PLC -1

Stn.suply. Healthy Contl. Supply on UPS UPS supply. Healthy. Stn.suply. Healthy Contl. Supply on UPS UPS supply. Healthy.

Comp.-A PLC ON
50%

OFF 100%

TRIP Unload

Amps

Comp.-B PLC ON

OFF

TRIP

Amps

Auto

Manual

Brk.ON

HMI ON Hlthy Auto OFF Manual HDr.Pr. - 6.35

50%

100%

Unload

HMI

Auto

Manual

Brk.ON

ON Hlthy Auto

ACW Hlthy. Dis.Air.Pr. Temp. H Auto Manual Load Unload

LOP Hlthy. HPDV Temp.H ON 50%

LO Temp. Hlthy. E.Stop

ACW Hlthy.

LOP Hlthy.

OFF Manual LO Temp. HDr.Pr. - 6.35 Hlthy.

Sequence OFF ON Bypass ON OFF

Dis.Air.Pr. HPDV Temp. H Temp.H

Auto Manual ON

E.Stop

OFF

OFF 100%

Load Unload

50%

100%

Com.A Comp.B Accept Reset

COMPRESSOR

ON/OFF

HEALTHY

AUTO/MANUAL

HEADER PRESSURE 6.35

PRIORITY START : ON / OFF

MENU

MENU
STATUS PRIORITY

EVENTS

ALARMS

SYS SETTINGS

RUNNING HRS.

STATUS

COMPRESSOR COMP A : COMP B : COMP C : COMP D :

PLC-1 HDR.PR. PLC-1 HDR.PR. -

STATUS : ON/ OFF ON/ OFF ON/ OFF ON/ OFF

-------------- kg/cm2 -------------- kg/cm2

PRIORITY

PRIORITY STATUS: COMP A : MANUAL COMP B : AUTO COMP C : AUTO COMP D : AUTO Note: ON Priority of Auto compressors may be changed as per requirement
PRIORITY : ON / OFF

EVENTS

In this window events are recorded if any changes in settings and auto manual
changeover of compressors ect, are taken place.

ALARMS

ALARMS ARE RECORDED AS:

1. 2. 3. 4. 5. 6. 7. 8. 9. Discharge air temperature high Lube oil pressure low Lube oil temperature high ACW pressure low HPDV temperature high Header pressure high Communication failure between two PLCs PLC fault Feed back fault

SYSTEM SETTINGS

PRT. SETTINGS

MANUAL SETTINGS

SCRN SETTINGS

LOCK

LOCK

D.V SETTINGS

PRT . SETTING

PRIORITY PRESSURE SETTINGS: LODING UNLOADING PRIORITY 1 6.00 L 6.85 L O PRIORITY 2 5.75 O 6.85 C C K K PRIORITY 3 5.50 6.85
HEADER PRESSURE: ------------- kg/cm2

MANUAL SETTINGS

PRESSURE SETTING OF MANUAL COMPRESSURE :

0% 50 % 100 %

LOADING 7.00 LOADING 6.70 LOADING 6.30

L O C K

HEADER PRESSURE:

----------- Kg/cm2

RUNNING HOURS

TOTAL RUNNING HOURS: Comp -A :Sub Total : Total Comp -B :Sub Total : Total
10:00
20:00 10:00 20:00 Clr.S.T
l o c k

Clr.S.T

l o c k

TOTAL

SELECTED COMP. RUNNING HOURS O% Loading 10:00 50% loading 20:00 100%loading 10:00 Total 20:00

OVER VIEW OF AIR RECEIVING SYSTEM

To ADU

Comp-A

Close

Comp-B

Close

Comp-C

Close

Comp-D

Close

Reciver tank -1

Reciver tank -2

Reciver tank -3

Reciver tank -4

AUTO

I F C

Open (Pressure)

Open

Open ( Pressure)

Open

Switch

Transmitter

Switch

Transmitter

Feed back to PLC

Feed back to PLC

IFC internal bypass pressure setting IFC external bypass pressure setting

: 5.8 kg/cm2 : 5.4 kg/cm2

CONTROL SUPPLY
Two control supplies are provided to the PLCs 1. UPS supply: which is taken from UPS-2 distribution board at control room 2. Station Supply: which is taken from USB MCB module
* Control supply is always on UPS , if there is any interruption in UPS supply it automatically changes over to station supply with out disturbing the running compressors. *To know operator whether the control supply is healthy or not lamps are provided on the panel for each supply.

COMPRESSORS CAN BE SWITCH ON NORMALLY 1. Auto 2. Manual IN EMERGENCY CONDTIONS

1. Any one of the PLC fail 2. Both PLCs fail and control supply remains ON 3. Both PLCs fail including the control supply

BEFORE SWITCHING ON THE COMPRESSOR

Ensure that control supply is healthy.
Ensure that Emergency push button is in unlocked mode. Ensure that all indication lamps are in healthy (glowing) condition except the lube oil which glows after switching on the compressor. Ensure that Loading / Unloading selector switch is on Loading mode.

AUTO
For switching ON the compressor in AUTO priority settings are must be set in the priority settings of HMI.
For getting ON the compressors in AUTO by priority, settings as 1,2,3 must be assigned to the compressors in sequence for which are to be kept in AUTO. Otherwise the priorities will not work as there is no sequence.

 As per priority compressors get ON in AUTO at the given priority pressure settings.
PRIORITY PRESSURE SETTINGS IN AUTO Loading priority -1 : 6.00 kg/cm2 priority-2 : 5.75 kg/cm2 priority-3 : 5.00 kg/cm2 Unloading for all : 6.85 kg/cm2

MANUAL
For switching ON the compressor in manual mode selected compressor must be kept in manual mode by keeping the AUTO/MANUAL selector switch in MANUAL. After keeping the selector switch in MANUAL, switch ON the selected compressor after pre-checks by pressing the ON push button provided on panel. Loading and unloading take place as per pressure settings provided in the manual settings. MANUAL PRESSURE SETTING

Loading

50% : 6.70 kg/cm2 100% : 6.30 kg/cm2 Unloadingfor all : 6.85 kg/cm2

ANY ONE OF THE PLC FAIL

PLC 1 FAIL
The following changes take place in the in PLC -2 panel

AUTO compressor comes to priority -1 automatically though the compressor is in priority 2 or 3 and manual compressor remains as it is. If both compressors are in auto one of the compressor comes to priority 1 and the other comes to zero priority.
If both the compressors are in MANUAL no changes take place.

ANY ONE OF THE PLC FAIL PLC 2 FAIL

No changes take place in the PLC-1 as it is master.
Switch ON the compressor in PLC-1 as per situation.

BOTH PLCS FAIL

CONTROL SUPPLY REMAINS HEALTHY
Keep the Bypass selector switch in BY - PASS ON mode provided in the Panel itself. Then switch ON the selected compressor by pressing the ON push button provided there after pre- checkups. Then operate the 50% and 100% loading push buttons provided on the panel by observing the pressure feed back from control room. In this situation compressor can be switch OFF by pressing the EMERGENY push button only.

BOTH PLCS FAIL AND

CONTROL SUPPLY FAIL
Keep the Bypass selector switch in BY - PASS ON mode provided in the Panel itself. Then switch ON the selected compressor by pressing the ON push button provided there, after pre- checkups. Then operate the 50% and 100% loading and unloading from field solenoids by observing the pressure feed back from control room. In this situation compressor can be switch OFF by pressing the EMERGENY push button only.

BEFORE SWITCHING ON THE COMPRESSOR FOLLOWIG PRE-CHECKUPS MUST BE DONE

1. Ensure that the control supply is healthy 2. Ensure that the power supply is healthy 3. Ensure that the Emergency push button is in release position 4. Ensure that the all indications lamps of protections are healthy (glowing) except lube oil pressure as it is glows during compressor ON. 5. Ensure that the Loading/Unloading selector switch is in loading position

PROTECTIONS
FOR THE SAFE OPERATION OF COMPRESSOR FOLLOWING INTERLOKS ARE PROVIDED IN THE PLC
1. 2. 3. 4. 5. 6. 7. Discharge air temp. high Lube oil pressure low Lube oil temperature high A.C.W Pressure low Motor overload Header pressure high H.P.D. air temperature (55 deg.C) (1.5 kg/cm2) (65 deg.C ) (0.7 kg/cm2) 286 A (7.80 kg/cm2) (190 deg.C) (Alarm (Alarm (Alarm (Alarm (Alarm & Trip) & Trip) & Trip) & Trip) & Trip)

( Alarm & Un load only)

(Alarm only)

All lamps of above protections will glow when they are healthy

CONTROLS
1. LOP healthy indication glows after 8 to 10 seconds after switching on the compressor. If it does not take place compressor trips after 15 seconds on LOP low. 2. When compressor is switched ON in manual mode compressor loading, unloading or 50% loading takes place after 20 seconds. 3. To switch ON the compressor Accept and Reset push buttons are to be pressed to reset the faults.

3. Auto selected compressors get ON as per priority selected with 10 seconds time delay one after the other as per predefined pressure settings provided PRIORITY SELECTOR SWITCH should be kept in AUTO. 4. The compressors running in AUTO get OFF as per priority whenever come to unload (i.e. priority -1 after 20 min, 2 after 15min and 3 after 10 min respectively). 5. Two sets of header pressure feedbacks are provided each contains one pressure switch and transmitter. Pressure transmitter is meant for PLC feed back and pressure switch is meant for unloading the compressor directly.