stop time and date and the counter output will be saved inside the PLC. The latest
records (100) will be stored inside PLC and must be visible on HMI.
Page 20
4 AMMONIA COOLING SYSTEMS

The cooling plant has two temperature systems. A low and a high temperature system. The low temperature system hereafter know
as freezing system. The high temperature system hereafter know as chilling system.
AMMONIA FREEZING SYSTEM

The ammonia part of the freezing system has his own economizer, separator and compressors. The functionality is described in the
next chapters.
4.1.1 ECONOMIZER
The high pressure liquid from the liquid receiver expands to economizer pressure. Due to this expansion a liquid and gas mixture
arises. The gas is sucked off by the compressors toward their economizer port. The entering liquid will be led to the ammonia
separator. To be able to operate the economizer at least 1 compressor has to be running at an adjustable capacity or higher. If there
is no compressor running or under the capacity setpoint minus offset, the economizer has to be by-passed by closing YV97.112.01,
YV97.112.02 and V97.112.03 and V97.112.04 has to be opened. If the capacity of at least 1 compressor is above setpoint for activating
the economizer, PV97.112.02 should be forced open to an adjustable value. If the pressure in the economizer PT97.112.01 drops
below its setpoint, PV97.112.02 is closed again and the economizer is released. Releasing the economizer means opening
YV97.112.01, YV97.112.02 and V97.112.03 and V97.112.04 has to be closed
4.1.1.1 LEVEL
The level of the ammonia liquid inside the economizer is measured by LT 97.112.01. The output to level control valve LV97.112.01 is
based on the output to LV 97.111.01 (level control valve separator) with an adjustable factor. A PID regulator will change this output
according the level measured by LT 97.112.01 and setpoint level economizer.
If the level inside the economizer comes above high level setpoint the level control valve LV97.112.01 will be controlled close and a
warning is displayed on the HMI. If the level inside the economizer falls under setpoint level the level control valve LV97.112.01 is
released to controlled open again. If the level inside the economizer comes above high-high level setpoint or LS 97.112.01 is activated
the block-in function of the level control valve LV97.112.01 and also pressure control valve PV97.112.01 will be activated. The
activation of the block-in is done by de-activating of the solenoids valves for air supply YV97.112.01 (level control valve) and
YV97.112.02 (pressure control valve). If the level control valve is disabled the economizer is out of order and the bypass valve
V97.112.04 will be controlled open after an adjustable delay-time to supply liquid to the separator. If the bypass valve V97.112.04 is
open the liquid line valve V97.112.03 will be controlled closed. If the level inside the economizer comes below high level setpoint the
system can be reset and the block-in will be de-activated.
A too high level in the economizer will not stop the compressors.
4.1.1.2 PRESSURE
The pressure inside the economizer is measured by PT97.112.01 and will only be regulated when the economizer is active. The output
to pressure control valve PV97.112.02 is based on the setpoint economizer pressure and the output to LV 97.112.01 with an
adjustable factor. A PID regulator will change this output according the pressure measured by PT 97.112.01.
4.1.2 SEPARATOR
The ammonia separator is a thermosiphon system, the separator is direct connected with the heat plate exchangers of the freezing
system. The ammonia liquid is circulating through the primary side of the heat plate exchangers. The heat of the coolant on the
secondary side will evaporate the ammonia in the heat plate exchangers. The mixture of liquid and gas rises upwards into the
separator. The liquid ammonia flushes at the bottom side of the separator. The suction gas is led to the compressors.
4.1.2.1 LEVEL
The level of the ammonia liquid inside the separator is measured by LT 97.111.01. The level control valve LV97.111.01 is regulating
on level setpoint separator with a PID regulator and is released when there is at least one compressor running.
If the level inside the separator comes above high level setpoint the level control valve LV97.111.01 will be controlled close and a
warning is displayed on the HMI. If the level inside the separator falls under setpoint level the level control valve LV97.111.01 is
released to controlled open again. If the level inside the separator comes above high-high level setpoint or LS 97.111.01 is activated
the block-in function of the level control valve LV97.111.01 will be activated. The activation of the block-in is done by de-activating
of the solenoid valve for air supply YV97.112.01 (level control valve).
Only the compressors will stop (and therefore also the control valves will close to stop water flow); the distribution pump(s) will keep
on running!
To lower the ammonia level in high level condition it is necessary to run a compressor. Because of the high-
high level in the separator the compressor will not run. For that we need to override the high-high level alarm
by pressing the Override button in the HMI screen. Switching operation in override mode is restricted to
Page 21
password level 5 (supervisor) and higher. When the system is in override mode there is a warning displayed
on the ammonia separator page and the alarm list.
During override mode (with an high-high level in the separator) only one compressor of the freezing system can start-up with a
limited capacity of a maximum 50% to prevent the compressor sucks liquid from the separator instead of gas.
4.1.2.2 PRESSURE
The pressure inside the separator is measured by PT97.111.01. If the pressure inside the separator comes below low pressure setpoint
a warning is displayed on the HMI and no more compressors can start-up, independent on the request for cooling capacity. This is
because more compressor capacity will create even lower separator pressure. If the pressure comes below low-low pressure setpoint
an alarm is displayed on the HMI and the compressors will be controlled stopped. If the pressure in the separator comes above high
pressure setpoint a warning is displayed and the compressor capacity will be limited until the suction pressure is under high pressure
setpoint.
4.1.3 COMPRESSORS
4.1.3.1 AUTOMATIC OPERATION

For automatic operation the compressors should be switched to remote on the Unisab control units, located on each compressor.
This Unisab III compressor control mode (stopped, manual, auto or remote) is also displayed in the compressor screen on the HMI,
however it cannot be changed from there.
Compressor unit C 99.***.01 will receive a start signal on command of cold buffer level of the stratification tank. This signal results
in a “capacity demand” for the compressor unit. This capacity demand is the “start/normal stop” signal (sent by the PLC through a
bus signal) towards the Unisab compressor controller. The PLC also gives a signal for the demand of capacity. Under normal conditions
the capacity demand will be regulated up in a short time and the compressor will run continuously on maximum capacity.
A serial hardware wired contacts from the compressor safety circuit processes into a “instant stop” signal towards the starter panel,
releasing the compressor for start and cause an immediate stop when one of the plant safeties fails. If the compressor is released for
start and the Unisab receives his start command (by Profibus) it will give a start feedback to the PLC. The PLC will start the compressor
motor.
Following plant safeties are part of the “instant” stop signal:

- LS 97.111.01: high level ammonia separator.
- PS 99.***.01 (high pressure switch)
- Low-low pressure PT 97.111.01 on the ammonia separator.
- Machine stop.
- Emergency stop.
- Ammonia detection, level >800 ppm.
As the compressor is designed for “full load” operation the compressor will regulate to 100% capacity when started and will keep
running at this capacity unless:
1. it is stopped because the “start/normal stop” signal is no longer present, requested level is reached, indicating that the
stratification tank is filled up. A normal stop means that the compressor regulates back to 0% and stops after the stop delay
timer.
2. It is stopped because the “instant stop” signal fails as a result of one of the process safeties, bearing or winding temperature
protection. In this case the compressor will stop instantly.
3. It is regulated back by the Unisab III compressor controller as a result of one of the limiting functions coming into operation.
Following limiting functions are present:
- Limiting on low suction pressure.
- Limiting on high discharge pressure.
- Limiting on high motor current.
In case the pre-alarm setting of one of the above process values is reached, the Unisab III compressor controller will reduce the
compressor capacity, thus overriding the capacity demand, in order to try and prevent the compressor from tripping when
reaching the actual alarm setting.
Page 22
The fact that a limiting function is in operation means that there is something wrong in the balance of the total system. Therefore
the actual operation of a limiting function indicates as warning on the HMI, furthermore it is indicated in the compressor screen at
“Unisab III compressor mode”.
When one compressor unit C 99.***.01 is not available for automatic operation, the next compressor in the sequence that is selected
on the HMI for operation on the coolant freezing cooling system starts up. This unit will automatically take over replacing the function
of the unit with a fault.
Compressor units will receive a start demand depending on the calculated cold level in the coolant freezing tank.
This is described in chapter 4.1.4.2
On the HMI the pressures, temperatures, capacity, current and status from each Unisab is visible in a pop-up, for more details see
the Profibus manual from the Unisab III controller.
4.1.3.2 MANUAL OPERATION

By means of the Unisab III compressor controller it is also possible to operate the compressor unit in manual mode. Therefore the
Unisab III has to be switched from remote to manual locally. When the Unisab III is set to manual this state is also indicated on the
OP in the corresponding compressor screen.
The compressor unit can now be started and stopped and increased and decreased in capacity by operating the corresponding keys
on the Unisab III, if there’s provided that:
- The “instant stop” signal is present (process safeties are OK).
- The internal safeties of the Unisab III are OK.
- PS 99.***.01 is safe.
- The machine stop on the unit is safe.
For detailed information on manual operation refer to the Unisab III manual. If a compressor is not in state “remote” a message will
appear.
4.1.3.3 MV MOTOR START

The starter panel of the compressor motor is a MV starter panel. The PLC has 2 contacts for start or stop the compressor motor. If
the compressor is ready the output of the normal stop will be activated. When the output normal stop is activated the relay for motor
stop in the starter panel is energized. If the motor stop relay is energized it is possible to start the compressor motor. When the MV
starter panel is ready and the Unisab gives a start command (manual or auto) to the PLC the PLC gives a pulse start command (3s) to
the starter panel contactor. The start pulse from the PLC will energized the start relay and the start relay will be remain energized by
his own contacts. If the start and stop relay are energized the contactor for the compressor motor will closed and the compressor
motor will run. If the compressor motor is controlled for stop the PLC will de-energized the normal stop relay. The stop relay will be
activated when the stop-start timer is finished and the compressor (Unisab) is ready.
4.1.3.3.1 Start-start timer

The start-start timer is needed to protect the compressor motor against too much starts in an hour. When the MV motor is started a
start-start timer becomes active. It is only possible to start a compressor when the start-start timer is finished.
4.1.3.3.2 Stop-start timer

When the MV motor is stopped a stop-start timer becomes active. It is only possible to start a compressor when the stop-start timer
is finished.
4.1.3.4 OIL COOLING SYSTEM

Oil cooling is realized by a thermosiphon operated ammonia system. High-pressure liquid from the receiver is fed to the ammonia
cooled oil coolers of the compressor units. The ammonia evaporates partly, thus cooling down the oil. The ammonia liquid/vapor
flows back to the liquid receiver. Ammonia circulation in such a system is driven by gravity forces.
4.1.3.5 WINDING PROTECTION

The MV motor is equipped with 6 temperature transmitters for trending and motor winding temperature protection. The alarm
setpoint is adjustable on the HMI.
Page 23
4.1.3.6 BEARING PROTECTION

The MV motor is equipped with 2 temperature transmitters for trending and motor bearing temperature protection. The alarm
4.1.3.7 SWING COMPRESSOR

The freezing system contains one compressor C 99.112.01 that can be used as swing compressor. The compressor is connected both
to the freezing and chilling system with control valves V 99.112.06/09). In a normal situation the compressor is running on the freezing
system. If the compressor is not running it is possible to swing the compressor to another system. From freezing to chilling and back.
The swing can only be manually activated on the HMI and is password protected. The applicable control valves will be opened or
closed automatically to connect the compressor to the desired system.
If a compressor is running on a different system the calculation of the COP must be changed accordingly.
Page 24
4.1.4 COOLANT FREEZING SYSTEM
4.1.4.1 OVERVIEW
The following compressors can be operated for the coolant freezing system:
Operating cond. [To Nom. cooling

Compressor Tag number Compressor type Phase
/ Tc] capacity *
1. C.99.111.01 SAB-233LME -10ºC / +37ºC 1477,7 [kW] 1
2. (swing) C.99.112.01 SAB-233LME -10ºC / +37ºC 1477,7 [kW] 1
* Cooling capacities will be calculated depending on operating conditions.
Remarks:
- The start/stop sequence of the compressors will be determined by the cold level in the stratification tank and the set points
and delay times for that are adjustable on HMI.
- The maximal amount of compressors on the freezing system is maximum 2 compressors.
4.1.4.2 COMPRESSOR CAPACITY TABLE

The capacity of the compressor is depending of the working range. To calculate the correct coolant flow through the ammonia heat
plat exchangers the capacity can be determined with the table below. If the swing compressor C99.113.01 from the chilling system
is working on the freezing system the capacity is equal.
= compressor cooling capacity including economizer operation
= compressor might be limited on capacity slide by the Unisab (due of high motor current) - value cooling capacity
(table) to be multiplied with the Yield (value from Unisab)
Page 25
4.1.4.3 COLD LEVEL

The requested compressor capacity is determined by the cold level in the stratification tank. The cold level inside the stratification
tank is calculated by temperature transmitters
c Temperature setpoint or TspAW

This the desired temperature of the coolant inside the stratification tank
d Adjustable parameter
This parameter is the parameter that gives the range of the cold level inside the stratification tank. For example:
TspAW=6°C and d=2°C
If Tav = 8°C cold level = 0%

Minimum cold level must be protected by 0%

Maximum cold level must be protected by 100%
e Number of correct TT in stratification tank

A TT is correct if there is no signal fail and the measured value is lower than the coolant setpoint plus M.
s Fixed value (1) for calculation cold level
F Cold level in stratification tank in %
M Maximum allowed deviation setpoint.

If the measured value is lower than the deviation setpoint, the measured value will be used for this TT in the calculation.
Page 26
4.1.4.4 SEQUENCE
Pos. Status Primary conditions Control Action Text W A
Start permission Cold Level < [80]% Start compressor

1 Compressor 1 = ON
compressor 1 and timer 5 minutes 1
Start permission Compressor 1 Cold Level < [70]% Start compressor Compressor 1 = ON
2
compressor 2 100% and timer 5 minutes 2 Compressor 2 = ON
Compressor 1
Stopping 100% Cold Level > [85]% Stop compressor
3 Compressor 1 = ON
compressor 2 Compressor 2 and timer 5 minutes 2
100%
Stopping Compressor 1 Cold Level > [95]% Stop compressor
4
compressor 1 100% and timer 5 minutes 1
Remarks:
- At all times the following general primary conditions should be taken into account:
Ammonia detection OK, emergency stop OK, ammonia separator LS 97.111.01 is “1” (OK), LT 97.111.01 actual value under H-
alarm value (adjustable) and PT 97.111.01 actual value above L-alarm value, condensing pressure PT 95.120.01 actual value
under H-alarm value and Unisab ready.
- Compressor should ramp up (p) (to 100%) / down (q) (to 0%) within 3 minutes (adjustable in Unisab).
- Between start/start compressor there is a time delay of 15 minutes. (Maximum starts/hour is 4)
- Between stop/start compressor there is a time delay of 5 minutes.
- If a Unisab is not ready, the next compressor in sequence will be started. Desired start sequence is restored when all
compressors are running, stopped or ready.
Page 27
4.1.4.5 FLOW CONTROL

Hereunder the control diagram is shown how the required primary coolant freezing flow (capacity) can be calculated. The following
steps have to be taken into account:
- Determine the temperature difference between the coolant freezing inlet temperature (TinAW) (TT 96.110.03) and set point
of the coolant freezing outlet (TspAW). The set point can be adjusted on the HMI.
- The temperature difference is being multiplied by the specific heat of coolant freezing (CpAW), which a constant value is being
4,2882kJ/kgK. The result (A) of the calculation should be higher as 1 (value g).
- In the table in paragraph 4.1.4.2 the compressor capacity has been specified. From each compressor operating on the coolant
freezing system it can be determined what the nominal cooling capacity is. The actual cooling capacity can be found in this
table based on actual evaporating temperature, condensing temperature and swept volume operating conditions.
- From each compressor it can be determined which nominal water flow (in m³/h) corresponds with the cooling capacity (in kW)
of the compressor using the formula from the control diagram:
To create a balance in energy, the needed coolant flow is calculated based on temperature difference between inlet temperature
PHE’s and desired coolant setpoint, the specific heat of the coolant (J/kg/K).
Q = m·c·ΔT is the base formula, m can be calculated. Q is in J/s, so m can be converted to kg / s.
With a known density of the coolant, this value can be converted to m³/h.
Q(Yxxx)
= FspAW*
CpAW x (TinAW - TspAW ) x ρ
ρ = density of coolant freezing [972,0 kg/m³]
Page 28
Example:
SAB 233LME (C 99.111.001):
To = -8ºC and Tc = +34º => compressor cooling capacity Qo = 1.428,2 kW.
At coolant freezing inlet temperature -2ºC and coolant freezing set point -5ºC this will result into an actual coolant freezing flow of:
1.428,2 kW x 3.600s x 1h
------------------------------------------------------- = 411,2 m³/h
(4,2882 KJ/kgK x (5°C-2°C) x 972,0 kg/m³)
This calculated flow is used for the cascade regulator in the next paragraph.
4.1.4.5.1 Cascade flow control

The cascade regulator has 3 individual PID controllers that all influence the calculated flow setpoint mentioned above.
1) Suction pressure controller.

The flow rate over a PHE will influence the evaporating pressure in the separator. To maintain a balance in ammonia
evaporating temperature and coolant temperature, a suction pressure regulator will correct the calculated primary flow
setpoint. The pressure transmitter on the liquid separator will give the process value for this controller. Setpoint for this
controller is the desired temperature difference for heat transfer in the PHE. A higher temperature difference will reduce
the primary flow setpoint, a lower temperature difference will increase the primary flow setpoint. The compensation for
the pressure is limited with a minimum and a maximum value. All parameters have to be adjustable on the HMI.
2) Temperature controller.
The flow rate over the PHE will influence the coolant outlet temperature from the PHE’s.
To maintain the desired coolant temperature setpoint, the flow setpoint (already corrected by the suction pressure
controller) will be corrected by the temperature controller. The coolant outlet temperature transmitter will give the process
value for this controller. A higher outlet temperature from the PHE’s will reduce the primary flow setpoint, a lower outlet
temperature will increase the primary flow setpoint. The compensation for the temperature is limited with a minimum and
a maximum value. All parameters have to be adjustable on the HMI.
3) Low Temperature guard controller

This controller will have no function during normal operation. In case the outlet coolant temperature of the PHE’s will be
lower than the setpoint for the low temperature guard controller. This controller will increase the coolant primary flow
setpoint. The compensation for the temperature is limited with a minimum and a maximum value. All parameters have to
be adjustable on the HMI.
Page 29
4.1.4.5.2 Primary coolant flow control

The primary coolant flow controller controls the primary coolant pumps and coolant valves in the inlet of the PHE’s. The flow
transmitter in the coolant supply line for the PHE’s will give the process value for this controller. Setpoint for this controller is the
calculated flow setpoint adapted by the three controllers mentioned above.
The output of this controller is divided in a split-range signal towards the primary pumps and the flow regulating valves of the PHE’s.
All parameters have to be adjustable on the HMI.
4.1.4.5.3 Coolant valves

Each plate heat exchanger (PHE) A 96.011x.01 has its own control loop as indicated in the control diagram above. Based upon the
physical cold water level in the coolant chilling tank the compressor(s) will be started. Whenever the compressor(s) starts this leads
to a temperature drop. As a result of this the flow across the PHE’s will be controlled by means of control valves V 96.110.0x which
leads to a constant outlet temperature. The opening degree of the control valves depend upon the temperature (PI) controller,
ammonia suction pressure (PI) controller, low temperature guard (PI) controller and number of PHE’s in operation.
At first start of a compressor the opening degree of the control valves is forced to 25%; from there the regulation of the opening
degree starts. In the screen you can specify how many and which PHE is in operation. The minimum flow across a coolant chilling PHE
is 25% of the design flow of 420 m3/h, being 105.0 m3/h. Below this flow fouling of the PHE may occur. The flow control valve will
regulated open or close according the calculated flow needed for the compressor(s). If the flow exceeds the minimum flow with 2
times (2x 105.0 m3/h = 210 m3/h) the next flow control valve of the next PHE will be controlled open. If the flow through the PHE’s
falls under the minimum flow for certain time the second PHE flow control valve will be closed.
Whenever a low flow is being detected by the flow transmitters FIT 96.120.0x there will be generated a low flow alarm without any
action. However if a ‘no’ flow (< 8 m3/h for a period of 20 sec.) is detected just after the compressor(s) have received their start
command, the compressor(s) will be stopped immediately as it might result into freezing of the PHE’s.
Page 30
To be sure that water is available from the water treatment plant it’s advisable to make an interlock between water treatment plant
and cooling plant disabling the cooling plant to start when water is not available!
When stopping the compressors the control valves must always close after a delay. If they would close immediately, the ramp down
time of the compressor(s) would cause freezing of the plate heat exchangers.
4.1.4.5.4 Primary coolant pumps

The distribution freezing pumps (P 96.111.0x) are frequency controlled (SX 96.111.0x) based upon the calculated flow of the flow
controller from section 4.1.4.5.2
1. One pump runs after the coolant freezing system has been switched on.
2. Pumps can only start whenever ammonia detection OK and emergency stop is OK.
3. The following pump(s) starts-up whenever requested flow is above the flow (setting) of the leading pump for a certain time.
4. All pumps will regulate speed based on discharge pressure.
5. The following pump(s) stops whenever requested flow is below the flow (setting) of the following pump for a certain time.
6. Pumps switch on/off in a predefined adjustable sequence.
7. Pumps with failure or out of operation status will be skipped in the start sequence.
8. Start/stop and timers high/low are adjustable on the display.
When changing the sequence of pumps first ‘new’ leading pump must be started and after –adjustable- time
delay the ‘old’ leading pump must be switched off.
4.1.4.5.4.1 Sequence
Primary
Pos. Status Control Action Text W A
conditions
All pump(s)
1 Compressor 11x OFF Pump 1 OFF
stop
Startup first
2 Compressor 11x ON Pump 1 ON Pump 1 ON
pump
Flow pump 1 =100%
Increase compressor Startup Pump 1 ON
3 Pump 1 ON and timer 60
capacity 11x second pump Pump 2 ON
seconds
Flow pump 1+2 Pump 1 ON
Increase compressor Pump 1 ON Startup third
4 =100% and timer 60 Pump 2 ON
capacity 11x Pump 2 ON pump
seconds Pump 3 ON
Pump 1 ON Flow pump 1+2+3
Decrease compressor Stop third Pump 1 ON
5 Pump 2 ON <=60% and timer 60
capacity 11x pump Pump 2 ON
Pump 3 ON seconds
Flow pump 1+2
Decrease compressor Pump 1 ON Stop up
6 <=60% and timer 60 Pump 1 ON
capacity 11x Pump 2 ON second pump
seconds
Page 31
4.1.4.5.5 Distribution coolant pumps

The coolant freezing pumps are frequency controlled (SX 121.111.0x) based upon pump pressure (PT 121.110.01). The total coolant
freezing flow is the sum which is measured by two flow transmitters (FIT 121.110.0x).
- One pump runs after the coolant freezing system has been switched on.
- Pumps can only start whenever ammonia detection OK and emergency stop is OK.
- The following pump(s) starts-up whenever requested flow is above the flow (setting) of the leading pump for a certain time.
- All pumps will regulate speed based on discharge pressure.
- The following pump(s) stops whenever requested flow is below the flow (setting) of the following pump for a certain time.
- Pumps switch on/off in a predefined adjustable sequence.
- Pumps with failure or out of operation status will be skipped in the start sequence.
- Start/stop and timers high/low are adjustable on the display.
Primary
conditions
Calculated cold Stratification tank low
1 Stratification tank empty Pump 1 in x
level < 5% cold level
External contact = All pump(s)
2 No cold request
“0” stop
External contact = Startup first
3 Cold request Pump 1 ON
“1” pump
Total flow FIT
Increase cold request 1 121.110.0x > Startup Pump 1 ON
4 Pump 1 ON
pump in. 400m3/h and timer second pump Pump 2 ON
60 seconds
Total flow FIT
Pump 1 ON
Increase cold request 2 Pump 1 ON 121.110.0x > Startup third
5 Pump 2 ON
pumps in. Pump 2 ON 800m3/h and timer pump
Pump 3 ON
60 seconds
Total flow FIT
Pump 1 ON
Decrease cold request 3 121.110.0x < Stop up third Pump 1 ON
6 Pump 2 ON
pumps in. 800m3/h and timer pump Pump 2 ON
Pump 3 ON
60 seconds
Total flow FIT
Decrease cold request 2 Pump 1 ON 121.110.0x < Stop up
7 Pump 1 ON
pumps in. Pump 2 ON 400m3/h and timer second pump
60 seconds
Total flow FIT
Coolant freezing low
5 Control min. flow Pump 1 ON 121.110.0x < x m3/h x
flow request
and timer 5 seconds
At least 1 pump
TE 121.110.16 > - Coolant freezing
6 Temperature control in + timer 5 x
5°C temperature high
minutes
Calculation coolant Total flow FIT Requested alcohol
7
freezing capacity request 121.110.0x water flow = …m3/h
Calculation coolant Total flow FIT Coolant freezing
8
freezing consumption 121.110.0x consumption = …m³
When operating with one pump the next pump is automatically stand-by for taking over in case the leading pump fails.
The first distribution pump (P 121.111.0x) will run as soon as the coolant freezing system is active. Every pump should have abilities
to on/off, manual and automatic control. The pump will be frequency controlled based upon discharge pressure (PT 121.110.01)
Whenever the pressure switch PS 121.110.01 encounters a low pressure (vacuum) the distribution pumps will automatically be
switched off.
Page 32
The temperature transmitters TT 121.110.13, TT 121.110.14 and TT 121.110.15 are only for indication on the HMI screen and for
energy calculation purposes.
For these temperatures there’s the possibility to adjust values for high/low temperature warnings and alarms.
4.1.4.5.5.2 Safety Functions

A low flow warning is issued when the sum of FIT 121.110.0x drops below a predefined flow (5 m3/h), indicating that there is a big
deviation from the normal situation.
4.1.4.5.5.3 Control
The coolant freezing supply to the consumers is transported by pumps P 121.11x.01. The leading pump is always active (when coolant
freezing system is switched on) and speed is controlled by means of discharge pressure. Starting and stopping additional pumps is
based on the created flow measured by FIT 121.110.0x.
4.1.4.6 COOLANT QUALITY CONTROL

In the central coolant inlet line of the PHE’s and each coolant outlet line, a quality sensor is placed QE96.110.01/02 and 03. The
measured values are send to the PLC by QT96.110.01. The measurement of the inlet and outlet are compared to detect possible
ammonia leakage in the coolant. In the PLC the difference of the 3 measurements is calculated and compared with an adjustable
alarm value. In case the measured difference is higher than the alarm setpoint, the flow valve ZT96.110.01 or 02 is forced closed and
an alarm is generated on the HMI. If QT 96.110.01 has a failure an alarm is displayed on the HMI.
Page 33
AMMONIA CHILLING SYSTEM

The ammonia part of the chilling system has his own economizer, separator and compressors. The functionality is described in the
next chapters.
4.2.1 ECONOMIZER
The high pressure liquid from the liquid receiver expands to economizer pressure. Due to this expansion a liquid and gas mixture
arises. The gas is sucked off by the compressors toward their economizer port. The entering liquid will be led to the ammonia
separator. To be able to operate the economizer at least 1 compressor has to be running at an adjustable capacity or higher. If there
is no compressor running or under the capacity setpoint minus offset, the economizer has to be by-passed by closing YV97.122.01,
YV97.122.02 and V97.122.03 and V97.122.04 has to be opened. If the capacity of at least 1 compressor is above setpoint for activating
the economizer, PV97.122.02 should be forced open to an adjustable value. If the pressure in the economizer PT97.122.01 drops
below its setpoint, PV97.122.02 is closed again and the economizer is released. Releasing the economizer means opening
YV97.122.01, YV97.122.02 and V97.122.03 and V97.122.04 has to be closed
4.2.1.1 LEVEL
The level of the ammonia liquid inside the economizer is measured by LT 97.122.01. The output to level control valve LV97.122.01 is
based on the output to LV 97.121.01 (level control valve separator) with an adjustable factor. A PID regulator will change this output
according the level measured by LT 97.122.01 and setpoint level economizer.
If the level inside the economizer comes above high level setpoint the level control valve LV97.122.01 will be controlled close and a
warning is displayed on the HMI. If the level inside the economizer falls under setpoint level the level control valve LV97.122.01 is
released to controlled open again. If the level inside the economizer comes above high-high level setpoint or LS 97.122.01 is activated
the block-in function of the level control valve LV97.122.01 and also pressure control valve PV97.122.01 will be activated. The
activation of the block-in is done by de-activating of the solenoids valves for air supply YV97.122.01 (level control valve) and
YV97.122.02 (pressure control valve). If the level control valve is disabled the economizer is out of order and the bypass valve
V97.122.04 will be controlled open after an adjustable delay-time to supply liquid to the separator. If the bypass valve V97.122.04 is
open the liquid line valve V97.122.03 will be controlled closed. If the level inside the economizer comes below high level setpoint the
system can be reset and the block-in will be de-activated.
A too high level in the economizer will not stop the compressors.
4.2.1.2 PRESSURE
The pressure inside the economizer is measured by PT97.122.01 and will only be regulated when the economizer is active. The output
to pressure control valve PV97.122.02 is based on the setpoint economizer pressure and the output to LV 97.122.01 with an
adjustable factor. A PID regulator will change this output according the pressure measured by PT 97.122.01.
4.2.2 SEPARATOR
The ammonia separator is a thermosiphon system, the separator is direct connected with the heat plate exchangers of the freezing
system. The ammonia liquid is circulating through the primary side of the heat plate exchangers. The heat of the coolant on the
secondary side will evaporate the ammonia in the heat plate exchangers. The mixture of liquid and gas rises upwards into the
separator. The liquid ammonia flushes at the bottom side of the separator. The suction gas is led to the compressors.
4.2.2.1 LEVEL
The level of the ammonia liquid inside the separator is measured by LT 97.121.01. The level control valve LV97.121.01 is regulating
on level setpoint separator with a PID regulator and is released when there is at least one compressor running.
If the level inside the separator comes above high level setpoint the level control valve LV97.121.01 will be controlled close and a
warning is displayed on the HMI. If the level inside the separator falls under setpoint level the level control valve LV97.121.01 is
released to controlled open again. If the level inside the separator comes above high-high level setpoint or LS 97.121.01 is activated
the block-in function of the level control valve LV97.121.01 will be activated. The activation of the block-in is done by de-activating
of the solenoid valve for air supply YV97.122.01 (level control valve).
Only the compressors will stop (and therefore also the control valves will close to stop water flow); the distribution pump(s) will keep
on running!
To lower the ammonia level in high level condition it is necessary to run a compressor. Because of the high-
high level in the separator the compressor will not run. For that we need to override the high-high level alarm
by pressing the Override button in the HMI screen. Switching operation in override mode is restricted to
password level 5 (supervisor) and higher. When the system is in override mode there is a warning displayed
on the ammonia separator page and the alarm list.
During override mode (with an high-high level in the separator) only one compressor of the chilling system can start-up with a limited
capacity of a maximum 50% to prevent the compressor sucks liquid from the separator instead of gas.
Page 34
4.2.2.2 PRESSURE
The pressure inside the separator is measured by PT97.121.01. If the pressure inside the separator comes below low pressure setpoint
a warning is displayed on the HMI and no more compressors can start-up, independent on the request for cooling capacity. This is
because more compressor capacity will create even lower separator pressure. If the pressure comes below low-low pressure setpoint
an alarm is displayed on the HMI and the compressors will be controlled stopped. If the pressure in the separator comes above high
pressure setpoint a warning is displayed and the compressor capacity will be limited until the suction pressure is under high pressure
setpoint.
Page 35
4.2.3 COMPRESSORS
4.2.3.1 AUTOMATIC OPERATION

For automatic operation the compressors should be switched to remote on the Unisab control units, located on each compressor.
This Unisab III compressor control mode (stopped, manual, auto or remote) is also displayed in the compressor screen on the HMI,
however it cannot be changed from there.
Compressor unit C 99.***.01 will receive a start signal on command of cold buffer level of the stratification tank. This signal results
in a “capacity demand” for the compressor unit. This capacity demand is the “start/normal stop” signal (sent by the PLC through a
bus signal) towards the Unisab compressor controller. The PLC also gives a signal for the demand of capacity. Under normal conditions
the capacity demand will be regulated up in a short time and the compressor will run continuously on maximum capacity.
A serial hardware wired contacts from the compressor safety circuit processes into an “instant stop” signal towards the starter panel,
releasing the compressor for start and cause an immediate stop when one of the plant safeties fails. If the compressor is released for
start and the Unisab receives his start command (by Profibus) it will give a start feedback to the PLC. The PLC will start the compressor
motor.
Following plant safeties are part of the “instant” stop signal:

- LS 97.121.01: high level ammonia separator.
- PS 99.***.01 (high pressure switch)
- Low-low pressure PT 97.121.01 on the ammonia separator.
- Machine stop.
- Emergency stop.
- Ammonia detection, level >800 ppm.
As the compressor is designed for “full load” operation the compressor will regulate to 100% capacity when started and will keep
running at this capacity unless:
4. it is stopped because the “start/normal stop” signal is no longer present, requested level is reached, indicating that the
stratification tank is filled up. A normal stop means that the compressor regulates back to 0% and stops after the stop delay
timer.
5. It is stopped because the “instant stop” signal fails as a result of one of the process safeties, bearing or winding temperature
protection. In this case the compressor will stop instantly.
6. It is regulated back by the Unisab III compressor controller as a result of one of the limiting functions coming into operation.
Following limiting functions are present:
- Limiting on low suction pressure.
- Limiting on high discharge pressure.
- Limiting on high motor current.
In case the pre-alarm setting of one of the above process values is reached, the Unisab III compressor controller will reduce the
compressor capacity, thus overriding the capacity demand, in order to try and prevent the compressor from tripping when
reaching the actual alarm setting.
The fact that a limiting function is in operation means that there is something wrong in the balance of the total system. Therefore
the actual operation of a limiting function indicates as warning on the HMI, furthermore it is indicated in the compressor screen at
“Unisab III compressor mode”.
When one compressor unit C 99.***.01 is not available for automatic operation, the next compressor in the sequence that is selected
on the HMI for operation on the coolant freezing cooling system starts up. This unit will automatically take over replacing the function
of the unit with a fault.
Compressor units will receive a start demand depending on the calculated cold level in the coolant chilling tank.
This is described in chapter 4.2.4.2
On the HMI the pressures, temperatures, capacity, current and status from each Unisab is visible in a pop-up, for more details see
the Profibus manual from the Unisab III controller.
Page 36
4.2.3.2 MANUAL OPERATION

By means of the Unisab III compressor controller it is also possible to operate the compressor unit in manual mode. Therefore the
Unisab III has to be switched from remote to manual locally. When the Unisab III is set to manual this state is also indicated on the
OP in the corresponding compressor screen.
The compressor unit can now be started and stopped and increased and decreased in capacity by operating the corresponding keys
on the Unisab III, if there’s provided that:
- The “instant stop” signal is present (process safeties are OK).
- The internal safeties of the Unisab III are OK.
- PS 99.***.01 is safe.
- The machine stop on the unit is safe.
For detailed information on manual operation refer to the Unisab III manual. If a compressor is not in state “remote” a message will
appear.
4.2.3.3 MV MOTOR START

The starter panel of the compressor motor is a MV starter panel. The PLC has 2 contacts for start or stop the compressor motor. If
the compressor is ready the output of the normal stop will be activated. When the output normal stop is activated the relay for motor
stop in the starter panel is energized. If the motor stop relay is energized it is possible to start the compressor motor. When the MV
starter panel is ready and the Unisab gives a start command (manual or auto) to the PLC the PLC gives a pulse start command (3s) to
the starter panel contactor. The start pulse from the PLC will energized the start relay and the start relay will be remain energized by
his own contacts. If the start and stop relay are energized the contactor for the compressor motor will closed and the compressor
motor will run. If the compressor motor is controlled for stop the PLC will de-energized the normal stop relay. The stop relay will be
activated when the stop-start timer is finished and the compressor (Unisab) is ready.
4.2.3.3.1 Start-start timer

The start-start timer is needed to protect the compressor motor against too much starts in an hour. When the MV motor is started a
start-start timer becomes active. It is only possible to start a compressor when the start-start timer is finished.
4.2.3.3.2 Stop-start timer

When the MV motor is stopped a stop-start timer becomes active. It is only possible to start a compressor when the stop-start timer
is finished.
4.2.3.4 OIL COOLING SYSTEM

Oil cooling is realized by a thermosiphon operated ammonia system. High-pressure liquid from the receiver is fed to the ammonia
cooled oil coolers of the compressor units. The ammonia evaporates partly, thus cooling down the oil. The ammonia liquid/vapor
flows back to the liquid receiver. Ammonia circulation in such a system is driven by gravity forces.
4.2.3.5 WINDING PROTECTION

The MV motor is equipped with 6 temperature transmitters for trending and motor winding temperature protection. The alarm
4.2.3.6 BEARING PROTECTION

The MV motor is equipped with 2 temperature transmitters for trending and motor bearing temperature protection. The alarm
4.2.3.7 SWING COMPRESSOR

The chilling system contains one compressor C 99.113.01 that can be used as swing compressor. The compressor is connected both
to the freezing and chilling system with control valves (V 99.113.06/09). In a normal situation the compressor is running on the chilling
system. If the compressor is not running it is possible to swing the compressor to another system. From chilling to freezing and back.
The swing can only be manually activated on the HMI and is password protected. The applicable control valves will be opened or
closed automatically to connect the compressor to the desired system.
If a compressor is running on a different system the calculation of the COP must be changed accordingly.
Page 37
4.2.3.8 COUPLE VALVE

The cooling plant is equipped with a couple valve (PV 99.130.01). With this valve it’s possible to connect and run the freezing
compressors on the chilling system. The couple valve will be controlled regulate on the desired suction pressure of the chilling system.
If the couple valve is active the calculated capacity that is used from the freezing need to be added to the flow calculation of the
primary pumps of the chilling system and distracted from the freezing system. The couple valve can only be activated manually with
a push button on the HMI and is password protected.
Page 38
4.2.4 COOLANT CHILLING SYSTEM
4.2.4.1 OVERVIEW
The following compressors can be operated for the coolant chilling system:
Operating cond. [To Nom. cooling

Compressor Tag number Compressor type Phase
/ Tc] capacity *
3. C.99.114.01 SAB-233LME -2ºC / +36ºC 1955,0 [kW] 1
4. C.99.115.01 SAB-233LME -2ºC / +36ºC 1955,0 [kW] 1
5. PV 99.130.01 Couple valve -2ºC / +36ºC 1955,0 [kW] 1
* Cooling capacities will be calculated depending on operating conditions.
Remarks:
- The start/stop sequence of the compressors will be determined by the cold level in the stratification tank and the set points
and delay times for that are adjustable on HMI.
- The maximal amount of compressors on the freezing system is maximum 2 compressors.
4.2.4.2 COMPRESSOR CAPACITY TABLE

The capacity of the compressor is depending of the working range. To calculate the correct coolant flow through the ammonia heat
plat exchangers the capacity can be determined with the table below. If the swing compressor C99.112.01 from the freezing system
is working on the chilling system the capacity is equal.
= compressor cooling capacity including economizer operation
= compressor might be limited on capacity slide by the Unisab (due of high motor current) - value cooling capacity
(table) to be multiplied with the Yield (value from Unisab)
Page 39
4.2.4.3 COLD LEVEL

The requested compressor capacity is determined by the cold level in the stratification tank. The cold level inside the stratification
tank is calculated by temperature transmitters
c Temperature setpoint or TspBW

This the desired temperature of the coolant inside the stratification tank
d Adjustable parameter
This parameter is the parameter that gives the range of the cold level inside the stratification tank. For example:
TspBW=6°C and d=2°C

Minimum cold level must be protected by 0%

Maximum cold level must be protected by 100%
e Number of correct TT in stratification tank

A TT is correct if there is no signal fail and the measured value is lower than the coolant setpoint added with the maximum
allowed deviation (value M). If the measured value is lower than the coolant setpoint, the setpoint value will be used for this
TT in the calculation.
s Fixed value (1) for calculation cold level
F Cold level in stratification tank in %
M Maximum allowed deviation setpoint.

If the measured value is lower than the deviation setpoint, the measured value will be used for this TT in the calculation.
Page 40
4.2.4.4 SEQUENCE
Pos. Status Primary conditions Control Action Text W A
Start permission Cold Level < [80]% Start compressor

1 Compressor 1 = ON
compressor 1 and timer 5 minutes 1
Start permission Compressor 1 Cold Level < [70]% Start compressor Compressor 1 = ON
2
Compressor 1
Compressor 1 = ON
Start permission 100% Cold Level < [30]% Start compressor
3 Compressor 2 = ON
compressor 3 Compressor2 and timer 5 minutes 3
Compressor 3 = ON
100%
Compressor 1
100%
Stopping Compressor 2 Cold Level > [35]% Stop compressor Compressor 1 = ON
4
Compressor 3
100%
Compressor 1
Stopping 100% Cold Level > [75]% Stop compressor
5 Compressor 1 = ON
compressor 2 Compressor 2 and timer 5 minutes 2
100%
Stopping Compressor 1 Cold Level > [95]% Stop compressor
6 Compressor 1 = ON
compressor 1 100% and timer 5 minutes 1
Remarks:
- At all times the following general primary conditions should be taken into account:
Ammonia detection OK, emergency stop OK, ammonia separator LS 97.121.01 is “1” (OK), LT 97.121.01 actual value under H-
alarm value (adjustable) and PT 97.121.01 actual value above L-alarm value, condensing pressure PT 95.120.01 actual value
under H-alarm value and Unisab ready.
- Compressor should ramp up (to 100%) / down (to 0%) within 3 minutes (adjustable in Unisab).
- Between start/start compressor there is a time delay of 15 minutes. (Maximum starts/hour is 4)
- Between stop/start compressor there is a time delay of 5 minutes.
- If a Unisab is not ready, the next compressor in sequence will be started. Desired start sequence is restored when all
compressors are running, stopped or ready.
Page 41
4.2.4.5 FLOW CONTROL

Hereunder the control diagram is shown how the required primary coolant chilling flow (capacity) can be calculated. The following
steps have to be taken into account:
- Determine the temperature difference between the coolant chilling inlet temperature (TinBW) (TT 96.120.03) and set point of
the coolant chilling outlet (TspBW). The set point can be adjusted on the HMI.
- The temperature difference is being multiplied by the specific heat of coolant chilling (CpBW), which a constant value is being
4,3583kJ/kgK. The result (A) of the calculation should be higher as 1 (value g).
- In the table in paragraph 4.2.4.2 the compressor capacity has been specified. From each compressor operating on the coolant
chilling system it can be determined what the nominal cooling capacity is. The actual cooling capacity can be found in this
table based on actual evaporating temperature, condensing temperature and swept volume operating conditions.
- From each compressor it can be determined which nominal water flow (in m³/h) corresponds with the cooling capacity (in kW)
of the compressor using the formula from the control diagram:
To create a balance in energy, the needed coolant flow is calculated based on temperature difference between inlet temperature
PHE’s and desired coolant setpoint, the specific heat of the coolant (J/kg/K).
Q = m·c·ΔT is the base formula, m can be calculated. Q is in J/s, so m can be converted to kg / s.
With a known density of the coolant, this value can be converted to m³/h.
Q(Yxxx)
= FspBW*
CpBW x (TinBW - TspBW ) x ρ
ρ = density of coolant chilling [989.0 kg/m³]
Example:
SAB 233LME (C 99.113.01):
To = -2ºC and Tc = +36º => compressor cooling capacity Qo = 1.955,0 kW.
At coolant chilling inlet temperature 5ºC and coolant chilling set point 2ºC this will result into an actual coolant chilling flow of:
1.955,0 kW x 3.600s x 1h
------------------------------------------------------- = 544. 2 m³/h
(4.3583 KJ/kgK x (5°C-2°C) x 989.0 kg/m³)
This calculated flow is used for the cascade regulator in the next paragraph.
Page 42
4.2.4.5.1 Cascade flow control

The cascade regulator has 3 individual PID controllers that all influence the calculated flow setpoint mentioned above.
4) Suction pressure controller.

The flow rate over a PHE will influence the evaporating pressure in the separator. To maintain a balance in ammonia
evaporating temperature and coolant temperature, a suction pressure regulator will correct the calculated primary flow
setpoint. The pressure transmitter on the liquid separator will give the process value for this controller. Setpoint for this
controller is the desired temperature difference for heat transfer in the PHE. A higher temperature difference will reduce
the primary flow setpoint, a lower temperature difference will increase the primary flow setpoint. The compensation for
the pressure is limited with a minimum and a maximum value. All parameters have to be adjustable on the HMI.
5) Temperature controller.
The flow rate over the PHE will influence the coolant outlet temperature from the PHE’s.
To maintain the desired coolant temperature setpoint, the flow setpoint (already corrected by the suction pressure
controller) will be corrected by the temperature controller. The coolant outlet temperature transmitter will give the process
value for this controller. A higher outlet temperature from the PHE’s will reduce the primary flow setpoint, a lower outlet
temperature will increase the primary flow setpoint. The compensation for the temperature is limited with a minimum and
a maximum value. All parameters have to be adjustable on the HMI.
6) Low Temperature guard controller

This controller will have no function during normal operation. In case the outlet coolant temperature of the PHE’s will be
lower than the setpoint for the low temperature guard controller. This controller will increase the coolant primary flow
setpoint. The compensation for the temperature is limited with a minimum and a maximum value. All parameters have to
be adjustable on the HMI.
Page 43
4.2.4.5.2 Primary coolant flow controller

The primary coolant flow controller controls the primary coolant pumps and coolant valves in the inlet of the PHE’s. The flow
transmitter in the coolant supply line for the PHE’s will give the process value for this controller. Setpoint for this controller is the
calculated flow setpoint adapted by the three controllers mentioned above.
The output of this controller is divided in a split-range signal towards the primary pumps and the flow regulating valves of the PHE’s.
All parameters have to be adjustable on the HMI.
4.2.4.5.2.1 Coolant valves

Each plate heat exchanger (PHE) A 96.12x.01 has its own control loop as indicated in the control diagram above. Based upon the
physical cold water level in the coolant chilling tank the compressor(s) will be started. Whenever the compressor(s) starts this leads
to a temperature drop. As a result of this the flow across the PHE’s will be controlled by means of control valves V 96.120.0x which
leads to a constant outlet temperature. The opening degree of the control valves depend upon the temperature (PI) controller,
ammonia suction pressure (PI) controller, low temperature guard (PI) controller and number of PHE’s in operation.
At first start of a compressor the opening degree of the control valves is forced to 25%; from there the regulation of the opening
degree starts. In the screen you can specify how many and which PHE is in operation. The minimum flow across a coolant chilling PHE
is 25% of the design flow of 260 m3/h, being 65.0 m3/h. Below this flow fouling of the PHE may occur. The flow control valve will
regulated open or close according the calculated flow needed for the compressor(s). If the flow exceeds the minimum flow with 2
times (2x 65.0 m3/h = 130.0 m3/h) the next flow control valve of the next PHE will be controlled open. The same action for the third
valve. If the flow through the PHE’s falls under the minimum flow for certain time the one PHE flow control valve will be closed.
Whenever a low flow is being detected by the flow transmitters FIT 96.120.0x there will be generated a low flow alarm without any
action. However if a ‘no’ flow (< 8 m3/h for a period of 20 sec.) is detected just after the compressor(s) have received their start
command, the compressor(s) will be stopped immediately as it might result into freezing of the PHE’s.
To be sure that water is available from the water treatment plant it’s advisable to make an interlock between water treatment plant
and cooling plant disabling the cooling plant to start when water is not available!
Page 44
When stopping the compressors the control valves must always close after a delay. If they would close immediately, the ramp down
time of the compressor(s) would cause freezing of the plate heat exchangers.
4.2.4.5.2.2 Primary coolant pumps

The distribution chilling pumps (P 96.121.0x) are frequency controlled (SX 96.121.0x) based upon the calculated flow of the flow
controller from section 4.2.4.5.2
- One pump runs after the coolant freezing system has been switched on.
- Pumps can only start whenever ammonia detection OK and emergency stop is OK.
- The following pump(s) starts-up whenever requested flow is above the flow (setting) of the leading pump for a certain time.
- All pumps will regulate speed based on discharge pressure.
- The following pump(s) stops whenever requested flow is below the flow (setting) of the following pump for a certain time.
- Pumps switch on/off in a predefined adjustable sequence.
- Pumps with failure or out of operation status will be skipped in the start sequence.
- Start/stop and timers high/low are adjustable on the display.
Primary
conditions
All pump(s)
1 Compressor 12x OFF Pump 1 OFF
stop
Startup first
2 Compressor 12x ON Pump 1 ON Pump 1 ON
pump
Flow pump 1 =100%
Increase compressor Startup Pump 1 ON
3 Pump 1 ON and timer 60
capacity 12x second pump Pump 2 ON
seconds
Flow pump 1+2 Pump 1 ON
Increase compressor Pump 1 ON Startup third
4 =100% and timer 60 Pump 2 ON
capacity 12x Pump 2 ON pump
seconds Pump 3 ON
Pump 1 ON Flow pump 1+2+3
Decrease compressor Stop third Pump 1 ON
5 Pump 2 ON <=60% and timer 60
capacity 12x pump Pump 2 ON
Pump 3 ON seconds
Flow pump 1+2
Decrease compressor Pump 1 ON Stop up
6 <=60% and timer 60 Pump 1 ON
capacity 12x Pump 2 ON second pump
seconds
Page 45
4.2.4.5.3 Distribution coolant pumps

The coolant freezing pumps are frequency controlled (SX 121.121.0x) based upon pump pressure (PT 121.120.01). The total coolant
chilling flow is the sum which is measured by two flow transmitters (FIT 121.120.0x).
9. One pump runs after the coolant chilling system has been switched on.
10. Pumps can only start whenever ammonia detection OK and emergency stop is OK.
11. The following pump(s) starts-up whenever requested flow is above the flow (setting) of the leading pump for a certain time.
12. All pumps will regulate speed based on discharge pressure.
13. The following pump(s) stops whenever requested flow is below the flow (setting) of the following pump for a certain time.
14. Pumps switch on/off in a predefined adjustable sequence.
15. Pumps with failure or out of operation status will be skipped in the start sequence.
16. Start/stop and timers high/low are adjustable on the display.
Primary
conditions
Calculated cold Stratification tank low
1 Stratification tank empty Pump 1 in x
level < 5% cold level
External contact = All pump(s)
2 No cold request
“0” stop
External contact = Startup first
3 Cold request Pump 1 ON
“1” pump
Total flow FIT
Increase cold request 1 121.120.0x > Startup Pump 1 ON
4 Pump 1 ON
pump in. 400m3/h and timer second pump Pump 2 ON
60 seconds
Total flow FIT
Pump 1 ON
Increase cold request 2 Pump 1 ON 121.120.0x > Startup third
5 Pump 2 ON
pumps in. Pump 2 ON 800m3/h and timer pump
Pump 3 ON
60 seconds
Total flow FIT
Pump 1 ON
Decrease cold request 3 121.120.0x < Stop up third Pump 1 ON
6 Pump 2 ON
pumps in. 800m3/h and timer pump Pump 2 ON
Pump 3 ON
60 seconds
Total flow FIT
Decrease cold request 2 Pump 1 ON 121.120.0x < Stop up
7 Pump 1 ON
pumps in. Pump 2 ON 400m3/h and timer second pump
60 seconds
Total flow FIT
Coolant chilling low
5 Control min. flow Pump 1 ON 121.120.0x < x m3/h x
flow request
and timer 5 seconds
At least 1 pump
TE 121.110.16 > - Coolant chilling
6 Temperature control in + timer 5 x
5°C temperature high
minutes
Calculation coolant Total flow FIT Requested alcohol
7
chilling capacity request 121.120.0x water flow = …m3/h
Calculation coolant Total flow FIT Coolant chilling
8
chilling consumption 121.120.0x consumption = …m³
When operating with one pump the next pump is automatically stand-by for taking over in case the leading pump fails.
The first distribution pump (P 121.121.0x) will run as soon as the coolant chilling system is active. Every pump should have abilities
to on/off, manual and automatic control. The pump will be frequency controlled based upon discharge pressure (PT 121.120.01)
Whenever the pressure switch PS 121.120.01 encounters a low pressure (vacuum) the distribution pumps will automatically be
switched off.
Page 46
The temperature transmitters TT 121.110.13, TT 121.110.14 and TT 121.110.15 are only for indication on the HMI screen and for
energy calculation purposes.
For these temperatures there’s the possibility to adjust values for high/low temperature warnings and alarms.
4.2.4.5.3.2 Safety Functions

A low flow warning is issued when the sum of FIT 121.110.0x drops below a predefined flow (5 m3/h), indicating that there is a big
deviation from the normal situation.
4.2.4.5.3.3 Control
The coolant freezing supply to the consumers is transported by pumps P 121.11x.01. The leading pump is always active (when coolant
freezing system is switched on) and speed is controlled by means of discharge pressure. Starting and stopping additional pumps is
based on the created flow measured by FIT 121.110.0x.
4.2.4.6 COOLANT QUALITY CONTROL

In the central coolant inlet line of the PHE’s and each coolant outlet line, a quality sensor is placed QE96.120.01/02/03 and 04. The
measured values are send to the PLC by QT96.120.01. The measurement of the inlet and outlet are compared to detect possible
ammonia leakage in the coolant. In the PLC the difference of the 4 measurements is calculated and compared with an adjustable
alarm value. In case the measured difference is higher than the alarm setpoint, the flow valve ZT96.120.01 or 02 is forced closed and
an alarm is generated on the HMI. If QT 96.120.01 has a failure an alarm is displayed on the HMI.
Page 47
MAKE-UP AND EXPANSION TANK

In this system we have one make-up tank and two expansion tanks, one for the coolant freezing system and one for the coolant
chilling system. To select a system to fill, there are two solenoid valves installed V 96.150.01 (coolant freezing) and V 96.150.02
(coolant chilling). V 96.015.02 must be open all the time, except when V 96.015.01 is opened.
To avoid a dangerous mixture (high alcohol percentage), power supply for the ethyl alcohol pump P 96.151.02 can only be activated
when water is filled in the make-up tank. The amount of water filled in the make-up tank is measured by FIT 96.150.01.
The allowed amount of ethyl alcohol that is filled is an adjustable percentage from the amount of water that is filled, percentage for
coolant freezing and coolant chilling is different.
The amount of ethyl alcohol that is filled is measured by the raising level, calculated to liters.
The following parts are installed:

- Alcohol-water make-up pump P 96.151.01.
- Level transmitter make-up unit LT 96.150.01.
- Level transmitter in expansion unit coolant freezing LT 96.150.02.
- Level transmitter in expansion unit coolant chilling LT 96.150.03.
- Flow transmitter FIT 96.150.01 in water supply make-up tank.
- Solenoid valve feed water supply make-up tank V 96.150.01
- Solenoid valve alcohol-water supply coolant freezing system V 96.150.02.
- Solenoid valve alcohol-water supply coolant chilling system V 96.150.03.
The expansion tank is placed on the highest point in the coolant freezing / chilling system and is keeping the system under static
pressure. Also it is a buffer for the deviation of the coolant freezing liquid density.
The make-up tank is used to mix alcohol and water in the correct ratio and it is a buffer to fill the coolant freezing / chilling system
A selection (manual-off-automatic) for make-up pump P 96.151.01 can be made on the HMI.
Manual selection: The pumps can be started and stopped by means of the corresponding push button near the pump.
This position is only used to make or mix a coolant freezing / chilling solution.
The ethyl alcohol drum pomp is running for a maximum adjustable time (this time delay is adjusted in
the PLC).
Automatic selection: The pump works on command of the start / stop levels in the expansion unit.
4.3.1 SETTINGS
The following settings must be available on the HMI
- Run time make-up pump
- Run time alcohol pump
- Alarm settings
4.3.2 SAFETY FUNCTIONS

The following safeties may stop the make-up pump (alarm messages will be issued on the HMI):
- Coolant level in make-up unit is low. Warning in HMI by LT 96.150.01.
- Coolant level in make-up unit is too low. Alarm by LT 96.150.01.
- Thermal overload relay make-up pump.
- Coolant freezing level in expansion tank is high. Warning in HMI by LT 96.150.02.
- Coolant freezing level in expansion tank is too high. Alarm in HMI by LT 96.150.02.
- Coolant chilling level in expansion tank is high. Warning in HMI by LT 96.150.03.
- Coolant chilling level in expansion tank is too high. Alarm in HMI by LT9 6.150.03.
The level of the expansion tank A 96.151.02 is indicated on the HMI by means of LT 96.150.02.
The level of the expansion tank A 96.151.03 is indicated on the HMI by means of LT 96.150.03.
Make-up unit warnings (A 96.0151.001):

- Coolant level is high (stop drum pump P 96.151.01), by LT 96.150.01.
- Coolant level is low (warning message), by LT 96.150.01.
- Coolant level is too low (stop make up pump P 96.151.01), by LT 96.150.01.
Same indication is valid for the expansion unit A 96.151.02:

- Coolant freezing level is high, by LT 96.150.02.
- Coolant freezing level is too high (stop make up pump P 96.151.01), by LT 96.150.02.
Page 48
- Coolant freezing level is low, by LT 96.150.02.

- Coolant freezing level is too low (alarm message on HMI), by LT 96.150.02.
Same indication is valid for the expansion unit A 96.151.03:

- Coolant freezing level is high, by LT 96.150.03.
- Coolant freezing level is too high (stop make up pump P 96.151.01), by LT 96.150.03.
- Coolant freezing level is low, by LT 96.150.03.
- Coolant freezing level is too low (alarm message on HMI), by LT 96.150.03.
4.3.3 DRUM PUMP

A filling pump P 96.151.02 is mounted for filling ethyl alcohol. A push button switch-box is mounted near the pump. The motor start-
relay with thermal overload is mounted in the central panel and a timer for maximum running time is programmed in the PLC. The
setting of this timer is approx. 5 min. (time used for filling one drum) and is adjustable in the HMI.
The pump can only fill by manual operation, the power supply to the pump is controlled by the plc.
4.3.4 FILLING PROCEDURE
4.3.4.1 GENERAL
Normally an ethanol-water solution is used with a concentration of 20% to 25% by volume for coolant freezing (-5 ºC) and 5% to 10%
for coolant chilling (+3 ºC). Concentration may be adjusted for operation with different coolant temperatures.
In case of low level in the make-up tank, a text on the HMI will be displayed as a warning. In the make-up tank the water and ethanol
have to be mixed first before putting it into the main system.
Note:
Separately filling water and ethanol directly into the main system will lead to mixing problems and possible
freezing of the evaporators!!
4.3.4.2 MIXING MAKE UP TANK

- Switch over P 96.151.01 to local mode on the HMI.
- Manually open valve 96.150.11.
- Manually close valve 96.150.09.
The make-up system will now circulate over the make-up tank only (=mixing) if P 96.151.01 is started.
- Fill the make-up tank with factory water by opening valve V 96.150.03.
- On flow meter FIT 96.150.01 the quantity of filled water can be read. Depending on the number of drums/containers with
ethanol and the desired coolant concentration a certain amount of water has to be filled.
- Fill ethyl alcohol with drum pomp P 096.0151.002 till the correct level is reached (a percentage of the amount of filled water,
calculated to a raise of level)
- Start P 96.151.01 for approximately 15 minutes
- Stop P 96.151.01 and take a sample to check the freezing point of the mixture
4.3.4.3 FILLING MAIN SYSTEM

- Open valve 96.150.09 and close 96.150.11.
- Open V 96.150.02 in case of filling coolant freezing (V 96.150.03 will close)
- Start P 96.151.01
- The mixed solution is now pumped into the correct system.
- When at last the level in the expansion tank (LT 96.150.02 or LT 96.150.03) starts to rise, one should also start purging for air
in the rest of the system by switching on the main coolant freezing / chilling pumps and now again opening the purge valves
installed on the highpoints of the system.
- The filling stops when the level in the expansion tank (LT 96.150.02 or LT 96.150.03) is reached or low level make up tank LT
96.150.01 is issued.
Page 49
5 BREWMAX SC4U
The cooling plant of the brewery needs to provide data to the brewery scada system for trending and operating purpose. Heineken
has enrolled a new system for integrating external utility suppliers into the overall brewery scada system. Each external utility system
needs to use the same structure and layout to make the work of the operators much easier. Each supplier needs to use the same
pre-defined DB delivered by Heineken inside the PLC for communication with the Brewmax visualization of that particular utility. The
DB has a structure that is visualized in an EXEL file so called SC4U template. In the template is defined the data that the brewery
needs to use for the Brewmax system. Each data has its own unique number. An example can be find below.
The utility supplier needs to fill in the EXEL file accordingly the data that needs to provide. The grey fields in the EXEL may not be
changed by supplier. For each analog value the green fields with the unit type and decimal needs to be provided.
Page 50

NL02!17!0464 Control Philosophy

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VUNGTAU VIETNAM BREWERY – COOLING PLANT

2 GENERAL FEATURES AND OPERATING STRATEGY .................................................................................................................................. 8

3 DETAILED DESCRIPTION AND INSTRUCTIONS ..................................................................................................................................... 13

3.1.1.1.3 Wet Bulb Temperature ...................................................................................................................................16

4 Ammonia cooling systems ................................................................................................................................................... 21

4.2.3.5 Winding protection ..............................................................................................................................................37

5 Brewmax SC4U ................................................................................................................................................................... 50

Customer: Heineken Vietnam Brewery Limited Company

Customer Reference: ...

Principal: Johnson Controls

Project Manager: Bastiaan Brouwer

Principal Reference: NL02/17:0464

0.1 NL02-17-0464 Cause and effect Rev.1 JCI

Date Description Location

The control software is written using the following development software:

Siemens SIMATIC TIA Portal V15

Development software for other systems in use is:

Danfoss MCT10 V3.27

Figure 1: Simple process diagram

A.96.10.01 .02 .03 A.98.10.01 .02 .03

A.96.11.01 Expansion A.121.10.01

Figure 2: Network layout

2 GENERAL FEATURES AND OPERATING STRATEGY

Basically there are two possibilities to work with the passwords:

2.3.1 AMMONIA DETECTION

• NH3 alarm 50ppm

2.3.2 EMERGENCY STOP BUTTONS

2.3.2.1 ALARMS AND STATUS

- Pull out the key button of the emergency stop.

After this is done the cooling plant can be started up manually.

2.3.3 ENGINE ROOM VENTILATION FANS

Receiving feedback for 4 louvres = 4 ventilation fans released for running.

2.3.3.1 MODE VENTILATION FANS

In “Off mode” the exhaust fan stops or stays off.

2.3.4 AMMONIA SCRUBBER

2.3.5 GUTTER PUMP

2.3.5.1 LOW LEVEL

2.3.5.2 HIGH LEVEL

2.3.5.3 HIGH-HIGH LEVEL

2.3.6 HIGH PRESSURE SWITCHES

2.3.7 LOCAL COMPRESSOR STOPS

2.3.8 ISOLATING SWITCHES

2.3.9 UNISAB III COMPRESSOR CONTROL UNITS

2.3.10 PLC CONTROL SYSTEM

2.3.11 BLOCK-IN VALVES

Economizer coolant freezing:

Economizer coolant chilling:

Ammonia separator coolant freezing:

Ammonia separator coolant chilling:

2.3.12 SAFETY VALVES ON VESSELS AND COMPRESSORS

VISUALIZATION STRUCTURE AND OPERATING STRATEGY

2.4.2 VISUAL ELEMENTS

2.4.3 AUTO AND MANUAL MODE

To acknowledge an alarm press the ACK key on the HMI;

2.4.6 SETTINGS SCREENS

3 DETAILED DESCRIPTION AND INSTRUCTIONS

With the ACK button you can acknowledge the alarms.

Following information can be read from the screen:

Following information can be read out on the screens:

- Actual discharge pressure PT 95.120.01.

- Status of the biocide pump (indicator).

Condenser pump standby:

discharge setpoint (°C)