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A new method for improving the design of temperature control systems in central control rooms

2026-04-06 05:15:20 · · #1
Abstract: This paper introduces a new method for realizing the free design of temperature control in different rooms of the central control room by conducting practical research and analysis on the problems existing in the design of temperature control in the central control room. Keywords: central control room air conditioning design temperature control. I. Introduction: With the rapid development of industrial automation and the widespread application of control systems such as DCS and PLC in the industrial field, the central control room, which is equipped with key control equipment such as DCS, PLC, safety barrier cabinet, terminal cabinet, operator station, and host computer, has been fully affirmed in the core position of factories or enterprises [1]. As part of the factory control system, the functional requirements of the central control room (such as electromagnetic interference prevention, radiation prevention, explosion prevention, waterproofing, anti-static, rodent prevention, reasonable temperature and humidity, etc.) have been gradually standardized and improved in design. According to the layout, the central control room basically includes: operator room, host computer room, cabinet room, power distribution room, corridor, and auxiliary personnel work room. It is generally equipped with a dedicated central air conditioning system to centrally control temperature and humidity. However, we have found that in the summer, the central control room air conditioning unit often malfunctions, and the cabinet room over-temperature alarms frequently occur. Electronic components such as DCS are prone to failure when operating in high-temperature environments. In order to make an emergency, many users have to drill through the explosion-proof wall of the central control room and temporarily install a few cabinet air conditioning units in the control room. However, when the temperature in the cabinet room is normal, the operators often have to wear cotton-padded clothes to work. II. Cause Analysis: 1. Based on years of experience in maintaining DCS in the central control room and the use of far-infrared thermometers to monitor the temperature of various parts and equipment in the control room under different conditions, we have obtained the temperature rate of different locations in the control room under the same air conditioning control. See the table of temperature distribution in the control room for details. Through actual analysis, we found that for a medium-sized or larger central control room, the number of control cabinets, safety barrier cabinets, etc. in the cabinet room is 3 to 5 times the number of equipment such as operating consoles and printers in the operating room[2]. Moreover, the average heat generation of each cabinet is greater than that of the operating console. Therefore, the temperature in the cabinet room is 2 to 5°C higher than that in the operating room. If the temperature in the cabinet room is in a relatively ideal temperature range of about 25°C, then the temperature in the operating room is often about 22°C. Since the operators work in the control room for a long time, they are often seen wearing cotton clothes. 2. Traditional design philosophy treats the central control room as a unified whole. Temperature control in the central control room mainly relies on the cooling capacity provided by a specially designed central air conditioning system to cool and balance the large amount of heat generated by the operation of electronic components such as computers, PLCs, DCS, and safety barriers. The air conditioning system is controlled by uniform temperature and humidity setpoints, ignoring the different temperature requirements and heat generation differences of rooms such as the cabinet room, operator room, upper computer room, and maintenance room. The air conditioning air supply channels are interconnected to distribute the cooling air volume evenly. However, for a medium to large-sized control room, the heat generation of the control stations, safety barriers, and other equipment in the cabinet room is 3 to 5 times that of the operator room. Therefore, a "hot and cold" phenomenon occurs, which is also the reason for the significantly higher failure rate of electronic components in the control system in summer. III. New design perspectives: 1. Use different air conditioning units with independent temperature settings and control: Based on the actual differences in the cooling requirements of each room in the central control room, the air conditioning of the central control room is designed in two groups. The first group: rooms with equipment such as control stations, terminal cabinets, safety barrier cabinets, and UPS distribution cabinets that generate a lot of heat are uniformly called cabinet rooms. Dedicated air conditioning for cabinet rooms is designed and the cooling operation is controlled according to the temperature requirements of the cabinet rooms. The other group: rooms such as operating rooms, upper computer rooms, and auxiliary work rooms that are frequently occupied by staff and where the heat generated by the machinery and equipment is relatively small are uniformly called operating rooms. Dedicated air conditioning for operating rooms is used to adjust the cooling operation according to the temperature requirements of the operating rooms (the temperature is best controlled within the normal temperature range). Independent personalized design can lower the temperature of the cabinet room (generally below 25℃) according to actual needs, ensuring that computer cards, safety barriers and other equipment operate in a relatively ideal environment and reducing the failure rate of cards; relatively independent temperature control of the operating room ensures that the temperature of the operating room is set between 25 and 28℃ without affecting the normal operation of the equipment, so that the operators can work more happily and fully reflect humanized design [3]. 2. Flexible Design: This design incorporates adjustable devices similar to duct baffles between the air conditioning supply ducts. The duct in the server room is designed as the main duct, while the duct in the control room is designed as a branch structure. Under normal conditions, the opening of the duct baffles is adjusted according to the temperature requirements of the control room to control the flow of cold air entering the control room. The control room directly controls the main air volume according to its temperature requirements. Since the temperature requirements of the control room are lower than those of the control room, this design allows for free adjustment and is the simplest operating solution. 3. Redundancy Design: Like the DCS system, PLC system, and transfer pumps, the air conditioning system in the central control room also adopts a redundant design. Furthermore, based on summer requirements, it appropriately considers the increasing demand due to future expansion and renovation of the facility, ensuring that there is still a backup air conditioner during the summer. Regular maintenance of the air conditioning system is guaranteed to prevent air conditioning failures from affecting the normal operation of the DCS and PLC control systems. 4. Real-time Temperature Monitoring Design: This mainly utilizes existing computer resources in the control room to input temperature and humidity signals from the server room and operator room into the computer system, directly controlling the air conditioning operation. The ambient temperature and humidity data of the control room are monitored and recorded in real time on the operator console and host computer, with alarm functions set, achieving digital control and a modern design for the central control room environment. IV. Effect Analysis: 1. The temperature in the control room can be effectively controlled below 25℃, ensuring that high ambient temperatures do not increase the chance of damage and failure of electronic components. The temperature in the operator room is controlled between 25℃ and 28℃, and the relatively smaller temperature difference with the outside environment effectively reduces cooling loss. 2. The central control room air conditioning system adopts a redundant design. Although the initial investment is larger, compared with temporarily installing several cabinet air conditioners in the control room, drilling through the explosion-proof wall and installing drainage pipes is not only more difficult to construct and affects normal operation, but also damages the integrity of the explosion-proof wall and violates the safety regulations that prohibit water pipes from passing through the control room. The cost is about the same. The redundant design ensures that there is still a backup air conditioner in summer, allowing for regular maintenance. In the long run, this effectively increases the service life of the air conditioner and avoids the impact of air conditioner failure on the normal operation of the central control system. 3. Real-time monitoring of the ambient temperature in the control room allows for timely detection and rapid handling of air conditioning system faults. By recording and analyzing the system's operating patterns, preventative maintenance can be carried out in advance. The above methods are worth considering when designing a central control room.
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