DOC.

NO:
TATA PROJECTS LIMITED

TPL-039-ME-CS-AC-1728 OPERATION & CONTROL PHILOSOPHY

8 MTPA IRON ORE CRUSHING & WASHING PLANT

TATA STEEL, KHONDBOND, ODISHA

OPERATION AND CONTROL PHILOSOPHY

FOR CHILLED WATER AND WATER COOLED PAC SYSTEMS

TPL-039-ME-CS-AC-1728

OWNER : -M/s TATA STEEL

CONTRACTOR : -M/s TATA PROJECTS LTD., HYDERABAD

VENDOR : M/s UTILITY PROJECTS & SERVICES PVT LIMITED

R0 R1 R2 R3
REV. NO. ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY AGP DSV DSV DSV

CHD. BY DJR DJR DJR DJR

R3
APD. BY DJR DJR DJR DJR

DATE 08-08-2018 17-12-2018 22-01-2019 28-02-2019

 CONTROL PHILOSOPHY OF CHILLED WATER SYSTEM

SELECTED EQUIPMENTS AND CONTROLS

 3 x 50% is the chiller selection with integral control panel, electrical power from
MCC.
 Water flow switch for each chiller at chiller outlet (both Cooling water & chilled
water) to ensure minimum flow to chiller, which is hooked to chiller panel.
 3 x 50% chilled water pumps – constant speed with starter panel, electrical
power from MCC.
 2 x 50% Chilled water Air handling units – constant flow, with LCP
 Heaters and humidifiers. (as per the selection sheet), interlocked with AHU LCP
 Thermostat and Humidistat at Return air path interlocked with AHU LCP for the
operation of Heater and humidifier.
 3 way motorized valves for AHUs, interlocked with AHU LCP control by
separate thermostat located at room.
 2 way motorized (ON/OFF) for Chiller inlet and outlet with common PDB
 3 x 50% cooling water pumps – constant speed, electrical power from MCC.
 3 x 50% Cooling towers – constant flow, electrical power from MCC.
 Level switch in each cooling tower basin.
 2 way motorized (ON/OFF) for Cooling tower inlet, with common PDB

The operation of the selected equipment’s shall be carried out in following mode:

1. Remote mode
2. Local/maintenance mode

The details of operation are described below:

1. Remote mode:

The remote mode shall be selected with the help of selector switch “in remote” at
field LPBS. Once selected in remote, there shall be following mode available in
DCS:

i. Auto mode:
a. Cooling tower fan, cooling water pumps and chilled water pumps shall
start in sequence will all interlock in one command from DCS.
b. The ON feedback of chilled water pump shall be provided to chiller
microprocessor as an input from DCS.
c. Once sufficient flow in the cooling water line and chilled water line is
available, chiller shall start automatically.
 ii. Manual Mode: Above mentioned equipment’s shall start in sequence
considering the interlocks manually by DCS operator.

2. Local / Maintenance mode:

The local mode shall be selected with the help of selector switch “in local” at field
LPBS. In this case, “local permissive” shall be provided by DCS operator in the
field. Then operator at field can start the above equipment manually.

Equipment can be stopped either from LPBS or from DCS in remote mode.

COOLING TOWER START PERMISSIVE

 No permissive required for Cooling tower fan operation. Directly ON.

COOLING WATER PUMP START PERMISSIVE

 Cooling water level at Cooling tower in basin (lead) is above minimum water
level sensed thru level switch.
 Cooling tower fan (lead) is On.
 Cooling tower (lead). - Cooling water inlet Motorized buttery valve is Open.

CHILLED WATER PUMP START PERMISSIVE

 Chiller outlet (lead). – Cooling water motorized butterfly valve is Open.
 Chilled water pump (lead) is ON.

CHILLER START PERMISSIVE

 Cooling tower is ON.
 Cooling water pump is ON.
 Chilled water pump is ON.
 Ensure minimum flow using water flow switch both Cooling water and chiller
water side.

CHILLER STOP INTERLOCK

 No permissive required for Chiller OFF. Directly OFF.

CHILLED WATER PUMP STOP INTERLOCK

 Chiller outlet (lead) – Chilled water motorized butterfly valve is Close
 Cooling water pump (lead) is OFF

COOLING WATER PUMP STOP INTERLOCK

 Chilled water pump is OFF
 Chiller outlet (lead). – Cooling water motorized butterfly valve is Close.
COOLING TOWER STOP INTERLOCK
 Chiller OFF
 Chilled water pump OFF
 Cooling water pump OFF
 Cooling tower Fan OFF.

AIR HANDLING UNIT INTER LOCKS AND WORKING PHILOSOPHY

 First the Air Handling Unit fan is ON manually from AHU LCP.
 3-way valve is Open to fluid flow inside coil based on Thermostat provided at
room. The set point is 30 deg C or 23 deg C based on the design basis’s room
conditions.
 Heater’s Humidistat is ON based on the Return Air Relative Humidity. The set
point is 60% of 23 deg C room and 70% of 30 deg C room. The heater is ON
when the RH increases the set point.
 Humidifier’s Humidistat is ON based on Return Air Relative Humidity. The set
point is 50% of 23 deg C room. The Humidifier is ON when the RH decreases
the set Point.
 AHU run feedback, trip feedback and control room temperature shall be made
available in DCS from AHU panel.

NOTE
Lead, Lag and standby chillers, cooling towers, cooling water pumps and chilled
water pumps will be selected thru DCS.
CONTROL PHILOSOPHY OF WATER COOLED PACKAGE SYSTEM

SELECTED EQUIPMENTS AND CONTROLS

 3 (22 TR) x 50% is the water cooled package unit with integral control panel,
electrical power from MCC.
 3 (17 TR) x 50% is the water cooled package unit with integral control panel,
electrical power from MCC.
 Heaters and humidifiers. (as per the selection sheet), interlocked with PAC LCP
 Thermostat and Humidistat at Return air path interlocked with PAC LCP for the
operation of Heater and humidifier.
 2 way motorized (ON/OFF) for PAC outlet with common PDB
 2 x 100% cooling water pumps – constant speed, electrical power from MCC.
 2 x 100% Cooling towers – constant flow, electrical power from MCC.
 Level switch in each cooling tower basin.
 2 way motorized (ON/OFF) for Cooling tower inlet, with common PDB

COOLING TOWER START PERMISSIVE

 No permissive required for Cooling tower fan operation. Directly ON.

COOLING WATER PUMP START PERMISSIVE

 Cooling water level at Cooling tower in basin (lead) is above minimum water
level sensed thru level switch.
 Cooling tower fan (lead) is On.
 Cooling tower (lead). - Cooling water inlet 2 way ON/OFF Motorized buttery
valve is Open.
 Cooling water pump is ON.

WATER COOLED PACKAGE UNIT START PERMISSIVE

 Cooling tower Fan is ON.
 Cooling water pump is ON.
 2 way motorized valve is Open.
 Water cooled package ON.

WATER COOLED PACKAGE UNIT STOP INTERLOCK

 No permissive required to STOP Water cooled package unit operation. Directly
OFF.
COOLING WATER PUMP STOP INTERLOCK
 Water cooled package unit is OFF.
 Cooling tower (lead). - Cooling water inlet 2 way ON/OFF Motorized buttery
valve is Close.
 Cooling water pump is OFF.

COOLING TOWER STOP INTERLOCK

 Water cooled package unit is OFF.
 Cooling water pump OFF
 Cooling tower Fan OFF.

WATER COOLED PACKAGE UNIT INTERLOCKS & WORKING PHILOSOPHY

 First the Water Cooled Package Handling Unit is ON.

 Thermostat provided at room. The set point is 29 deg C or 23 deg C based on
the design basis’s room conditions.
 Heater’s Humidistat is ON based on the Return Air Relative Humidity. The set
point is 45% of 23 deg C room and 55% of 29 deg C room. The heater is ON
when the RH increases the set point.
 Humidifier’s Humidistat is ON based on Return Air Relative Humidity. The set
point is 45% of 23 deg C room and 55% of 29 deg C room. The Humidifier is
ON when the RH decreases the set Point.

NOTE
Water Cooled PAC operation sequence will be operated through DDC panel
whereas for Cooling tower & Condensing pump operation sequence will be taken care
by TPL/TSL.
 CONTROL PHILOSOPHY OF AIR COOLED PACKAGE SYSTEM

AIR COOLED PACKAGE UNIT INTERLOCKS AND WORKING PHILOSOPHY

 First the Air Cooled Package Handling Unit is ON.
 Thermostat provided at room. The set point is 23 deg C based on the design
basis’s room conditions.
 Heater’s Humidistat is ON based on the Return Air Relative Humidity. The set
point is 55% of 23 deg C room. The heater is ON when the RH increases the
set point.
 Humidifier’s Humidistat is ON based on Return Air Relative Humidity. The set
point is 45% of 23 deg C room. The Humidifier is ON when the RH decreases
the set Point.

NOTE
Air PAC Unit operation sequence will be operated through DDC.
 WATER COOLED CHILLER ON SEQUENCE STEPS
STEP 1 : COOLING TOWER ON PHIOLOSPHY STEP 2 : COOLING WATER PUMP ON PHIOLOSPHY STEP 3 : CHILLED WATER PUMP ON PHIOLOSPHY
CWP 1 CWP 2 CWP 3
CT 1 CT 2 CT 3
STEP 4: WATER COOLED CHILLER ON PHIOLOSPHY
CHWP 1 CHWP 2 CHWP 3
NOTE :
CT - COOLING TOWER
MBFV - MOTORISED BUTTERFLY VALVE
CWP - COOLING WATER PUMP
CHWP - CHILLED WATER PUMP
WCC - WATER COOLED CHILLER
TSL-WATER COOLED CHILLER OPERATIONAL SEQUENCE

COOLING TOWER
WATER LEVEL SWITCH
MIN WATER LEVEL
FEEDBACK FROM
WATER LEVEL SWITCH

DCS
MOTOR ON
FEEDBACK TO DCS COOLING TOWER ON COMMAND FROM DCS
(STEP 1)
MOTOR

ON
VALVE OPEN
FEEDBACK TO DCS COOLING TOWER OPEN COMMAND FROM DCS
(STEP 2)
MOT. BUTTERFLY VALVE

ON
VALVE OPEN
FEEDBACK TO DCS CHILLER COOLING SIDE OPEN COMMAND FROM DCS
(STEP 3)
MOT. BUTTERFLY VALVE

ON
PUMP ON
FEEDBACK TO DCS COOLING WATER ON COMMAND FROM DCS
(STEP 4)
PUMP

ON
VALVE OPEN
FEEDBACK TO DCS CHILLER CHILLED WATER OPEN COMMAND FROM DCS
(STEP 5)
MOT. BUTTERFLY VALVE

ON
PUMP ON
FEEDBACK TO DCS CHILLER CHILLED WATER ON COMMAND FROM DCS
(STEP 6)
PUMP

FEEDBACK FROM
CHILLER WATER FLOW WATER FLOW SWITCH
FEEDBACK

ON COMMAND FROM DCS (STEP 7)

ON
CHILLER ON
FEEDBACK TO DCS WATER COOLED
CHILLER NOTE :
LEAD, LAG & STANDBY CHILLERS,
COOLING TOWERS, COOLING WATER
PUMPS, CHILLED WATER PUMPS
WILL BE SELECTED THROUGH DCS.
TSL-WATER COOLED PACKAGE OPERATIONAL SEQUENCE

COOLING TOWER
WATER LEVEL SWITCH
MIN WATER LEVEL
FEEDBACK FROM
WATER LEVEL SWITCH

DCS
MOTOR ON
FEEDBACK TO DCS COOLING TOWER ON COMMAND FROM DCS
(STEP 1)
MOTOR

ON
VALVE OPEN
FEEDBACK TO DCS COOLING TOWER OPEN COMMAND FROM DCS
(STEP 2)
MOT. BUTTERFLY VALVE

ON
PUMP ON
FEEDBACK TO DCS COOLING WATER ON COMMAND FROM DCS
(STEP 3)
PUMP

ON
PAC UNIT ON
FEEDBACK TO DCS WATER COOLED ON COMMAND FROM DCS
(STEP 4)
PAC UNIT

TSL-AIR COOLED PACKAGE OPERATIONAL SEQUENCE

DCS
PAC UNIT ON
FEEDBACK TO DCS AIR COOLED ON COMMAND FROM DCS
(STEP 1)
PACKAGE UNIT

NOTE :
LEAD, LAG & STANDBY CHILLERS,
COOLING TOWERS, COOLING WATER
PUMPS, PAC UNITS WILL BE
SELECTED THROUGH DCS.