Pres - SVCPLUS Cooling Training Engineering

Dr.
Zahner
Dr. Zahner
25.04.2016
SVC PLUS Cooling System

Training
Siemens AG 2014 All rights reserved.
Answers for energy.
Dr.
Zahner
Dr.
Zahner
Agenda
1. Introduction and overview

2. Basic data of the cooling system
3. Presentation of the components

4. Control of the cooling system
5. Safety Instructions
6. Service and Maintenance (Practical Training)
27. April 2016
EM TS TI MS CSS
Dr.
Zahner
Dr.
Zahner
1 Introduction and overview
27. April 2016
EM TS TI MS CSS
Dr.
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Dr.
Zahner
1 Introduction and overview
27. April 2016
EM TS TI MS CSS
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Agenda


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Flow Diagram
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Agenda

Pump
Ion exchanger
Filters
Cooler
Bypass valve
Refill system
Expansion tank
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Cooling System Arrangement

Expansion Tank
Bleeding Valves
Fine Filters
Connection Pipes to Converter
Main Filter
Sensors
Main Pumps
Refill Tank with

Refill Pump
Internal Bypass
Connection to the
Outdoor Cooler
Ion Exchanger
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Components
Pumps
Function: Creation of sufficient flow to reach

cooling capacity at power modules
Canned Motor Pump
Redundant System
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Components
Ion Exchanger
Function: Cleaning the cooling agent in order to reach a sufficiently high electrical resistance in the medium
Stainless steel cartridge filled with mixed bed resin in both systems
Changes in colour indicate damaged resin
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Components
Filters
Function:
Main Filter: Prevent particles to get into the converter
Fine Filter upstream of ion exchanger: Prevent particles from refill system to get into the ion exchanger
Fine Filter downstream of ion exchanger: Prevent Particles from ion exchanger to get into the cooling system
1 x Fine Filter 3 m (downstream of IEX)
1 x Fine Filter 3 m (upstream of IEX)
1 x Main Filter 250 m
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Components
Cooler
Function: Dissipate heat from cooling agent to ambient air

Horizontal design with project specific amount of fans
One fan is redundant exchange is possible during operation
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fan M1-M10
Fan operation start conditions:
- water temperature higher than 42C

- no fan failure signal (temerature switch, MCB, Sinamic, Undervoltage)
Fan operation stop conditions:

- water temperature gets lower than 35C
- fan failure
fan speed regulation by PID controller with the setpoint value of T=45C inlet water temperature
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Components
Bypass Valve
Function: Circulation of cooling agent inside of the container in order to avoid condensation at low
temperatures
Flap Combination with connection link
belimo drive -M13

drive operation
regulated by PID controller with the setpoint value of
T=35C water temperature
in case of inlet temperature under 35C The cooling
water flows partly or completely through the internal by-pass
(depending on the temperature development)
Bypass open
Bypass closed
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Components
Refill System
Function: Filling of cooling agent into the cooling system; automatic refilling of the system to cover normal
medium losses.
Barrel pump for pumping larger amounts of medium into the system (connected to drain valve on outdoor cooler)
Automatic refill system consisting of tank and small refill pump
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Components
Expansion Tank
Function:
Ensuring the primary pressure for the suction side of the pumps
Providing the reserve volume for normal medium losses
Offering the compensation volume for the thermal expansion of the medium
Tank open to atmosphere no further pressure necessary
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Components
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Sinker Flow Meter

Visualisation of volumetric flow
Expansion tank
through the ion exchanger
Strainer 3m
Belimo drive for

bypass regulation
Ion Exchanger
Strainer 250m
refill pump
refill tank
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Agenda


Sensors
Alarms and trips (Detailed explanation of all possible TRIPs, their delays and differentiation compared to
Warnings
Control of fans and bypass valve
Operating the cooling system
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Control of the Cooling System

Sensors
Level Sensor
Level Switch
Conductivity
Inlet Temperature
Pressure (Transducer and Gauge)
Differential Pressure
(Electric Switch and
Gauge)
Outlet Temperature
Refill Tank Level Switch
Conductivity downstream of IEX

Flow through IEX Bypass
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Sensors
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mechanical manometer P10
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measuring converter -P10
electromechanical pressure
difference switch -PS11
adjustment screws for

lower and upper limit
measurement connection
HIGH Pressure
LOW Pressure
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Sensors
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measurment connection for

pressure difference switch PS11
measuring point HIGH pressure
measurement connection for
main conductivity B12
Inlet temperature sensor T10

Signal generator for
INLET TEMPERATURE HIGH ALARM (>52C) and
measurement connection for
INLET TEMPERATURE TRIP (>53C)
manometer P10
analog/digital
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Sensors
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ultrasonic proximity switch -L11
level limit switch -L13
Measurement of the fluid level in the expansion tank
Signal generator for EXP_LOW_TRIP
0-100%
Signal generator for refill pump operation (<30%) and
EXP_LOW_TRIP (<8%)
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Sensors
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Ion exchanger conductivity sensor B11

Signal generator for
ION EXCHANGER CONDUCTIVITY HIGH ALARM (>0,25S)
Strainer 3m
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Alarms/Trips
SER #
Description
Type
Delay
Cause
625
No Flow Trip
Trip
2s
Pressure has been too low for 2 s heat dissipation not sufficient at
power module heat sinks
626
Inlet Temperature Trip
Trip
30 s
Temperature has been over 53 C for 30 s (Failure with drycooler, bypass

Valve or temperature sensor) heat dissipation not sufficient at power
module heat sinks because of lower temperature difference
627
High Conductivity Trip
Trip
5 min
Conductitvity has been over 0.8 S/cm for 5 min Electrical Resistance
between heat sinks is not sufficient and corrosion can occur
628
Expansion Level Trip
Trip
1s
Expansion Tank level has been lower than 8 % for more than 1 s
Massive loss of cooling agent and thus drop of pressure on the suction side
of the pump (cavitation possible)
629
Cooling System AC Failure
Alarm
Drop in/ Loss of the AC supply
630
Cooling System DC Failure
Alarm
Drop in/ Loss of the DC supply
631
Waterflow Low Alarm
Alarm
500 ms
Pressure has been too low for 500 ms Problem with pump
632
Inlet
Temperature
Alarm
Alarm
Temperature is over 52 C see 626
633
Main Conductivity High

Alarm
Alarm
Conductivity is over 0.5 S/cm see 627
634
Expansion Level Low Alarm
Alarm
Expansion Tank Level is lower than 25 %
635
Ion Exchanger Conductivity

High Alarm
Alarm
Conductivity downstream of ion exchanger is over 0.3 S/cm IEX resin

is used up
636/637
Pump 1/2 Failure
Alarm
Failure from MCB or Hydraulic Phase Monitoring
High
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Alarms/Trips
SER #
Description
Type
Delay
Cause
638
Refill Pump Failure
Alarm
Refill Pump MCB is switched off
639
Refill Tank Low Alarm
Alarm
Level switch in refill tank signals low level
640-651
Fan 1 Failure
Fan 12 Failure
Alarm
Maintenance switch is switched off

Status relay issues alarm
664
Air Condition Failure
Alarm
One of the two MCBs are switched off or the supply issues alarm
665
Inlet Temperature Low

Alarm
Alarm
Inlet temperature is below 5 C Condensation on piping system

possible
666
Excessive use of Refill

Pump
Alarm
Refill Pump is switched on more than 3 times during 24 hrs leak

probable
673
Cubicle Temperature High

Alarm
Alarm
Temperature in the control cubicle is over 55 C electric components

get too hot
696
Cooling System
acknowledged
Confirmation of the Acknowledge command from the TDC
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Control of fans and bypass valve
Bypass Valve:
Set point is 35 C:
Fans:
Set point is 45 C:
> 35 C: Bypass valve closes and water flows through the outdoor cooler
< 35 C: Bypass valves opens and all the water flows on the inside
If the temperature is around 35 C a intermediate position of the valve is possible
> 45 C:
Fans start running at 20 % of the top speed and accelerate if heat dissipation is not
sufficient (EC motors)
Drycooler is designed to dissipate enough heat to ensure an inlet temperature of 52 C when the converter is on maximum
load and one fan is not in operation
All fans run for 4 h every 23 days in order to prevent the bearings from getting seazed up
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Operating the System
Preconditions for Pump Start:

On-button is activated
AC undervoltage relay is not in fault
Pump is not in fault
Expansion Tank level is sufficient
The pump will be automatically switched off in
case:
Expansion Tank Level is below critical level
Off button is activated
Inlet temperature is above 60 C
A high pressure alarm has been active for 5
seconds
The connection to the pressure sensor is lost for
5 seconds and the differential pressure is above
alarm level
Caution: Pressing the OFF-button will cause the
SVC to trip
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Agenda


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Safety Instructions
Qualified Personnel
The device/system may only be set up and used in conjunction with the cooling system manual.
Commissioning and operation of a device/system may only be performed by qualified
personnel.
Qualified persons are defined as persons who are authorized to commission, ground and label devices,
systems and circuits in accordance with established safety practices and standards.
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Safety Instructions
Personal Safety Equipment:

For the handling of the cooling agent, ion exchanger resin and filter inserts goggles, protective clothing
and gloves are recommended. The local regulations must be complied with.
Disposal:
Filters and Filter inserts: Contaminated filter inserts are hazardous waste and must be disposed of
properly or submitted to a collection system.
Coolant with Monoethylene Glycol: Must be disposed as hazardous waste. The local regulations
must be complied with
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Agenda


Regular works
Pressure test
Module exchange
Draining and Filling of the system
Pump switchover
Fault acknowledge
Troubleshooting
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Service and Maintenance

Regular Works
Intervals
Item number of
component
Component name
Number of persons
for maintenance
work
Work duration Maintenance tasks

in minutes
Every quarter
0201
Main pump
0231
Refill pump
Check for smooth running

Check for normal enclosure temperatures
(not too hot)
Visible inspection for leaks
Complete system
0401
Expansion tank
0431
Refill tank
1
Piping system
1
Hoses
Gaskets
Screwed glands
Check level and fill as required
10
Visible inspection for:
Leaks
Aging
Damage
Heat exchanger
cooling fins
Check cooling fins for contamination
30
Clean cooling fins as required
Heat exchanger
Ventilators
10
Check:
Bearing noise
Freewheeling
Direction of rotation
Once yearly
0101
0101
Coolant without
additive (distilled
water)
Coolant with ethylene 1
glycol
Checking unnecessary
15
In the fall: Check concentration of ethylene

glycol and adapt as required
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Intervals
Dr.
Zahner

Regular Works
Component name
Number of
persons for
maintenance
work
Work
duration in
minutes
Maintenance tasks
Every three 0504

years
1202,1203
Ion exchanger
15
Replace ion exchanger resin every three years
Fine filter
15
Replace fine filter
Every five
years
Measuring
instruments
Gaskets
60
See data sheet for calibration

Intervals
15
Check and replace as necessary
60
Dismounting of the aggregate (see operator's

manual)
- Visual check for damages
- Check of the gaps acc. to manufacturers manual
- Check of the stator resistance acc. to
manufacturers manual
- exchange of parts if necessary
- installation of new static seals
Item number of
component
0601-0999
Every eight
years
Every ten
years
0201
At standstill 1201
1202,1203
Screwed
glands
Main Pump
Main filter
Fine filter
Maintenance-free
1
15
Replace filter units:
Flow rate < 7.5 l/min
When replacing the ion exchanger resin
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Zahner

Cleaning the Main Filter
Main Filter is maintenance-free. Cleaning only necessary when contamination is expected

1. Switch off the cooling system.
2. Close the valves in the filter inlet and outlet.
3. Open the drain valve 1101 on filter, and drain the case.
4. After complete draining (filter is pressure-free), open the quick-action fastener on blind cover.
5. Remove the filter enclosure cover.
6. Unscrew the filter insert.
7. Clean the filter insert from the outside to the inside using compressed air, or replace it.
8. Check all gaskets for damage, and replace any damaged ones.
9. Introduce the filter insert into the filter enclosure.
10. Attach the filter enclosure cover with quick-action fastener, and close.
11. Close the drain valve.
12. Open the filter inlet and outlet.
Note
In the case of high contamination, the system should be purged completely following switch-on.
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Exchange of the Ion Exchanger
Please observe the safety regulations referred to in the safety data sheet of the
ion exchanger resin.
1. Close the valves in the inlet and outlet of the ion exchanger (1035 &1036).
2. Open the vent valve on the mixed bed cartridge. The system is then relieved
(some liquid may escape).
3. Unscrew the inlet and outlet hoses from the cartridge.
4. Remove the cartridge.
5. Carefully position the cartridge at an angle and allow the remaining water to
escape.
6. Store and dispose of the resin in accordance with the statutory disposal
regulations.
7. Fill the cartridge with new or regenerated resin.
8. Connect the water hoses again.
9. Close the vent valve.
10. Open the ball valves 1035 and 1036.
Note
Ion exchanger resin
The resin requires a little time before it starts to work.
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Replacing the Circulating Pump

2. Close the valves in the pump inlet and outlet.
3. Secure the filter enclosure by tightening the rope.
4. Loosen the screwed glands to the flange, main filter, and base plate.
5. Following complete draining (pump is pressure-free).
6. Lift up and move the pump using the supplied pulley, which is secured on the crane rail.
7. Remove the circulating pump.
8. Insert the new circulating pump.
9. Secure the screwed glands to the flange at 20 Nm, to the main filter, and to the base plate.
11. Open the pump inlet and outlet.
12. Replace the faulty pump and the pulley.
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Replacing the Fine Filter Units
Replacing the fine filters is necessary when the flow drops under 7.5 l/min or when the ion exchanger is
replaced. Proceed as described in the following
2. Close the valves to the main system (1036, 1037).
3. Drain the ion exchanger system.
4. Following drain completely (both filters are pressure-free).
5. Open the quick-action fasteners.
6. Loosen the screwed glands.
7. Loosen the enclosure holders.
8. Replace the filter units (enclosure, filter cartridge).
10. Attach the quick-action fasteners, and close.
11. Close the drain.
12. Open the valves to the main system.
Note
High contamination
In the case of high contamination, the system should be purged completely following switchon.
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Replacing the Refill Unit
Note
Replacement during operation of the system
The refill pump can be replaced during operation of the cooling system since it is not part of the main
cooling circuit. The pump does not have drain or vent units.
1.
2.
3.
4.
5.
6.
Switch off the Pump MCB

Loosen the hoses on the suction and pressure sides
Disconnect the electrical connection
Replace the whole refill unit
Connect the level switch electrically
Connect the hoses on the suction and pressure sides.
The pump is a self-priming diaphragm pump.

Filling and venting is thus unnecessary.
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Pressure Test (based on DIN 4279)
The coolant's temperature should be in the range of the ambient temperature (20 +- 5 C).
Air must be reliably evacuated from the test object before testing is begun. For the Pressure Test, the refill
pump can be manually operated with the relay K5. After the test, the relay has to be switched back to
Automatic mode.
1. Valve 1031 in the supply line to the expansion tank must be closed before starting the pressure test.
2. Carry out the pressure test as shown in the figure:
Preliminary test: The test pressure of 6 bar must be applied within 10 minutes with the refill pump (for
further information see 3.7).
The testing time begins when the test pressure is reached. The test pressure must be kept constant
by re-pumping during the
first 10 minutes. During a 20-minute-break the pipes may deform elastically.
Main test: The main test directly follows the preliminary test. First, the applied pressure P 1 is read off.
This pressure is noted as the
reference value. After 30 minutes, the pressure (P 2 ) is read off again and is compared to the
reference value P 1 . During the testing time (total of 60 minutes), the test object is checked visually for leaks.
The pressure test is passed if no leaks are visible and the pressure difference P 1 P 2 < 0.04
MPa.
3. If there is a loss in pressure, check the system carefully for leaks (screwed glands, flange connections).
4. Reduce the system pressure following the test, open valve 1031 to the expansion tank again.
If leaks are discovered, the complete test must be repeated after they have been repaired.
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1)
2)
3)
4)
6)
7)
8)
9)
Dr.
Zahner

Module Exchange
Switch off the coolant pump on the operating panel of the control cabinet.
Close the coolant valves (in the supply and return pipes) in the two phases the damaged module is not part of
Drain the water into a suitable tank or container
Loosen the cooling-hose connections (4 pieces), using the 14mm Garant combination spanner ( BOM pos-no. 17)
Caution: Place a cloth underneath as hoses might drain or residual pressure might escape from the
system and wet the Power-Module. It has to be assured that the Power Module will not get wet at any
circumstance.
Replace submodule (follow Instruction No. A5E02630072)
Re-establish all four screw connections of the water hoses. Tighten terminal nut by hand, as far as it will go.
Subsequently apply 1/4 rotation (90) with the 14mm Garant combination spanner.
Caution: The sealing of the SERTO pipe connection is purely metallic. Do not damage sealing
surface. Lubricate in case of repeated assembly.
Set both ball valves of the coolant supply back to flow and fill the prepared water with the refill pump which is in
scope of delivery. Then switch on circulation pump to vent the system.
Check coolant connections at the Submodule for possible leakages. If necessary additionally check and tighten
the SERTO connections.
Caution: Leaks or air bubbles in the coolant connections will cause malfunctions and will damage the
converter.
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Draining and Filling of the system
Draining:
The draining of the complete system is done at the drain valve on the outdoor cooler as this is the
lowest point of the system. A hose has to be connected to the nozzle and then the valve can be
opened. A suitable tank or vessel has to be used (Chemically resistant, clean and big enough)
Further drain valves are included at certain points of the system: filters and ion exchanger
Filling:
Make sure that all valves (except drain valves) are open
The system can be filled with the supplied barrel pump. The hose can be connected to the drain
valve of the outdoor cooler. The level in the expansion tank has to be observed in order to avoid an
overflow
Check system for leakages. Retighten connections if necessary.
Start the pump for a few seconds in order to remove air (several times)
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Zahner

Fault acknowledge
Acknowledge via the Reset button or the Acknowledge button from the HMI in
the C&P room
Reset of fan faults and refill pump counter
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Troubleshooting
Fault
Cause
Possible Remedies
Pump does not work
No main voltage
Ensure Power supply
Pump fault
Check power supply

Check the liquid supply and outlet.
Check for leaks
Check the pressure sensor
Replace pump if necessary
Pump running into cavitation
Reduce the flow/ bleed the system
Defective Bearings
Replace/ repair the bearings
Foreign particles inside the pump
Cleaning
Primary Pressure has fallen due to

leakage losses
Check the system for leakage
Normal loss of medium
Refill medium
Bypass control faulty
Check valves
Cooling power is too low
Check the heat exchanger for

contamination
Circulating pump faulty
Replace pump
Excessive heat development in

converter system
Control system
Noises of the pump/ motor
Primary Pressure is too low
Temperatures are too high
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Troubleshooting
Fault
Cause
Possible Remedies
Flow rate is too low; can be concluded

from reduced differential pressure
Stop valves are not completely open
Completely open all stop valves in main

circuit
Filter is contaminated
Cleaning
Expansion tank level too low
Check refill pump

Check sensor
Ion exchanger resin is exhausted
Renew the resin
Flow rate in the ion exchanger bypass

is not ensured
Clean the filter in the bypass

Open all valves in the bypass
Conductivity is too high
For all issues a check of the HMI in the C&P room is recommended
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SVC PLUS Cooling System

Siemens AG 2014 All rights reserved.

Answers for energy.

1. Introduction and overview

3. Presentation of the components

Siemens AG 2014 All rights reserved.

27. April 2016

1 Introduction and overview

Siemens AG 2014 All rights reserved.

27. April 2016

1 Introduction and overview

Siemens AG 2014 All rights reserved.

27. April 2016

1. Introduction and overview

3. Presentation of the components

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

1. Introduction and overview

3. Presentation of the components

4. Control of the cooling system

Siemens AG 2014 All rights reserved.

27. April 2016

Cooling System Arrangement

Refill Tank with

Siemens AG 2014 All rights reserved.

27. April 2016

Function: Creation of sufficient flow to reach

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

Function: Dissipate heat from cooling agent to ambient air

Siemens AG 2014 All rights reserved.

27. April 2016

- water temperature higher than 42C

Fan operation stop conditions:

Siemens AG 2014 All rights reserved.

27. April 2016

belimo drive -M13

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

Siemens AG 2014 All rights reserved.

27. April 2016

Sinker Flow Meter

through the ion exchanger

Belimo drive for

27. April 2016

1. Introduction and overview

3. Presentation of the components

Siemens AG 2014 All rights reserved.

27. April 2016

Control of the Cooling System

Refill Tank Level Switch

Conductivity downstream of IEX