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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
© ABB Group
May 6, 2013 | Slide 2
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
© ABB Group
May 6, 2013 | Slide 3
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
© ABB Group
May 6, 2013 | Slide 4
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
© ABB Group
May 6, 2013 | Slide 5
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
© ABB Group
May 6, 2013 | Slide 6
Scope of Project
Building Management System for Controlling AHU
Environment Monitoring System
US FDA (GAMP5) compliant
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© ABB Group
May 6, 2013 | Slide 7
Solution ㆃ㉗Ⳟ➙
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
© ABB Group
May 6, 2013 | Slide 8
Solution– System Architecture
PROFIBUS
TCP/IP
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3# S800 I/O
4# S800 I/O
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Operator Station 1#
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Operator Station 2#
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VFD
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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
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© ABB Group
May 6, 2013 | Slide 9
Design – AHU Type
Type 1: General + one VFD
Type 2: General + two VFD
Type 3: General + two VFD + Exhaust Fan
© ABB Group
May 6, 2013 | Slide 10
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
© ABB Group
May 6, 2013 | Slide 11
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
© ABB Group
May 6, 2013 | Slide 12
Design – Mode of Operation of AHU
Season Mode
Spring & Autumn Mode
Summer Mode
Total Exhaust Air Mode
Energy saving Modes
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© ABB Group
May 6, 2013 | Slide 13
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
© ABB Group
May 6, 2013 | Slide 14
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.
© ABB Group
May 6, 2013 | Slide 15
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
Enthalpy
Outside Air
Enthalpy
Return Air
Mixed Air
Compare
Enthalpy Comparison
Enthalpy
Difference
Economizer
ON/Off
© ABB Group
May 6, 2013 | Slide 16
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
Cooling
Vlv
Humid
Vlv
PI
TT
FT
RH
HSel
DPS
FZ
FS
AHU
Zones
TT RH
Return Air
Supply AirOA
EA
RA
Supply Temp
RH Ret. PID
Clg PID
Htg PID
RH PID
DPS
TT
© ABB Group
May 6, 2013 | Slide 17
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
Cooling
Vlv
TT
Temperature
State Driver
Damper
Enthalpy
Outside Air
Enthalpy
Return Air
Mixed Air
Compare
Enthalpy Comparison
PIDPar
PIDPar
PIDPar
© ABB Group
May 6, 2013 | Slide 18
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
AHU2
Supply ABB Drive
Fan Control
Temp Control
Pressure Control
Humidity ControlAHU7
Supply&Recirc
Fan Control
Temp Control
Pressure Control
Humidity Control
Coordinate Startup
& Shutdown of
major equipment
Startup/Shutdown
Sequence
AHU1
Supply
Fan Control
Temp Control
Pressure Control
Humidity Control
Chiller
To other
Applications
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© ABB Group
May 6, 2013 | Slide 19
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
© ABB Group
May 6, 2013 | Slide 20
Scheduler Objects
ApplicationX
AHU Template
Fan Control
Temp Control
Pressure Control
Humidity Control
Scheduler SchedulerOptimizer
SP, PV
O.A.
Temperature
Scheduler
Holidays To other
equipment
To other
Applications
Usage:
© ABB Group
May 6, 2013 | Slide 21
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
B
TT
D
P
CHWS
A
Chiller 1
Chiller 2
C
B
A
C
Chiller 3
Cooling
Vlv
Cooling
Vlv
Cooling
Vlv
CHWR
FT
Temp SP Reset /
Demand SP Reset
Flow/DP SP Reset
TT
Secondary Pumps
Variable Speed Pumps
Primary Pumps
Fixed Speed Pumps
© ABB Group
May 6, 2013 | Slide 22
Graphic 1 - AHU
© ABB Group
May 6, 2013 | Slide 23
Graphic 2 - AHU
© ABB Group
May 6, 2013 | Slide 24
Graphic 3 - Chiller
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© ABB Group
May 6, 2013 | Slide 25
Graphic 4 – AHU Overview
© ABB Group
May 6, 2013 | Slide 26
Graphic 5 - Room
© ABB Group
May 6, 2013 | Slide 27
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