I & C Maintenance Manual.doc

Preface This I & C Maintenance Manual is based on I & C equipment instruction and related drawings. It is only for the maintenance of I & C equipment in Pacitan 2×315MW coal-fired power plant, Indonesia. The manuals will be revised and improved with the project progress development.

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Content 1.1

MAINTENANCE OF I/A SERIES CONTROL SYSTEM.........................................................5

1.1.1

SYSTEM HARDWARE INSTALLATION AND ENERGIZATION.............................................................................5

1.1.2

SYSTEM MONITOR SOFTWARE.......................................................................................................................7

1.1.3

DAILY MAINTENANCE....................................................................................................................................11

1.1.4

OPERATION AND MAINTENANCE OF I/A’S SYSTEM.....................................................................................14

1.1.5

COMMON FAULTS AND SOLUTIONS FOR I/A SYSTEM.................................................................................19

1.1.6

THE MAINTENANCE MANAGEMENT OF THE I/A SYSTEM EQUIPMENT.......................................................21

1.2

DIGITAL ELECTRO-HYDRAULIC SYSTEM (DEH)............................................................44

1.2.1

DEH SYSTEM GENERAL DESCRIPTION.......................................................................................................44

1.2.2

COMPOSITION OF DEH CONTROL SYSTEM HARDWARE............................................................................44

1.2.3

MAIN FUNCTIONS OF DEH CONTROL SYSTEM..........................................................................................61

1.2.4

BASIC MAINTENANCE ITEMS AND TECHNICAL REQUIREMENTS................................................................62

1.2.5

DEH SYSTEM FUNCTION TEST....................................................................................................................66

1.2.6

FAULT DIAGNOSES AND COMMON TROUBLE SHOOTING...........................................................................70

1.3

TSI SYSTEM MAINTENANCE............................................................................................72

1.3.1

TSI SYSTEM OVERVIEW................................................................................................................................72

1.3.2

TSI SYSTEM FUNCTIONS AND COMPONENTS.............................................................................................72

1.3.3

TSI SYSTEM OPERATION MONITORING.......................................................................................................79

1.3.4

TSI SYSTEM STARTUP..................................................................................................................................79

1.3.5

TSI TEST.......................................................................................................................................................81

1.3.6

LOCAL MAINTENANCE AND TECHNICAL REQUIREMENTS...........................................................................81

1.3.7

TYPICAL FAULT ANALYSIS & TROUBLE-SHOOTING OF TSI SYSTEM........................................................82

1.3.8

CAUSES OF AXIAL DISPLACEMENT AND PROTECTIVE METHODS..............................................................83

1.3.9

CAUSES OF EXCESSIVE EXPANSION DIFFERENCE AND MONITORING MEASURES...................................84

1.3.10

CAUSES OF TURBINE OVER-SPEED AND PROTECTIVE MEASURES...........................................................85

1.4

ETS SYSTEM MAINTENANCE...........................................................................................86

1.4.1

SYSTEM DESCRIPTION..................................................................................................................................86

1.4.2

WORKING PRINCIPLE....................................................................................................................................86

1.4.3

MAINTENANCE ITEMS AND TECHNICAL REQUIREMENTS OF ETS..............................................................87

1.4.4

TEST PRIOR TO UNIT STARTUP...................................................................................................................89

1.4.5

OPERATION AND MAINTENANCE OF ETS....................................................................................................89

1.4.6

COMMON FAULTS AND TROUBLE-SHOOTING OF ETS................................................................................90

1.5

ELEMENT AND INSTRUMENT FOR I&C MEASUREMENT...............................................91

1.5.1

INSTRUMENT FOR TEMPERATURE MEASUREMENT.....................................................................................91

1.5.2

PRESSURE MEASURING ELEMENT AND INSTRUMENT................................................................................96

1.5.3

ELECTRIC CONTACT WATER LEVEL GAUGE.............................................................................................100

1.5.4

ROTATION SPEED MEASURING EQUIPMENT..............................................................................................101

1.5.5

ZIRCONIA ANALYZER..................................................................................................................................102

1.5.6

FURNACE FLAME MONITORING SYSTEM...................................................................................................104 Page 3 of 112

1.5.7

DRUM WATER LEVEL TV MONITORING SYSTEM......................................................................................105

1.5.8

BOILER SOOT BLOWING PROGRAM CONTROL SYSTEM..........................................................................107

1.5.9

MAINTENANCE OF UNIVERSAL SMALL SIZE RELAY.................................................................................109

1.5.10

MAINTENANCE OF TRAVEL SWITCH...........................................................................................................109

1.5.11

ELECTRIC ACTUATOR.................................................................................................................................109

1.5.12

AI-MI SERIES ELECTRIC ACTUATOR.........................................................................................................110

1.5.13

PNEUMATIC ACTUATOR...............................................................................................................................110

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1.1

Maintenance of I/A Series Control System

1.1.1

System Hardware Installation and Energization Before installation, power supply, grounding, etc. should be checked firstly. Install equipment if everything is right. Usually, the control room should lay static electricity-proof floor; I/A equipment cabinet and operation room should be isolated by transparent glass, therefore, operator could inspect the front parts of cabinets to know operation conditions of I/A modules; cabinet and operation console should be installed on the base plate tightly; when installing cables, cable troughs should be used to keep strong power apart from weak power.

1.1.1.1

Before installation, check whether following tools are well prepared: (Hex Driver) (Letterbug Tool) System Installation Drawing System Installation Manual These goods will be delivered as accessories in I/A system. The Hex driver and the Letterbug Tool are special tools for installing I/A equipment. Besides, the customers should prepare one set of straight screwdrivers or cross screwdrivers. The system installation drawing explains location, inter-connection, power distribution and grounding of I/A system equipment. Equipment showed in installation drawing has the Part Number which consists of numbers and letters. Equipment has attached labels for checking. Insert socket into MS slot. Drawing 1－1 is the Installation Drawing for FCP270.

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Push module into slot. Fasten fix screws with the Hex Driver. Press terminal cable socket of external equipment with one hand slightly. On the top of module, there is an external equipment loading/unloading screw. Use the Hex Driver to drive this screw for 1/2 circle till contact pin contacting with socket. 1.1.1.2

Installation of AW390 Host computer for 390 is Pentium PC, No special installation and wire connections. Installation of FBM Before installation, please read System Installation Drawing to check FBM positions in cabinets. Generally, slots for FBM is called FBM slot. Push FBM into slots. Fasten fix screws at upper and lower corners with the Hex Driver. Fit FBM terminal cable connection joints with opposite FBM. Fasten central screw with the Hex Driver.

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Notice:

1.1.1.3

1.

Please install I/A series modules according to System Installation Drawing carefully.

2.

Connect wires carefully. Arrange wires in order.

3.

During installation, please do not hurt equipment contacts pins.

Power on procedures After installation, it can be energized. Before Energization, please check and make sure urban power and UPS are normal. Each power wire is connected correctly. After check, offer power to CRT, printer, etc. for self-inspection, and then, energize equipment with modules. Activate AW work station. Check the green and red lamps of DNBI or DNBX module of AW. At the beginning, red lamp is on, green lamp blinks regularly. After module self-inspection, work station will load work software. At this moment, only green lamp is on. Next, activate other work stations and FBM cabinets. After self-inspections and startup, all the green lamps of module are on while all the CRT displays. That is to say, system starts to work normally. Please set clock after system startup. Detailed information about clock set please refers to Notice: when energizing cabinet, turn on main power source firstly and then secondary power source

1.1.1.4

Shutdown procedures Operation system for I/A is a multi-customer multi-task system. Therefore, do not cut off power randomly even there is nobody using computer. Shut down it according to following procedures. Otherwise, file system or hardware may be damaged. AW/WP shutdown: enter into process control engineer station, select [SftMnt], and Shutdown_AW. Wait and then cut off power if handing it. Click Start button at left corner of Windows XP display and get a menu. Do not use its last item Shut Down to turn off computer. Since that menu only closes XP in C: but not close I/A in D and it may cause computer crash.

1.1.2

System Monitor Software I/A system provide one set of software package to monitor working condition of the system. We call it System Monitor. After activation of I/A, the software will put into service automatically. By using the software and its MMI, we can know and respond system equipment operation and system communication conditions.

1.1.2.1

Start MMI Move the cursor to the SYS on menu, and click mouse left key. The pull-down menu will appear. Find Sys_MNt and select it; after several seconds, one display pops up. (See 1-3). Page 7 of 112

This is MMI, which connects operator and system monitor software.

图 1-3 Fig. 1-3 Click CLOSE key on menu for quitting MMI. Note:Sys_Mgmt location may change since the environment setting is changed for the customer’s requirement. Please ask the designer for exact location. CLR MSG –Clear testing information on the top of screen ACK CBL - Acknowledge cable alarm ACK ALL - Acknowledge all alarms SAL- System Alarm List, displaying alarm equipment name list NETWORK - Display I/A network structure TIME - Set the clock PERF - Communication Performance display, display communication conditions CONFIG - Display selected working station OFFLINE- Offline diagnosis INH DISP – Equipment name list (its alarm is inhibited) ACK ALL above is used for acknowledging all alarm. If need to confirm alarming equipment, operate according to following steps: Page 8 of 112

Select station → Config → select module. At this time, the bottom will appear EQUIP INFO button; press it and then ACK button to confirm module alarm. 1.1.2.2

Time setting Choose TIME key which is at the bottom of human-computer display. The display, showing in 8-6, will display. Click the big or small arrows to adjust time. Choose RETURN-SET, confirm time you set and get back to previous display. Choose RETURN-CANCEL; get back to previous display without changing system original time.

图 1－4 Fig 1-4 Notice: Use time setting function to confirm time after I/A system startup to keep time of entire stations are the same. Otherwise, even if the times are correct, some software still can not be activated, like CIO configuration device etc 1.1.2.3

Fault response Any equipment in system fails to work, like printer cable comes free, the intelligent transmitter can not communicate with I/A system, may activate system monitor software alarm. SYS key zone on the I/A menu will turn to red and flash. At the Page 9 of 112

same time, the preset printer will send out alarm signal. SYS zone exists in any cases. It has four kinds of color to indicate present condition of different system hardware. Stable green

Normal

Blinking green acknowledgement) Blinking red Stable red 1.1.2.4

System had fault but get back to normal now (without

System had fault (without acknowledgement) Existing fault have not been solve yet (already acknowledged)

Fault location The system monitor software indicates equipment present condition and system communication condition according to Letterbug color changing and frame color changing situations in each monitor display. White frame

Normal condition; system communication is normal

Red frame

System has communication fault

Grey Letterbug White Letterbug

this module should not be in the system Module works normally

Yellow Letterbug Sub-equipment of the modules or one part of redundant modules may work abnormally Red Letterbug

The module has fault.

The shining letters and asterisk(＊) means that there is un-acknowledged faults in system. If “15%

Relay cabinet

R39-(4,7)

Interior signal

38

MSV2 calibration begins

Servo controller

1BD121-9(c,k)

Interior signal

39

CV1 calibration begins

Servo controller

1BD121-10(c,k)

Interior signal

40

CV2 calibration begins

Servo controller

1BD121-11(c,k)

Interior signal

41

CV3 calibration begins

Servo controller

1BD121-12(c,k)

Interior signal

42

CV4 calibration begins

Servo controller

1BD121-13(c,k)

Interior signal

43

ICV1 calibration begins

Servo controller

1BD121-14(c,k)

Interior signal

44

ICV2 calibration begins

Servo controller

1BD121-15(c,k)

Interior signal

45

Calibration permits

Servo controller

1BD121-16(c,k)

Interior signal

46

Synchronization permits

Electric

TB6-(92/93)

47

DEH trip

ETS

TB6-(1/2)

48

HP trip solenoid valve 1 test 6YV

ETS

TB6-(13/14)

49

HP trip solenoid valve 2 test

ETS

TB6-(5/6)

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Interior signal

7YV 50

HP trip solenoid valve 3 test 8YV

ETS

TB6-(21/22)

51

HP trip solenoid valve 4 test 9YV

ETS

TB6-(7/8)

52

Rotation speed