TCI Control System Overview

Presentation Sections:

• The Company

• The Question: Why TCI?

• The Analysis & Proposal

• The Control Philosophy

The Company

•Solely Dedicated to

•Efficient Operation of Industrial Refrigeration Systems

•Parent Company:

•Advanced Monitoring Technologies Inc.

•Incorporated in 1996

•Involved in innovative system design and implementation

•Wastewater System control

•Aquaculture

•On-line Equipment Vibration Monitoring & Analysis

•Industrial Refrigeration Control Development

•Initial offering involved stand alone units

•2nd Generation produced TechCold Integrated (TCI)

•History of TCI Development

•Sales meeting with another large corporation

•They indicated that they were satisfied with the operation of their PLC

based controls.

•At that time, we had a system that was best suited for systems without

viable automatic controls.

•We agreed that a system that combined their PLCs with our algorithms

might be a good platform.

•We were given a relatively new plant in Maine to use for TC I prototype

development along with their technical assistance.

•After two years of on and off site research & development, we were

pleased to report a 20% energy savings within their new cold storage

warehouse (2003).

•Some Employees

•Ernie Adsett, P.Eng.

•Over 30 years of energy conserving system R&D, design, implementation

and monitoring.

•Brad Watts, CM:

•Has over 25 years of hands-on and design experience with industrial

refrigeration systems

•Gui Richard, BSc CS

•Senior computer programmer and systems integrator

•Rob O’Kane, CET

•Senior PLC programmer and systems integrator

•Hong Zhao, MSc E, P.Eng

•System modeling and graphics/tag interfacing and development

•Iman Ebrahimi, PhD P. Eng.

•Research and Development (Dynamic Suction Control, etc.)

•Some of our Clients

•McCain Foods Limited

•Maple Leaf Foods

•VersaCold

•Nordic Cold Storage

•Omstead Foods

•Clearwater Seafoods

•Bayside Food Storage

•Comeau Seafoods

•Municipalities of:

•Moncton, NB

•Fredericton, NB

•Halifax, NS

The Question: Why TCI?

•Why install TCI when we have a good PLC driven PLC system?

•TCI does not replace the existing system, it complements it.

•The PLC still provides basic control, the TCI provide the optimization.

•Why can’t the PLC design be upgraded to perform the TCI tasks?

•The TCI provides control algorithms and speed that is not possible

within the PLC environment.

•The Result: Less Energy Consumption and a Smaller Energy Footprint

The Analysis & Proposal

TCI Analysis and Proposal

1) Data Input to Simulation Model

2) System/ Cost Modeling

With and without TCI

TCI Energy Savings

TCI capital cost

Payback Period

Other Considerations

Desuperheater attractiveness

Heat pump attractiveness

3) Proposal Submission

The Control Philosophy

The Control Philosophy of TCI

To complement present infrastructure and controls architecture

To allow each controls component to operate where it fits best

The PLC to do the basic house work and alarming.

The TCI to determine the higher end control and to indicate the results to the

PLC for final I/O (Input/Output) control.

Compressor Optimization Control

TCI’s Energy Consumption Advantages

Capacity and power changes have an almost directly

proportional relationship with the variance in the compressor

speed (above 50% of maximum speed).

For this reason, when a variable speed device is available, it is

prudent to operate it as the trimming machine as much as is

possible.

TCI will accommodate this by determining which compressors

(based on capacity) should be turned on and off in order to

attempt to keep the variable speed compressor within its 50%

to 100% range.

When the variable speed compressor cannot be kept within

range TCI will operate all units in accordance with the

standard slide valve controller algorithms.

Compressor Variable Speed Modulation Control


Compressor Slide Valve Modulation Control


Courtesy: UofW

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Dynamic Discharge Pressure Control


Courtesy: UofW



The TechCold Solution: The TCI will float the discharge pressure based

upon the ambient conditions and the capabilities/ capacities of the system.

The TCI will maximum the total efficiency (Tons/kW) for each combined group of compressor/condensers. This is based on intelligent determination of the optimum ambient/ refrigerant approach temperature.



Discharge Pressure Reset during hot gas defrost in order to allow reduced head pressure at other times.

Zoned control through separate temperature indication will allow “load shifting”.

Anti-stratification fan control instead of continuous operation.

Evaporator Control


Performance Display

TCI’s Interface

Trends

TCI’s Interface

HMI Displays with RSView, Wonderware, etc.

TCI’s Interface

TCI’s Service & Support

Service & Support means:

• Monitoring remotely the refrigeration system operation

• To determine any abnormalities

• To work with plant staff to increase efficiency

• Software updates as required and as developed

• Troubleshooting remotely and if necessary on site

• Report generation indicating the system health

• On site review of the system operation at the end of the year, if necessary

TCI’s Service & Support

Service & Support means:

• We are available (phone & e-mail) to discuss your questions and comments – at no cost!

• The first year of service and support is covered at no additional cost.

• After the initial one year of operation:• We offer an attractive program at a

reasonable cost to ensure that your system is updated and optimized as necessary.

TCI’s Spare Parts

All control system parts are conventional, close at hand and easily maintained by qualified plant personnel or local integrators.

For more information regarding TCI products or service, please contact TechCold International at:

Head Office:

TechCold International

127 Rocky Road

Keswick Ridge, NB, Canada

E6L 1V1

Toll Free: 1-800-807-DATA(3282)

http://www.techcold.com

Suction Groups

TCI’s Engineering Interface (example)

Documents

TCI Control System Overview