Maintenance Problem

7/31/2019 Maintenance Problem

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PT TRANSPORTASI GAS INDONESIA

BELILAS GBS Maintenance:

1. GTGC A, Node 8 Error, PLC product Obsolete

2. GTGC A, Engine Flame Out

3. GTGC A, GP Over speed

4. Gas & Detection System, Power Supply BA04

Product Obsolete


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GTGC A,Node 8 Error, PLC product Obsolete

Date/Time GTGC A O & M

01-05-2009 @17.14 FL367 Node 8 Connector Error (Alarmcant Reset, Unit UnavailableUnplanned)

Check wiring connection of Module FlexI/O ZF 2080

Check PLC by Software found errorsignal at ZF2081 N63 : 17 Active Node 8 Slot 1 Error active.

Check Connection of ZF2081, OKReset Power to ZF2081 and measurepower to ZF2081, OK

Suspected Module Flex I/O ZF2081Problem (Alarm cant Reset)

Shutdown Historical :


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02-05-2009 Control Net not working Normally

Replaced Net module with New Module

Check and Monitoring PLC programperformance.

Found Node 8 Slot 2 Error at ModuleZF2082

Function Test of enclosure fan 1 & 2with bypass module, found Enclosure

Fan Normal Run

Perform Program simulation

Function Test Relay related to ModuleI/O ZF2080 to ZF2083



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03-05-2009 Function test Equipment that isconnected to ZF2082 (Post Lube Fan 1and Fan 2)

04-05-2009 Replace Discrete Module and ComboModule Flex I/O

Consult to Transavia,PT :

Found the problem is that eachreplacement of the Net adapter module

must be perform network reconfigureusing software RS network for ControlNet.

(RS software progress on order)



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07-05-2009 Try to communicate between PLC & RSnetwork, failed.

08-05-2009 Reconfiguration




12-05-2009 Found Module 1794-ACNR ser A F/W rev D

(Module Discontinue) PLC ObsoleteReplaced Module 1794-ACNR ser A F/W rev Dwith Module 1794-ACNR ser A F/W rev E(Spare from Transavia,PT. Last stock noproduction yet)



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12-05-2009 Found No communication to Node 8 AddressModule

Recommendation from Transavia,PT:

Need to Prepare upgrade the Control net adapterand PLC5/40C processor to Control net 1.5Protocol or other option is change to controllogix system.

05-10-2009 Upgrading PLC:

Replace 7ea Control Net Adapter 1.5 ser C 1794-ACNR 1.25 to ser C 1794-ACNR 1.5

Replace 1 ea PLC5 Programmable Controllers1785-L40C 32 ser E to 1785-L40C 15 ser F



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05-10-2009 Reconfigure Control net network and downloadto processor.

Testing Control net network, found only Chanel A

working properly but Chanel B as redundant isnot working properly.

06-10-2009 Try to using only 2 Module(2 node) installed, butthe problem not solve.

Found new PLC is not working properly

especially on redundant control net network.Switch back 7ea Control Net Adapter 1.5 ser C1794-ACNR 1.5 to ser C 1794-ACNR 1.25

Switch back 1 ea PLC5 Programmable Controllers1785-L40C 15 ser F to 1785-L40C 32 ser E



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06-10-2009 Put back new PLC5 by Transavia,PT to claim toRockwell



9/19

GTGC A, Engine Flame Out


02-12-2009 @11.39 FN472 Engine Flame Out, Restart OK




18-12-2009 Press Switch S349(PCD) calibration ,retighten nut & bolt, and cableconnection

PMV calibration, cable connection check

and retighten, recondition CM switch



04-01-2010 TPD 344 Test, EGF 344 function Test



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02-02-2009 Monitor Voltage of DP Switch S349

(PCD) line from TCS(Control Room)-JB(field) record voltage if shutdownhappened (No Engine Flame Out)

03-02-2010 @11.32 FN 472 Engine Flame Out, and FL346EGF344 Position failed, Restart OK



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04-01-2010 @11.32 FN 472 Engine Flame Out, and FL346EGF344 Position failed, Restart OK

05-02-2010 PM 8K, Function Test EGF344 & PMV

Surge Valve20-02-2010 TCS Panel Often power loss suddenly

Check physically TCS Batteries, Find1pc Batteries burn out. ReplacedBattery and Engine Flame Out Solved.



12/19

GTGC A, GP Over speed


21-11-2011 @22.59 FN476 GP Over Speed, Restart OK

22-11-2011 Engine Wash






14-12-2011 @21.32 FN476 GP Over Speed, Restart OK14-12-2011 Check probe sensor, retighten cable

connection line TCS-JB-Sensor


21-12-2011 Replace Probe Sensor



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26-12-2011 FN476 GP Over Speed, Restart OK

26-12-2011 Check measure frequency & voltage

Test NGP sensor using tools FT51010

calibration:

NGP 100 ; 75 ; 50 ; 25 ; 0

Freq 3000 ; 2500 ; 1500 ; 750 ; 0

24-01-2012 @00.21 FN 476 GP Over Speed, Restart OK

24-01-2012 Check cable connection at JB, retighten24-01-2012 @02.23 FN476 GP Over Speed, Restart OK





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29-01-2012 Check probe sensor, retighten cableconnection line TCS-JB-Sensor

Calibrations Backup Over speed

Check cable sensor of PT


Swap Burrier from GTGC C to A

11-02-2012 FN476 GP Over Speed, Restart OKCheck and measure shield grounding




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14-03-2012 Dismantle and install new EGFReconnected all cables and tubesFunction test with RS logix5 program

15-03-2012 Test Crank failed, FN476 GP Over speed28-03-2012 Replace module ZF2091, ZF2092 and

ZF2093 with new module , RESET onPLC (as per solar suggestion)

28-03-2012 Start Failed, FN476 GP Over Speed

30-03-2012 Change the resistor on ZF2090 (fromnode 07 to node 05) from 10K ohm to20K ohm(as per Solar suggestion)

30-03-2012 Start Failed, FN476 GP Over Speed



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05-04-2012 Perform Troubleshooting with FSR:

Checked ground system at ControlConsole (PE, IE, IS) Found that there is

no connection between them wichmean that ground rod are not bondedtogether.

Checked shield installation for NGPspeed probe. Found that shield is notconnect to IS ground bar but connect

to other shield cables that connect toanywhere. Tracked shield of cable ofthe NGP speed and connected to ISground bar.

Checked installation of the NGP speed

probe



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Found that shield that use wire markerof NGP speed probe come from cableFuel Signal of EGF system. Ensureshield connection of EGF system arecorrect base on Electrical Schematic.

Edit logic for temporary to capturespike at GP speed measurement insidethe logic.

06-04-2012 Start GTGC Unit, collect data from

Controller using Strip chart (using RS5and External Strip chart).

Found unit run normally and there is nospike at GP speed



18/19

Gas Detection System Power SupplyBA04, Gas Detector Product Obsolete


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Maintenance Problem