VENTILATION SYSTEM COMMISSION REPORT

1. General information

This technical report contains the results of tests and commissioning of automation systems for ventilation systems P1-B1, P2-B2, P3-B3, P4-B9, B4, B5, B6, B7, PB1, mounted in building No. 5 

The work was carried out according to the program given in this report. In the course of the work, the automation objects were analyzed, the design documentation, quality checks of the installation work and the technical condition of the automation equipment were carried out, an application package for the microprocessor controller was developed, and control loop settings were made.

On the basis of the obtained results, conclusions were formulated and recommendations on equipment operation were made.

2. Program of work

1. Analysis of the design and technical documentation, the requirements of manufacturers of equipment automation systems.

2. Acquaintance with the features of the equipment operation (start and stop conditions, equipment behavior under variable conditions, protection action, main disturbances affecting the equipment operation).

3. Development of methods for calculating the performance indicators of control circuits.

4. Development of control algorithms for technological equipment of ventilation systems.

5. Development of an application package.

6. Verification of the installation of automation equipment and its compliance with the project, the identification of deficiencies and defects in installation.

7. Checking the technical condition of automation equipment.

8. Conduct autonomous testing of automation equipment.

9. Testing, debugging and adjustment of application programs based on the results of autonomous system setup.

10. Comprehensive testing of the operation of ventilation systems, coordination of input and output parameters and characteristics.

11. Analysis of test results and development of recommendations for equipment operation.

12. Registration of the technical report.

3. CHARACTERISTICS OF AUTOMATION OBJECTS

The object of automation is the process equipment of ventilation units P1-B1, P2-B2, P3-B3, P4-B8, B4, B5, B6, B7, PB1.

Ventilation units P1-B1, P2-B2 are designed to maintain the air in industrial premises with the following parameters:

· temperature ……………………………. + 21 ± 2 ° C;

· Relative humidity ……………. 50% ± 10% ;;

· Cleanliness class…. ………………. ……… .Р8.

Indoors clean air is not standardized.

P1-V1, P2-B2 ventilation units are made according to a scheme with partial redundancy by installation of P2-B2 installation of P1-V1 unit when it stops or fails.

 Installation П1-В1 is made according to the direct-flow scheme. The installation includes:

· Intake air valve;

· Filter section;

· Section of the first heating;

· Irrigation chamber;

· Cooling section;

· Section of the second heating;

· Section of the supply fan;

· Fresh air filter section;

· Fresh air valve;

· Section of the exhaust fan;

· Exhaust air valve.

The P2-B2 installation is executed according to the direct-flow scheme. The installation includes:

· Intake air valve;

· Filter section;

· Section of the first heating;

· Irrigation chamber;

· Cooling section;

· Section of the second heating;

· Section of the supply fan;

· Fresh air filter section;

· The reserve air valve;

· Section of the exhaust fan;

· Exhaust air valve.

Heat supply of air heaters of ventilation units P1-B1, P2-B2 is provided from the existing heat point, the heat carrier for the ventilation system is the heating water with parameters 130/70 ° С in the winter (heating) period. In the summer period, the first heating circuit is not used. In the summer, hot water with parameters 90/70 ° C (heat source - electric heater) is used to heat the air heater of the second heating.

The control units of air heaters of the first and second heating are made with mixing pumps. To change the flow rate of the coolant through the air heater of the first heating, a two-way control valve is provided. To change the flow of coolant through the air heater of the second heating there is a three-way control valve.

Refrigeration of coolers P1-B1, P2-B2 is provided from the chiller. A 40% ethylene glycol solution with parameters 7/12 ° C is used as a coolant. To change the flow of coolant through air coolers, three-way control valves are provided.

Installation P3-B3 is made by the direct-flow scheme. The installation includes:

· Intake air valve;

· Filter section;

· Section of the supply fan;

· Section of the exhaust fan;

· Exhaust air valve.

The installation P4-B8 is made according to the direct-flow scheme. The installation includes:

· Intake air valve;

· Filter section;

· Section of the supply fan;

· Section of the exhaust fan;

The heat supply of the air heaters of the P3-B3, P4-B8 ventilation units is provided from the existing heating point, the heat carrier for the ventilation system is the heating water with parameters 130/70 ° С in the winter (heating) period. In the summer period, the heating circuit is not used.

Control units for air heaters are made with mixing pumps. To change the flow of coolant through the heater has a two-way control valve.

The B4, B5, B6, B7 installations are made according to the direct-flow scheme. The installations include:

· Section of the exhaust fan;

· Exhaust air valve.

The installation of PB1 is based on the recirculation scheme. The installation includes:

· Intake air valve;

· Section of the supply fan;

· Recirculation air valve.

 

4. Characteristics of automation systems

To solve the problems of automation of P1-B1, P2-B2, P3-B3, P4-B8, B5, B6, B7, PB1 installations, a set of technical means of production f. Honeywell based on Excel 5000 series I / O conversion modules and Excel  WEBmicroprocessor controller series . The controller of this series is freely programmable, provided with hardware and software for dispatching.

For the organization of information exchange between the controller P1-B1, P2-B2, P3-B3, P4-B9 and the dispatcher computer, a local area network Ethernet with the BACNET protocol is provided .

A local LON network is provided for organizing the exchange of the I / O conversion modules and the controller .

Manual and automatic mode is provided to control the ventilation unit.

Manual mode is used to test equipment during the adjustment works.

Control in the automatic mode is carried out by the controller commands.

The technological equipment of the P1-B1, P2-B2, P3-B3, P4-B8 ventilation units is controlled from the ShAU-P control cabinet.

To solve the problems of automation, a complex of Honeywell hardware was used , which includes:

· Microprocessor controller Excel WEB S1000;  

· Modules for converting analog outputs XFL 822 A ;

· Modules for converting analog inputs XFL 821 A ;

· Modules for converting digital outputs XFL 824 A ;

· Modules for converting digital inputs XFL 823 A ;

P1-V1 ventilation unit:

· Temperature sensors based on thermistors:

 - air after the heater first heating LF 20 (TE P1.1);

- air after the cooling circuit T7411A1019 (TE P1.4);

 - return water after the heater first heating VF 20 A (TE P1.2);

 - return water after the second preheater heater VF 20 A (TE P1.3);

· Duct temperature and humidity sensors:

 - supply air H 7015B1020 ( MRE / TE P1);

 - exhaust air H 7015B1020 ( MRE / TE B1);

· Flow rate sensors:

 - supply air IVL 10 ( S E P1);

· Control valve actuators with control signal 0..10 V:

- heating circuits ML 7420 A 6009 ( Y П1.2),   M 7410 E 2026 ( Y П1.3);

- cooling circuit ML 7420 A 6009 (Y П1.4 ) ;

· Thermostat for protection of the heater of the first heating circuit against freezing Т6950А1026 ( TS П1 );

· Sensors-relays of differential pressure on the filter DPS 200 ( PDS P1.1, PDS P1.2);

· Differential pressure switch-relay on the inlet fan DPS 400 ( PDS П1.3);

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS В1);

· Two -position actuators of air valves  S 20230-2 POS - SW 2 ( Y П1.1), S 10230-2 POS ( Y В1);

· Air valve drive with control signal 0..10 V N 10010 ( Y П1.5);

· Frequency converter for changing the rotational speed of the motor of the supply fan HVAC 07 C 2 / NXLOPTC 4 (FC-P1);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

ventilation unit П 2 -В 2 :

· Temperature sensors based on thermistors:

            - outdoor air A F 20 (TE HB);

 - air after the heater first heating LF 20 (TE P2.1);

- air after the cooling circuit T7411A1019 (TE P2.4);

 - return water after the first preheater heater VF 20 A (TE P2.2);

 - return water after the second preheater heater VF 20 A (TE P2.3);

· Duct temperature and humidity sensors:

 - supply air H 7015В1020 ( MRE / TE П2);

 - exhaust air H 7015B1020 ( MRE / TE B2);

· Flow rate sensors:

 - supply air IVL 10 ( S E P2);

· Control valve actuators with control signal 0..10 V:

- heating circuits ML 7420 A 6009 ( Y П2.2, Y П2.3);

- cooling circuit ML 7420 A 6009 (Y P 2 .4 ) ;

· Thermostat of protection of the heater of the first heating circuit against freezing Т6950А1026 ( TS П2 );

· Sensors-relays of differential pressure on the filter DPS 200 ( PDS P2.1, PDS P2.2);

· Sensor-differential pressure switch on the inlet fan DPS 400 ( PDS P2.3);

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS B2);

· Two -position actuators of air valves  S 20230-2 POS - SW 2 ( Y П2.1), S 10230-2 POS ( Y В2);

· Air valve drive with control signal 0..10 V N 10010 ( Y П2.6);

· Frequency converter for changing the rotational speed of the engine of the HVAC 16 C 2 / NXLOPTC 4 intake fan( PCh -P2);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

ventilation unit П 3 -В 3 :

· Temperature sensors based on thermistors:

 - supply air LF 20 (TE P3.1);

- return water after heating heater VF 20 A (TE P3.2);

· Thermostat to protect the heating circuit heater from freezing T6950A1026 ( TS P3);

· Differential pressure sensor switch on the DPS 200 filter ( PDS P3.1);

· Differential pressure switch-relay at the inlet fan DPS 400 ( PDS P3.2);

· Differential pressure switch relay on exhaust fan DPS 400 ( PDS B3);

· Two -way actuators of air valves  S 20230-2 POS - SW 2 ( Y П3.1), S 10230-2 POS ( Y В3);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

P4-B8 ventilation unit:

· Temperature sensors based on thermistors:

 - supply air LF 20 (TE P4.1);

- return water after heating heater VF 20 A (TE P4.2);

· Thermostat to protect the heating circuit heater from freezing T6950A1026 ( TS P4);

· Sensor-differential pressure switch on the filter DPS 200 ( PDS П4.1);

· Pressure differential pressure switch at the inlet fan DPS 400 ( PDS П4.2);

· Two -way actuator of the air valve  S 20230-2 POS - SW 2 ( Y П4.1),

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

B4 ventilation unit:

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS В4);

· Two -way actuator of the air valve  S 10230-2 POS ( Y В4);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

B5 ventilation unit:

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS B5);

· Two -way actuator of the air valve  S 10230-2 POS ( Y В5);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

B6 ventilation unit:

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS B5);

· Two -way actuator of the air valve  S 10230-2 POS ( Y В5);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

B7 ventilation unit:

· Differential pressure switch-relay on the exhaust fan DPS 400 ( PDS B5);

· Two -way actuator of the air valve  S 10230-2 POS ( Y В5);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

B8 ventilation unit:

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

ventilation unit PB1:

· Temperature sensors based on thermistors:

             - fresh air  LF 20 (TE PB1);

· Drive of air valves with control signal 0..10 V S 20010 SW 2 ( Y PB1.1) and N 20010 ( Y PB1.2);

· Elements of the switching equipment of the control cabinet (control keys, relay contacts and additional contacts of magnetic starters).

The main characteristics of the equipment subjected to the tests are listed in Tables 4.1 and 4.2.

Table 4.1 - the main characteristics of the sensors

Measured parameter	Sensor type	Type of sensitive element	Working range
one	2	3	four
Outdoor temperature	AF 20	NTC thermistor, resistance, 20kΩ at 25ºС	- 2 0 .. + 3 0 ºС
The air temperature after the circuit of the first heating of the P1-B1, P2-B2 installations, the flow temperature air units P3-B3, P4-B8, PB1	Lf 20	NTC thermistor , resistance, 20kΩ at 25ºС	-20 .. + 100 ºС
Air temperature after cooling circuit of installations P1-B1, P2-B2	T7411A1019	Pt 1000, resistance, 1000 ohms at 0ºС	- 4 0 .. + 8 0 ºС

 

Continuation of table 4.1

one	2	3	four
Heat carrier temperature after the air heater of the first and second heating of the P1-B1, P2-B2 installations, after the air heaters of the P3-B3, P4-B8 installations	VF 20A	NTC thermistor , resistance, 20kΩ at 25ºС	-20 .. + 110 ºС
Temperature and relative humidity of supply and exhaust air of P1-B1, P2-B2 installations	H 7015B1020	NTC thermistor , resistance, 20kΩ at 25ºС; ChE capacitive type 0..10 V	-30 .. + 70 ºС     5..95% Rh
Air temperature after air heater of the first heating P1-B1, P2-B2, temperature after the air heater of the P3-B3, P4-B8 installations	T6950A1026	Capillary	-7 .. + 16 ºС
Pressure drop across the filter	DPS 200	Silicone membrane	20..200 Pa
Pressure drop across the filter	DPS 400	Silicone membrane	40..400 Pa

 

Table 4.2 - Main Drive Characteristics

Controlled equipment	type of drive	Control signal	The presence of a return spring	Time of the full stroke opening / closing, with	Working stroke	Torque Nm
Air valves	S20010 N10010 N 20 010	= 0 ..10V	there is not not	90/20 110/110 110/110	95 ° ± 3 °	20 ten 20
Control valves for coolant and coolant-body	ML 7420A6009   ML 7410 E2026	= 0..10V	not	60/60   150/150	20 mm   6.5 mm	600   180

 

Technical descriptions of the installed automation equipment are given in the annex to the report.

5.  The results of the analysis of project documentation and quality control of installation works

The project of automation of ventilation systems (AOB brand section) and installation of automation systems was performed

The analysis of the project documentation showed that the working drawings were made in accordance with the requirements of the current regulatory documents and the technical documentation of the equipment manufacturers.

The performed check of the compliance of the installation of the automation equipment with the project and the requirements of the manufacturers did not reveal significant deficiencies and defects.

6. INDICATORS OF THE QUALITY OF WORK OF THE REGULATION CIRCUIT AND THE METHOD OF THEIR CALCULATION

6.1. Mathematical model of the control loop

To calculate the performance of the control circuits, a mathematical model of the control loop was adopted in the form of a closed automatic control system (ATS) with regulation according to the Polzunov-Watt principle. The structural scheme of the SAR is shown in Figure 6.1, where the following notation is adopted:

Δу - adjustable parameter;

yzad is the set value of the controlled parameter (setpoint);

u - control action;

g - disturbing effect;

CR - gain;

Ti is the integration constant;

TD - constant differentiation.

The choice of the type of control law was made on the basis of the carried out analysis of the characteristics of the automation object (p. 3), the design features of the sensors and actuators (p. 4), and also the experience of setting up regulators of similar systems.

As the law of regulation was selected:

· The isodromic law (PI regulation), while it is assumed TD = 0;

The isodromic law was used for the following control loops:

air temperature behind air coolers;

supply air temperature;

return heat carrier temperature after air heater of the first heating;

humidity when systems are operating in the WINTER / SUMMER mode.

 

6.2. The performance of the control loop and

the transition process. The evaluation of the control loop was carried out on the basis of an analysis of the characteristics of the transition process. Transient processes in ventilation and air conditioning systems equipped with automatic control systems are characterized by the following indicators (see Fig. 6.2):

1) the static regulation error is defined as the maximum deviation of the value of the adjustable parameter from its specified value after the end of the transition process;

2) dynamic error is defined as the maximum deviation of the controlled parameter from the specified value, observed during the transition process. In aperiodic regulation processes, there is only one maximum and one dynamic error value . In the case of oscillatory transients, several maxima and, consequently, dynamic error values are observed:  (see Fig. 6.2);

3) the degree of attenuation of the transition process y is determined by the formula: (2)

where - values of a dynamic error;

4) the value of overshoot j is determined by the ratio of two adjacent maxima (3)

5) the duration of the transition process ;

6) the number of maxima during regulation.

 

6.3. Reference disturbances

Under the perturbations are the factors that cause the deviation of the adjustable parameter from its specified value and upset the balance in the SAR.

To check the quality of the control loop, reference perturbations of the following types were introduced.

Perturbation of the form 1. 

To form a disturbance, the position of the control valve stem was changed . The disturbance is shown in fig. 6.3.

 

The selection of the parameters of the reference perturbation should be made in the following order:

1) turn off the control valve actuator (at the time of formation of the disturbance);

2) create a disturbance by manually moving the valve actuator to the "more" ("less") side by 10-15% of the stroke value, focusing on the pointer scale;

3) turn on the drive, determine the value of the deviation of the controlled parameter and analyze the transition process. If the obtained deviation of the regulated parameter is comparable with the amplitude of its pulsation and the transition process is poorly observed, increase the perturbation by 1.2..2 times;

4) turn off the drive, form the corrected disturbance, turn on the drive again. If during the transition process the adjustable parameter changes within acceptable limits and this change is clearly visible, we can assume that the reference disturbance is selected.

A perturbation of the form 2. 

To cause a disturbance, a change in the reference was used. The disturbance plot is shown in Figure 6.4.

The selection of the parameters of the reference perturbation should be made in the following order:

1) change the reference stepwise by 10..15% of the value of the control range;

2) determine the value of the deviation of the controlled parameter and analyze the transition process. If the maximum deviation of the value of the regulated value is small and the transition process is not clearly visible due to pulsations or a small change in the controlled value, increase the disturbance effect by 2..3 times, taking into account that the adjustable parameter during the transition process does not reach the maximum permissible value for this system ;

3) Repeat the experience, forming a corrected external disturbance. If the transition process is clearly expressed and is characterized by a sufficient change in the regulated value, this disturbance can be taken as a reference for this control loop.

 

6.4. Control loop test method

6.4.1. Procedure for quality control of the control loop

The quality of the control loop is assessed according to the compliance of the registered transients (when forming external and internal disturbances) to the established requirements.

The quality control of the control loop and its parameters should be checked in the following order:

1) set the calculated values of the parameters:

· Setting an adjustable value;

· PID-controller parameters;

2) turn on the ventilation system and monitor the operation of the automation system;

3) prepare measuring instruments for recording parameters;

4) after the installation of the ventilation system to the established mode, proceed to the tests, introducing the disturbances provided for by the test program.

 

6.4.2. Tests of the control loop when applying a disturbance of the form 1

To test the control loop with a perturbation of type 1, you need:

1) Select the value of the reference internal disturbance in accordance with clause 6.3.

2) Apply a reference perturbation in the following order:

· Start recording the values of the parameters (regulatory impact and regulated value);

· Fix the value of the adjustable parameter for 1..3 minutes before causing a disturbance and record these values until the end of the transition process every 10..30 s. These intervals are selected depending on the duration of the transition process;

· Apply standard perturbation.

3) Process the resulting transition graphs and determine the performance of the control loop in accordance with clause 6.2.

4) Observe the following parameters of the transient process for internal and external disturbances when optimally adjusting the control loop:

the maximum deviation of the value of the regulated value  must not exceed the permissible limits;

attenuation degree y should be in the range of 0.85..0.9;

the transition process should not be delayed in time.

5) When adjusting the control loop, refer to the following:

· If during the experiment the degree of attenuation of the process is less than 0.85, and the transition process has a pronounced oscillatory character, it is necessary to reduce the gain coefficient Kp, or increase the integral component Ti;

· If the transient process has the form of an aperiodic transient process and is delayed in time, the gain coefficient Kp should be increased, or the integral component Ti should be reduced;

· Change the values of Kp, Ti to produce separately;

· Make adjustments when applying internal reference perturbations in the direction of "more" and "less" alternately.

6) Tests should be carried out until a satisfactory transient is obtained.

7) Fix:

· The load value at which the control loop was tested;

· Position setting;

· The value of the reference perturbation;

· Satisfactory transient parameters.

 

6.4.3. Tests of the control loop when applying a disturbance of the form 2

To test the control loop with a perturbation of type 2, you need:

1) Select the value of the reference internal disturbance in accordance with clause 6.3.

2) Apply a reference perturbation in the following order:

· Start recording the values of the parameters (regulatory impact and regulated value);

· Fix the value of the adjustable parameter for 1..3 minutes before causing a disturbance and record these values until the end of the transition process every 10..30 s. These intervals are selected depending on the duration of the transition process;

· Apply reference disturbance "more".

Next, perform the actions in the sequence described in clause 6.4.2.

 

6.4.4. Tests of the control circuit in case of emergency lowering of the air temperature behind the heater

The operation of the anti-freeze thermostat is characterized by the following parameters:

· Temperature of operation  ;

· The value of the minimum return temperature when the thermostat is triggered ;

· The duration of lowering the temperature of the return coolant below the specified minimum value .

The quality check of the thermostat and the control loop, as well as the adjustment of the PID controller settings should be made in the following order:

1) set the following settings to the calculated position: thermostat setting element (setpoint);

2) include a ventilation unit;

3) control the exit to the mode of maintaining the set value of the supply air temperature;

4) install the probe after the air heater;

5) turn on the automatic control system;

6) record the system parameters before causing a disturbance;

7) bring disturbance to the system, for which gradually closing the valve on the supply pipe, to achieve a decrease in temperature behind the heater until the thermostat triggers;

8) to restore normal heat supply of the air heater, for which purpose to fully open the valve on the supply pipe;

9) process the test results;

10) when adjusting the control loop setting, one should be guided by the recommendations of clause 6.4.2;

11) tests carried out to obtain a satisfactory transition process.

7. RESULTS OF THE VERIFICATION OF THE TECHNICAL CONDITION OF AUTOMATION EQUIPMENT

The check of the technical condition of the automation equipment was carried out using measuring instruments according to the list of Appendix 1. The results of the check are given in Appendix 10.

Check temperature sensors.

The temperature sensors were tested by measuring the resistance of the NTC 20, Pt 1000 sensitive element and comparing the measured value with the table value (see Appendix 10, Table 1) at a fixed temperature at the time of measurement.

The installed temperature sensors were recognized as working, the accuracy of the readings was within the permissible error.

Checking the control valve actuators on the heat and coolant.

Checking the actuators of the control valves of the heating and cooling circuits was carried out by comparing the setpoint set from the operator's terminal to open / close the control valve with the actual position of the valve actuator after working out the command (see Appendix 10, Table 2).

The actuators of the control valves are good and the specified commands are fulfilled.

Check the differential pressure sensor relays on filters and fans.

To test the pressure on the pressure side of the sensor and the vacuum on the suction side. The sensor was monitored by turning on the indicator light of the automation panel and changing the state of the controller's discrete input (see Appendix 10, Table 3).

Differential pressure switch relays are good.

Check thermostats for protection against freezing of air heaters.

Testing thermostats was carried out by cooling the sensitive element to the mechanical circuit of the changeover thermostat contact. The performance monitoring was carried out by turning on the light of the automatic control panel and changing the state of the controller's discrete input (see Appendix 10, Table 4).

Thermostats are working and provide air heater protection against freezing.

Checking the actuators of the air valves.

Checking the actuators of the contour air valves was carried out by comparing the setpoint set from the operator's terminal to open / close the control valve with the actual position of the valve actuator after working out the command (see Appendix 10, Table 5).

All drives are good. When the fan stops, the drives close.

Testing the operation of control keys, relay contacts and magnetic starters.

The operability of the control keys, relay contacts and magnetic starters was checked by mechanically closing the contacts of the corresponding keys, relays and magnetic starters. The performance monitoring was carried out by changing the state of the discrete input of the controller (see Appendix 10, Table 6).

8. Application Software Development 

Application programs were developed using the specialized software package CARE XL Web version 8.02.

The programs were developed in accordance with the algorithms described in Appendices 6, 7, 8. The algorithms correspond to the circuit design of the AOB sections and implement the following main functions of automation systems:

for ventilation systems P1-B1, P2-B2:

· Maintaining the temperature of the supply air supplied to the serviced premises by controlling the actuators of the control valves of the cooling circuit (in the summer operation mode), heating circuits (in the winter operation mode);

· Maintaining supply air humidity by controlling the equipment of the irrigation chamber and the control valve of the second heating circuit;

· Shutdown of the air handling unit by the “Fire” signal;

· Maintaining the temperature of the return network coolant according to the schedule in the "parking" mode (during the period of winter operation);

· Continuous operation of circulation pumps during the period of winter operation and the prohibition of their start during the period of summer operation;

· Control of supply and exhaust fans;

· Protection of the intake, exhaust fans and the circulation pump from failure in abnormal and emergency situations;

· Protection of the air handling unit against freezing;

· Monitoring the operation of the process equipment of air handling units;

· Issue of light signals to the front panel of the automation panel on the working and emergency modes of operation of equipment of air handling units;

· Output / input of parameter values and control commands to / from the dispatcher’s automated workplace.

The algorithm of the installation control programs P1-B1 and P2-B2 is given in Appendix 6.

for ventilation systems P3-B3, P4-B8:

· Maintaining the supply air temperature (during the period of winter operation) supplied to the serviced premises by controlling the drive of the control valve of the heating circuit;

· Supply of outdoor air to the serviced premises (during the period of summer operation);

· Shutdown of the air handling unit by the “Fire” signal;

· Maintaining the temperature of the return network coolant according to the schedule in the "parking" mode (during the period of winter operation);

· The continuous operation of the circulating pump during the winter operation period and the prohibition of its starting during the summer operation period;

· Control of supply and exhaust fans;

· Protection of the intake, exhaust fans and the circulation pump from failure in abnormal and emergency situations;

· Protection of the air handling unit against freezing;

· Monitoring the operation of the process equipment of the air handling unit;

· Issue of light signals to the front panel of the automation panel on the working and emergency operation modes of the equipment of the air handling unit;

· Output / input of parameter values and control commands to / from the dispatcher’s automated workplace.

The algorithm of the P3-B3 and P4-B8 installation management programs is given in Appendix 7.

for ventilation systems B4, B5, B6, B7:

· Exhaust air from the serviced premises;

· Shutdown of installations on a signal "Fire";

· Control of the exhaust fan;

· Protection of the exhaust fan from failure in abnormal and emergency situations;

· Control of the installation process equipment;

· Issue of light signals to the front panel of the automation panel on the working and emergency modes of operation of the installation equipment;

· Output / input of parameter values and control commands to / from the dispatcher’s automated workplace.

The algorithm of the B4, B5, B6, B7 installation management programs is given in Appendix 8.

for air handling unit PB1:

· Maintaining the temperature of the supply air supplied to the compressor station by controlling the actuators of the recirculating and receiving air valves;

· Shutdown of the installation by the “Fire” signal;

· Control of the supply fan;

· Protection of the intake fan against failure in abnormal and emergency situations;

· Control of the installation process equipment;

· Issue of light signals to the front panel of the automation panel on the working and emergency modes of operation of the installation equipment;

· Output / input of parameter values and control commands to / from the dispatcher’s automated workplace.

The algorithm of the PB1 installation control program is given in Appendix 8.

The text of the installation management programs is given in Appendix 9.

9. Conducting TESTS and commissioning

After carrying out quality checks of the installation, the technical condition of the automation equipment and the elimination of the identified deficiencies, the developed programs were loaded into the operational storage devices (RAM) and they were written into the nonvolatile memory of the controller. A preliminary check of the correct operation of the programs was carried out using the built-in XwOnline debugger .

Verification of work for the Excel WEB controller was carried out using a laptop computer and Internet Explorer browser .

Tests of automation systems were carried out in the sequence determined by the test programs, which are given in Appendices 2, 3.

Before testing, a preliminary testing of the systems was carried out, bringing them to working condition. Before the start of each test cycle, the systems were brought to a steady state. The test cycle was considered complete after the completion of the transition process, i.e. until the restoration of the steady state of the system. The tests were terminated if the measured parameters reached values outside the limits established by the test program.

During the tests, the following conditions were met:

· The equipment is in the mode for which the tested system was calculated;

· The tested system is in operation and maintains the set value of the regulated value;

· The adjustable range is sufficient to eliminate the disturbances introduced during the tests;

· During operation of several control loops interconnected by the technological process (control circuits of the first and second heating, humidity, air cooler), those circuits were first of all established and tested that eliminate disturbances resulting from the operation of other circuits;

· Technological protection devices are included to prevent the occurrence of an accident in the event of the malfunction of the control loop under test.

When adjusting the control loops, the following quality indicators were determined:

· Dynamic error ;

· The degree of attenuation of the transition process y

· The value of the overshoot j;

· The duration of the transition process TPP;

· The number of maxima of the dynamic error during regulation  .

The results of the calculation of indicators are given in paragraph 10.

10. Test results and commissioning

In the process of commissioning the following work was carried out:

· Testing of individual elements and units;

· Actuation of technological protection devices;

· The inclusion of systems in the work and their output on the nominal mode;

· Adjustment of control circuits to maintain the set value of the adjustable parameter;

· Checking the correctness of the response of the control loops to the disturbances introduced;

· Adjustment of parameters of control circuits.

Testing of elements and assemblies showed that all of them are in working condition.

During the tests, the reaction of the automation system to the operation of the following technological protection devices was tested:

· Capillary thermostats of protection against freezing;

· Anti-freeze program thermostats based on a return heat carrier temperature sensor;

· Control circuits for triggering magnetic actuators;

· Sensors of the fan belt break;

· Thermal relays of electric motor protection;

· Schemes for switching off fans by the “FIRE” signal from the building APS.

Inspections of technological protection devices were carried out in the following sequence.

Checking the operation of capillary thermostats for protection against freezing was carried out according to the method described in section 6.4.4. The thermostat setting was set to its scale at 5ºС. The specified minimum return heat carrier value was assumed to be 12 ºС (for installations П1-В1, П3-В3, П4-В8) and 18 ºС (for installation П2-В2). The results of inspections when the systems are in the working and parking modes are given in Table 10.1.

During repeated tests of the systems, the setpoint value was determined at which the parameter = 0. It amounted to 10.5 ºС (for installations P1-B1, P3-B3, P4-B8) and 16.5 ºС (for installation P2-B2).

Table 10.1 - Results of checks of automation systems when triggered

freeze protection capillary thermostats

Ventilation system	Mode	, ºС	, ºС	, ºС	, with
P1-B1	Job	five	12	10.5	23
P1-B1	Parking	five	12	10.6	22
P2-B2	Job	five	18	16.5	25
P2-B2	Parking	five	18	16.8	20
P3-B3	Job	five	12	10.3	nineteen
P3-B3	Parking	five	12	10.5	17
P4-B8	Job	five	12	10.8	20
P4-B8	Parking	five	12	10.9	22

 

Testing the operation of anti-freeze program thermostats based on a return heat carrier temperature sensor was carried out according to the procedure described in section 6.4.4. The setting of the programmable thermostat controller 52 Px _ RWFrzPidSet was set at 12 ° C (for installations P1-B1, P3-B3, P4-B8, x = 1,3,4) and 18 ºC (for installation P2-B2, x = 2). The value  52 Px _ RWFrzStatSet was taken equal to 10.5 ° С (for installations П1-В1, П3-В3, П4-В8) and 16.5 ° С (for installation П2-В2). The results of checks when the systems are in working and parking modes are given in table 10.2.

Table 10.2 - Results of inspections of automation systems when anti-freeze program thermostats are triggered based on a return heat carrier temperature sensor

Ventilation system	Mode	Temperature of return heat carrier when thermostat triggers, ºС	, ºС	, with
P1-B1	Job	eleven	11.1	0
P1-B1	Parking	eleven	11.6	0
P2-B2	Job	17	17.1	0
P2-B2	Parking	17	17.6	0
P3-B3	Job	eleven	11.3	0
P3-B3	Parking	eleven	11.5	0
P4-B8	Job	eleven	11.2	0
P4-B8	Parking	eleven	11.6	0

 

As can be seen from the table, the operation of the anti-freeze protection thermostats based on the return heat medium temperature sensor is satisfactory.

Verification of the control circuit for triggering magnetic actuators was carried out to form the following alarm signals:

System P1-B1: 52 P 1_ RaFanStsAlm , 52 P 1_ SaFanStsAlm , 52 P 1_ Htg 1 PmpStsAlm ;

System P2-B2: 52 P 2_ RaFanStsAlm , 52 P 2_ SaFanStsAlm , 52 P 2_ Htg 1 PmpStsAlm ;

A3-B3 System 52 P 3_ RaFanStsAlm , 52 P 3_ SaFanStsAlm , 52 P 3_ Htg 1 PmpStsAlm ;

System P4-B8: 52 P 4_ RaFanStsAlm , 52 P 4_ SaFanStsAlm , 52 P 4_ Htg 1 PmpStsAlm ;

System В4: 52 V 4_ RaFanStsAlm ;

System B5: 52 V 5_ RaFanStsAlm ;

System B6: 52 V 6_ RaFanStsAlm ;

System B7: 52 V 7_ RaFanStsAlm ;

System B8: 52 V 8_ RaFanStsAlm ;

System P in 1 : 52 RV1 _ RaFanStsAlm .

 

All control schemes showed their performance. The reaction of the automation systems corresponded to the systems operation algorithms (Appendices 6, 7, 8)

The check of the sensors of the fan belt break was carried out to form the following alarm signals:

System P1-B1: 52 P 1_ RaFanDpsAlm , 52 P 1_ SaFanDpsAlm ;

System P2-B2: 52 P 2_ RaFanDpsAlm , 52 P 2_ SaFanDpsAlm ;

A3-B3 System 52 P 3_ RaFanDpsAlm , 52 P 3_ SaFanDpsAlm ;

System P4-B8: 52 P 4_ SaFanDpsAlm ;

System В4: 52 V 4_ RaFanDpsAlm ;

System B5: 52 V 5_ RaFanDpsAlm ;

System B6: 52 V 6_ RaFanDpsAlm ;

System B7: 52 V 7_ RaFanDpsAlm ;

Automation systems have worked out the alarm signals in accordance with the systems operation algorithms (Appendices 6, 7, 8).

When simulating the accident of the frequency converters of the inlet fans of the P1-B1 and P2-B2 installations was carried out by closing the corresponding relay contact. When simulating the operation of thermal relays of motor protection motors (by pressing the “ TEST ” button on the machines), the corresponding motors turned off, the automation systems controlled the equipment in accordance with the systems operation algorithms (Appendices 6, 7, 8).

When imitating the “Fire” signal, the intake and exhaust fans turned off from the fire alarm station, the air valves were closed, and in the “WINTER” mode the circulation pumps continued to work.

When translating systems into automatic mode, sequential operation of components and assemblies was ensured in accordance with the operation algorithms given in Appendices 6, 7, 8.

The duration of the systems to the nominal mode when they are included in the work are given in table 10.3.

Table 10.3 - Duration of the systems to the nominal mode, min

System	Season	Regulation circuit
		Air cooler temperature	Supply air temperatures	Relative humidity of the supply air
P1-B1	Winter	18	1 9	2 2
	Summer ( * )
P2-B2	Winter	20	21	2 3
	Summer ( * )
P3-B3	Winter	-	15	-
	Summer ( * )
P1-B1	Winter	-	14	-
	Summer ( * )
PB1	Winter	-	ten	-
	Summer ( * )

 

After reaching the nominal mode, all the control loops ensured that the controlled parameter is maintained with a given accuracy (see Section 3).

The checks of the response of the control loops to the introduced disturbances were carried out in accordance with the procedure described in Section 6. Checks were performed for the following circuits:

1) Systems P1-B1, P2-B2 season "WINTER"

· Relative humidity of the supply air;

· Air temperature after the second heating;

· Return heat carrier temperature after the first preheater;

· Return heat carrier temperature after the first preheating air heater with an emergency temperature drop.

2) Systems P1-B1, P2-B2, season “SUMMER” (*)

· Air temperature behind air coolers;

· Air temperature after the second heating;

· Relative humidity of the supply air.

3) Systems P3-B3, P4-B8, season "WINTER"

· Supply air temperature;

· Return heat carrier temperature after heating air heater;

· The temperature of the return heat carrier after the heating air heater at an emergency lowering of the temperature.

4) Systems P1-B1, P2-B2, season “SUMMER” (*)

· Air temperature behind air coolers;

· Air temperature after the second heating;

· Relative humidity of the supply air.

5) PB1 systems, season "WINTER"

· Supply air temperature;

The results of the selection of parameters are given in table 10.4.

As can be seen from the table, in the process of adjustment, the parameters of the contours were selected, which ensure a satisfactory quality of transients.

(*) - adjustment of systems was carried out in the "WINTER" mode

Table 10.4 - Results of adjustment of control loops (system P1-B1)

No. p / p	Season	Adjustable parameter	Charter	Regulator Parameters		Transient parameters (type perturbation1)					Transient parameters (type perturbation2)
				Cr	Ti	Y1	ψ	φ	Np	CCI, with	Y1	ψ	φ	Np	CCI, with
one.	Winter	Relative humidity of the supply air	50%	100	300	13.8%	0.87	57.14	3	435	14.5%	0.88	55.3	3	446
2		Air temperature after the second heating	20 ºС	25	250	22,5ºС	0.89	78.24	3	318	23.7ºС	0.89	77.52	3	367
3		The temperature of the return heat carrier after the air heater of the first heating	27.5 ºС	eleven	115	34.7ºС	0.85	64.34	3	234	37,1ºС	0.84	63.15	3	298
four.		The temperature of the return heat carrier after the air heater of the first heating at an emergency lowering of the temperature	15 ºС	6	0	-	-	-	-	23	-	-	-	-	34
five.	Summer	Air temperature behind air coolers	20 ºС
6		Air temperature after the second heating	20 ºС
7		Relative humidity of the supply air	50%

 

Test conditions: mode "Winter" Tnar.v = -7 º C;

Summer mode Tnar. = ____ ºС.

Table 10.4, continued - Results of adjustment of control loops (system P2-B2)

No. p / p	Season	Adjustable parameter	Charter	Regulator Parameters		Transient parameters (type perturbation1)					Transient parameters (type perturbation2)
				Cr	Ti	Y1	ψ	φ	Np	CCI, with	Y1	ψ	φ	Np	CCI, with
one.	Winter	Relative humidity of the supply air	50%	100	300	16.8%	0.88	59,34	3	465	17.6%	0.89	58.5	3	463
2		Air temperature after the second heating	20 ºС	thirty	300	23.1 ° C	0.87	71.45	3	327	24,5ºС	0.88	73.56	3	375
3		The temperature of the return heat carrier after the air heater of the first heating	35.5 ºС	20	200	42.7ºС	0.86	69.55	3	253	44.1ºС	0.85	68,10	3	307
four.		The temperature of the return heat carrier after the air heater of the first heating at an emergency lowering of the temperature	20 ºС	6	0	-	-	-	-	26	-	-	-	-	38
five.	Summer	Air temperature behind air coolers	20 ºС
6		Air temperature after the second heating	20 ºС
7		Relative humidity of the supply air	50%

 

Test conditions: mode "Winter" Tnar.v = -10º;

Summer mode Tnar. = ____ ºС.

Table 10.4, continued - Results of adjustment of control loops (system P3-B3)

No. p / p	Season	Adjustable parameter	Charter	Regulator Parameters		Transient parameters (type perturbation1)					Transient parameters (type perturbation2)
				Cr	Ti	Y1	ψ	φ	Np	CCI, with	Y1	ψ	φ	Np	CCI, with
one.	Winter	Air temperature after heating	20 ºС	25	130	24.1 ° C	0.88	65.66	3	316	24.6ºС	0.88	63.46	3	327
2		The temperature of the return heat carrier after the air heater of the first heating	38,5 ºС	17	180	43.5ºС	0.89	58,34	3	242	45.8 ºС	0.87	65.10	3	278
3		The temperature of the return heat carrier after the air heater of the first heating at an emergency lowering of the temperature	15 ºС	6	0	-	-	-	-	29	-	-	-	-	40
four.	Summer	Air temperature behind air coolers	20 ºС
five.		Air temperature after the second heating	20 ºС
6		Relative humidity of the supply air	50%

 

Test conditions: mode "Winter" Tnar.v = -12º;

Summer mode Tnar. = ____ ºС.

Table 10.4, continued - Results of adjustment of control loops (system P4-B8)

No. p / p	Season	Adjustable parameter	Charter	Regulator Parameters		Transient parameters (type perturbation1)					Transient parameters (type perturbation2)
				Cr	Ti	Y1	ψ	φ	Np	CCI, with	Y1	ψ	φ	Np	CCI, with
one.	Winter	Air temperature after heating	20 ºС	27	150	24.4ºС	0.88	63.13	3	325	25.1ºС	0.89	66.51	3	336
2		The temperature of the return heat carrier after the air heater of the first heating	37.3 ºС	18	180	41.3ºС	0.87	60,56	3	251	47.8ºС	0.86	63.11	3	283
3		The temperature of the return heat carrier after the air heater of the first heating at an emergency lowering of the temperature	15 ºС	6	0	-	-	-	-	thirty	-	-	-	-	39
four.	Summer	Air temperature behind air coolers	20 ºС
five.		Air temperature after the second heating	20 ºС
6		Relative humidity of the supply air	50%

 

Test conditions: mode "Winter" Tnar.v = -11 ° C;

Summer mode Tnar. = ____ ºС.

Table 10.4, continued - Results of adjustment of control loops (PB1 system)

No. p / p

Season

Adjustable parameter

Charter

Regulator Parameters

Transient parameters (type perturbation1)

Transient parameters (type perturbation2)

Cr

Ti

Y1

ψ

φ

Np

CCI, with

Y1

ψ

φ

Np

CCI, with

one.

Winter

Supply air temperature

17 ºС

thirty

300

21.1ºС

0.85

45.66

3

168

21.6ºС

0.86

50.31

3

172

2

Summer

Supply air temperature

___ ºС

 

Test conditions: mode "Winter" Tnar.v = -6 º C;

Summer mode Tnar. = ____ ºС.