ABB Automation Solution for HVAC · 2017-10-21 · ABB Automation Solution for HVAC XiaoSong Wang,...

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王晓松药厂车间 DCS 系统空调自控解决方案

© ABB Group May 6, 2013 | Slide 1

ABB Automation Solution for HVAC XiaoSong Wang, PA Control Technology, 2013-06-06


Project Profile

Client: CSPC OuYi Pharma. Co. Ltd.

Site: New Technological Development Zone of Shijiazhuang in

Hebei province, China

Application: Building Management System for AHUs and Environment

Monitoring System designed and built to FDA cGMP

Scope of work Automation Solution from ABB and Validation


Project Profile

Wrokshop 8 - Oral solid dose Product: Vitamin C Tablet

Total area: 18,000 m2

Clean Area: 6300 m2

First floor: Tablet Compression, Coverage, Quarantine Materials and Products Warehouse

Second floor: Blending, HVAC, Package Material and QC

Third floor: Weighing, Sieving, Granulating, HVAC System, Water System, Raw Material and Excipient Warehouse and QC Microbiology Lab


Project Profile

Wrokshop 9 - Celphems Oral Dosage and Powder Injection

Product: Vitamin C Tablet

Total area: 18,000 m2

Clean Area: 6300 m2

First floor: Warehouse and Power Facilities

Second floor: Production areas

Third floor: QC and Utilities, HVAC Systems


Project Purpose

Design, Build, Install and Validate a Automation System Providing Building Management System (BMS) and Environment Monitoring System (EMS) for,

Workshop 8 Air Handle Unit: 23

Clean Room ( Class C, D ): Temperature, Humidity, Diff. Pressure

Workshop 9 Air Handle Unit: 28

14 for oral dosage production line

6 for powder injection production line

8 for QC labs together with others

Clean Room ( Class C, D ): Temperature, Humidity, Diff. Pressure


Scope of Project

Building Management System for Controlling AHU

Environment Monitoring System

US FDA (GAMP5) compliant

277-王晓松PPT.indd 277 2013/5/7 13:17:18此文件来自2013（第五届）弗戈制药工程国际论坛，严禁转载

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Solution 解决方案

Total Solution Redundant Controoller & Remote I/O - instead of individual DDCs and

EMSs

All in One – instead of third party software

Interfaces

Interface to VFD – Profibus DP Interface to 3rd Party PLCs - Modbus Interface for EMS, etc. - OPC Interface to BACNet

Redundancy – increase Availability of System

Controllers Input/Output

Network Power Supply

Libraries – Facility Automation Solution


Solution– System Architecture

PROFIBUS

TCP/IP 工业以太网

MODBUS

PROFIBUS

1# S800 I/O

Printer

打印机

Engineer Station

工程师站

The 3rd Party System PLC

第三方系统

2# S800 I/O

3# S800 I/O

4# S800 I/O

PROFIBUS

Operator Station 1#

操作员站 1#

Operator Station 2#

操作员站 2#

VFD

变频器

1# S800 I/O

2# S800 I/O

3# S800 I/O

4# S800 I/O

5# S800 I/O

6# S800 I/O

7# S800 I/O

8# S800 I/O

PROFIBUS

VFD

变频器


Design – AHU Type

Type 1: General + one VFD

Type 2: General + two VFD

Type 3: General + two VFD + Exhaust Fan


Design – AHU Control

Control Loops AHU Fresh Air Supply Flow Control – Enthalty Calculation

AHU Mixing Air flow control - PID

AHU Exhaust Air valve control – On/Off

AHU Supply Air Flow Control - PID

AHU Return Air pressure Control – PID

AHU Exhaust Air pressure Control - PID

AHU Air Cooling & Dehumidification - PID

AHU Air Heating - PID

AHU Air Humidification - PID


Design – Monitoring of AHU

Monitoring Loops AHU Return Air Fan Differential Pressure

AHU Supply Air Fan Differential Pressure

AHU Supply Air Temperature & Humidity Monitoring

AHU Primary HEPA filter ( G4 ) Differential Pressure

AHU Return Air HEPA Filter Differential Pressure

AHU Supply Air Medium Filter Differential Pressure


Design – Mode of Operation of AHU

Season Mode Spring & Autumn Mode

Summer Mode

Total Exhaust Air Mode

Energy saving Modes


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Design – Clean Rooms

Control Loops Diff. Pressure with Reture Air Damper

Diff. Pressure with Room Exhaust Fan

Diff. Pressure with Returen Air Damper and Room Exhause Fan

Monitoring Loops Temperature

Humidity

Diff. Pressure


Adjacent Room Differential Pressure

Usage: The room differential pressure object determines the

absolute value of differential pressure between two rooms (i.e. clean room and corridor by subtracting the room pressure in the adjacent rooms). Adjacent room differential pressure object will be connected to two production suites or zones where static room pressure is available in an application.


Enthalpy & Mixed Air Calculation

Enthalpy Calculation: Based on dry bulb temp and humidity. The Dew Point is

also calculated.

Mixed Air Calculation: Determine high and low enthalpy conditions based on

outside and return enthalpies. When outside enthalpy is higher than return enthalpy, ‘Outside Air’ will be used for heating. When return enthalpy is higher, ‘return air’ will be used for heating. The output is used to switch to/from an economizer mode within an AHU template

ApplicationX

AHU Template

EnthalpyOutside Air

EnthalpyReturn Air

Mixed Air Compare

Enthalpy Comparison

EnthalpyDifference

EconomizerON/Off


Air Handler Unit (Supply & Recirculation)

Usage:

The AHU template is used in an application directly if no changes are necessary or copied into a project specific library and customized to project needs.

The figure depicts a possible physical layout of an AHU.

The location of heating and cooling coils, sensors, switches, filters, etc will vary from installation to installation, but the control scheme will be the same

Recirc AHU Template

AHU

Heating Vlv

CoolingVlv

HumidVlv

PI

TT

FT

RH

HSel

DPS

FZ

FS

AHU

Zones

TT RH

Return Air

Supply AirOA

EA

RA

Supply Temp

RH Ret. PID

Clg PIDHtg PID

RH PID

DPSTT


Temperature State Driver

Usage: Controls three separate PID loops to control one

process variable (supply temperature), while preventing conflicts.

Use O.A. based on enthalpy/temperature condition. Economizer!

Simple tuning of each separate PID. Parameters are optimized for the end element.

The state driver consists of a Sequential Function Chart (SFC) with 6 states (Heating w/Low Enthalpy, Damper Cooling w/Low Enthalpy, Cooling w/Low Enthalpy, Heating w/High Enthalpy, Damper Cooling w/High Enthalpy, Cooling w/High Enthalpy)

AHU Template

Heating Vlv

CoolingVlv

TT

TemperatureState Driver

Damper

EnthalpyOutside Air

EnthalpyReturn Air

Mixed Air Compare

Enthalpy Comparison

PIDPar

PIDPar

PIDPar


Facility Startup/Shutdown Sequence

Usage:

Coordinate the startup and shutdown within a facility or plant area.

Connects to any major pieces of equipment (AHUs,Production Suites, Chillers, Boilers, Schedules, etc.).

Used for initial startups and transitioning from Main Power to Back-Up Power conditions.

ApplicationX

AHU2Supply ABB Drive

Fan Control Temp Control

Pressure ControlHumidity ControlAHU7

Supply&RecircFan Control

Temp ControlPressure ControlHumidity Control

Coordinate Startup & Shutdown of

major equipment

Startup/ShutdownSequence

AHU1Supply

Fan Control Temp Control

Pressure ControlHumidity Control

Chiller

To other Applications


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Scheduler Objects

Energy saving strategy. Temperature set-points are set lower during periods when the building / facility is occupied / un-occupied (night time and weekend)

7 day Scheduler (Monday – Sunday)

Up to 6 timed events per day

Manual Override based on start and stop time

Program in Special and Holiday Days (up to a 1yr adv.) in Scheduler Holiday

Optimize start and stop times of system (AHU, Chiller etc) using Scheduler Optimizer

One to many pieces of equipment can connect to one scheduler

Up to 8 user definable output modes for scheduler (i.e. Occupied, Unoccupied, Full speed, Half Speed)

Optionally, use Batch Manager to schedule equipment


Scheduler Objects

ApplicationX

AHU TemplateFan Control

Temp ControlPressure ControlHumidity Control

Scheduler SchedulerOptimizer

SP, PV

O.A.Temperature

SchedulerHolidays To other

equipment

To other Applications

Usage:


Utility Objects – Chiller Distribution template

Usage: The Chiller Distribution template is used directly if no

changes are necessary or copied into a project specific library and customized to project needs.

This diagram depicts a possible physical layout of a Chiller.

The inlet pumps into the chillers are fixed speed and are started with each chiller startup.

The secondary pumps are variable speed to control the flow or differential pressure. The pumps are started and stopped to maintain the necessary flow/DP set-point.

Other utility equipment can be sequenced in place of a chiller (boilers, compressors, etc)

Chiller Functions Variable Flow Primary/Secondary Template

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TT

DP

CHWS

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Chiller 1

Chiller 2

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A

CChiller 3

CoolingVlv

CoolingVlv

CoolingVlv

CHWR

FT

Temp SP Reset /Demand SP Reset

Flow/DP SP Reset

TT

Secondary PumpsVariable Speed Pumps

Primary PumpsFixed Speed Pumps


Graphic 1 - AHU


Graphic 2 - AHU


Graphic 3 - Chiller


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Graphic 4 – AHU Overview


Graphic 5 - Room



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ABB Automation Solution for HVAC · 2017-10-21 · ABB Automation Solution for HVAC XiaoSong Wang,...

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