Upgrade of Detector Electronics Racks for Safety Interlocks Implementation
This project involves upgrading the detector electronics racks to implement safety interlocks using a centralized PLC system. The concept aims to enhance monitoring and control of safety interlocks for improved flexibility, cost savings, and efficiency. The upgrade will allow interaction with other systems and provide signals/status to MCR. Analog and digital input signals will be connected to IO cards, and the PLC and HMI will be networked for remote monitoring and interfacing. Existing network infrastructure will be utilized, and a proposed PLC hardware configuration is outlined for the implementation.
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WBS 2.04.01.03: Detector Electronics Racks and Rack generic support Safety Interlocks Joel Vasquez 1 Rack Safety Interlocks November 25th, 2019
Project Plan Description: WBS 2.04.01.03 Detector Electronic Racks and Rack Generic Support: Rack power distribution panel and safety interlocks (buckets) upgrade. Scope: This concept is to implement a centralized PLC that can monitor and control our detector s safety interlocks. Centralized PLC will monitor water leaks, smoke, temperature, power and others signals. Human machine interface (HMI) will be used to read signals and write commands. Each rack monitors our safety interlocks. If any of these interlocks are ON then, contactor will be de-energized. Opportunity: The need to improve flexibility and cost savings in the subsystems' racks. New PLC technology is needed to control and monitor our racks and other devices more efficiently. Future Benefit: This upgrade will provide flexibility to interact with other systems such as: Lighting Control Flow Meter monitoring Rack Power Monitoring Provide signals/status to MCR (EPICS) New detector / Detector upgrades 2 Rack Safety Interlocks November 7th, 2019
Conceptual Design Analog and digital input signals are connected to IO cards (PLC) PLC and HMI are connected to the network via TCP/IP to monitor and interface remotely 3 Rack Safety Interlocks November 7th, 2019
Network Overall Layout Existing network infrastructure can be re-used to connect new components. 4 Rack Safety Interlocks November 7th, 2019
Basic Logic System (Conceptual) Ladder Logic (Concept) 5 Rack Safety Interlocks November 7th, 2019
PLC Configuration PLC configuration (Hardware) can be done in few different ways. I m proposing the following configuration: Qty Catalog # Hardware Description 001 1769-L33ER CompactLogix 5370 L3 Controller, 2Mb Memory, w/Supercap Backup, up to 16 1769 I/O expansion modules, 32 EtherNet/IP and 120 TCP connections 001 1769-ARM Compact Address Reserve Module 002 1769-PA4 120/240V AC Power Supply (5V @ 4 Amp) 003 1769-IQ16 16 Point 24 VDC Sinking/Sourcing Input Module 001 1769-CRR1 Right bank-to-right bank expansion (305 mm) 003 1769-OW16 16 Point Relay Output Module 005 1769-IF8 8 Channel Analog Voltage/Current Input Module This configuration has room for revision and expansion. 6 Rack Safety Interlocks November 7th, 2019
Infrastructure Layout 208 VAC Power Distribution: NEMA 12 enclosure with inner panel (installed in the IR) fully assembled, wired and tested. It includes: Main 200A Disconnect switch 3 Pole 30A circuit breakers 3 Pole 40 A contactors, 24VDC coil. For incoming 208 VAC power- Transient Voltage Surge suppressor (TVSS) 120 VAC Control Power: Building Power (existing Infrastructure) will be used to supply power to PLC and controller. 24 VDC Control Power: Power supply (~10 Amp) will be used to energize contactor coil and sensors. 24 VDC Control Power 120 VAC Control Power TVSS/208 VAC Power Distribution 7 Rack Safety Interlocks November 7th, 2019
Temperature Monitoring and Control Rack Installation: Platinum RTD element (1PR100K) is suitable for extremely low or high temperatures. Signal conditioner (Omega DRF-RTD) is designed to accept a broad range of input signals and provide standard process outputs of 4 to 20 mA. Connections are safely and securely made through pluggable screw terminal connector. PLC Enclosure (AH Installation): 4-20 ma Analog Card (Allen Bradley 1769-IF8) offers 8 analog input channels for every card that can connect to current input devices. Digital Output Card(Allen Bradley 1769-OW16) offers 16 digital outputs that can control 16 contactors independently. An external power supply (~10Amp) wired to the card is needed to drive the contactor (Eaton XTCE018C) . *Note: HMI (AB PanelView Plus 1000) displays each rack s temperature 8 Rack Safety Interlocks November 7th, 2019
Smoke Sensor and Control 12VDC/24VDC smoke sensor head (Bosh-F220-B6RS) includes a normally open relay contact and a built-in sounder. Smoke Head Sensor Base Wiring 9 Rack Safety Interlocks November 7th, 2019
Water Leak Detector and Control TTK FG-NET F Digital Leak Detection Panel has the capacity to connect three circuits. 40 sense cables can be connected on each circuit. It uses RS485 serial link with MODBUS /JBUS communication protocol for interfacing with PLC system. TTK FG-EC Digital Sense Cable detects and pin-points the rack location of water leaks, communication per cable and controller map alert for fast location. So the site will know which rack is leaking and have a quicker response, because that individual cable is communicating and there is a map displayed on the controller showing the effected rack. Ethernet/IP to Modbus Serial (PLX31-EIP-MBS) gateway is a module to interface PLC and water leak detector controller. Water Leak Interlock Network Diagram 10 Rack Safety Interlocks November 7th, 2019
Cost Summary ITEM CAP REQ BUDGETED AMOUNT AMOUNT UNIT PRICE QTY VENDOR Smoke Detection System $1,809 Bosh Not Included: - Horns - Indicators - Buttons - Rack Breakers - Other Accessories Bosch F220-P Photoelectric Smoke Detector $1,208.52 $33.57 36Bosh Bosch F220-B6RS 24 VDC Four Wire Base Sounder $600.12 $16.67 36Bosh Leak Detection System TTK FG-NET TTK FG-ECB TTK FG-CLC TTK FG-TMC TTK FG-NC1 TTK FG-NC7 TTK ES-EC Sense Cable Labels $29,619 Faber Industrial Technologies 1Faber Industrial Technologies 36Faber Industrial Technologies 1Faber Industrial Technologies 1Faber Industrial Technologies 5Faber Industrial Technologies 9Faber Industrial Technologies 1Faber Industrial Technologies $5,724.00 $21,184.20 $106.66 $77.33 $786.65 $1,667.97 $72.00 $5,724.00 $588.45 $106.66 $77.33 $157.33 $185.33 $72.00 Temperature Monitoring System 1PT100K2515 DRF-IAC-24VDC-5A-4/20 $7,880 Omega 36Omega 36Omega $824.04 $7,056.00 $22.89 $196.00 Power Distrubiton Panel w/ contactors NEMA 12 ENCLOSURE WITH INNER PANEL MAIN 200A NON FUSED DISCONNECT SWITCH SURGE PROTECTOR - ST2083PYG POWER DISTRIBUTION BLOCK THREE POLE 30A CIRCUIT BREAKERS THREE POLE 40A CONTACTORS CUSTOM NAMEPLATE ON DOOR PANEL TO INCLUDE UL LABEL LOT PANEL PHYSICAL LAYOUT DRAWING WIRING DIAGRAMS $7,950 $7,950.00 Benfield Benfield Benfield Benfield Benfield Benfield Benfield Benfield Benfield Benfield Benfield BILL OF MATERIAL DRAWINGS AND CUT SHEETS TO BE SUBMITTED FOR APPROVAL Benfield Benfield PLC System AB 5069-L306ER AB 5069-RTB64-SCREW AB 5069-IB16 AB 5069-RTB18-SCREW AB 2711P-T9W21D8 AB 9324-RLD200ENE AB 9701-VWSTMENE $7,441 Turtle & Hughes 1Turtle & Hughes 1Turtle & Hughes 7Turtle & Hughes 18Turtle & Hughes 1Turtle & Hughes 1Turtle & Hughes 1Turtle & Hughes $937.50 $26.73 $1,457.19 $880.56 $2,289.60 $914.00 $935.00 $937.50 $26.73 $208.17 $48.92 $2,289.60 $914.00 $935.00 CAPITAL TOTALS $54,698 11 Rack Safety Interlocks November 7th, 2019
Major Components https://ep-us.mersen.com/sites/mersen_us/files/DS-ST-Surge-Trap-Modular-Mersen.pdf Three Pole 30A Circuit Breakers (FAZ-NA) https://cdn.automationdirect.com/static/specs/eatonfazna.pdf Three Pole 40A Contactors (XTCE018C10) https://www.yorksupply.com/v/vspfiles/pdf/Eaton_Motor_Controls_XTIEC_Motor_Starters_Manual.pdf PLC https://www.nhp.com.au/files/editor_upload/File/Product-Tech-Data-Sheets/1769L33ER.pdf I/O Modules Output: https://literature.rockwellautomation.com/idc/groups/literature/documents/in/1769-in062_-en-p.pdf Input: https://www.nhp.com.au/files/editor_upload/File/Product-Tech-Data-Sheets/1769IQ16.pdf Analog: https://literature.rockwellautomation.com/idc/groups/literature/documents/in/1769-in067_-en-p.pdf Human Machine Interface (HMI) https://ab.rockwellautomation.com/Graphic-Terminals/2711P-PanelView-Plus-7-Terminals Smoke Head Sensor http://resource.boschsecurity.com/documents/Installation_Manual_enUS_2707953931.pdf Water Leak Detector Controller http://www.ttkuk.com/water-acids-leak-detection/products/alarm-units/locating-units/fg-net/ Cable Sensor http://www.ttkuk.com/water-acids-leak-detection/products/sense-cables/water-sense-cables/fg-ec/ Communication Module https://www.prosoft-technology.com/prosoft/download/9999/210509/version/6/file/PLX31-EIP-MBS+datasheet.pdf Temperature Sensor https://assets.omega.com/spec/1PT100K-RTD-ELEMENTS.pdf RTD Transmitter https://assets.omega.com/pdf/communication-and-connectivity/signal-conditioners-and-transmitters/signal-conditioners/DRF-RTD.pdf Surge Protective Device (ST2083PYG) 12 Rack Safety Interlocks November 7th, 2019
