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Maintenance Problem

The document summarizes maintenance issues and repairs for PT TRANSPORTASI GAS INDONESIA. It describes issues with a GTGC A including a Node 8 error with an obsolete PLC product, engine flame outs, and gas pressure overspeed. It also describes an obsolete power supply BA04 for a gas detection system. Troubleshooting and repairs are documented for each issue.

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bgs_ndrt
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158 views

Maintenance Problem

The document summarizes maintenance issues and repairs for PT TRANSPORTASI GAS INDONESIA. It describes issues with a GTGC A including a Node 8 error with an obsolete PLC product, engine flame outs, and gas pressure overspeed. It also describes an obsolete power supply BA04 for a gas detection system. Troubleshooting and repairs are documented for each issue.

Uploaded by

bgs_ndrt
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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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

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time 01-05-2009 @17.14 GTGC A O & M FL367 Node 8 Connector Error (Alarm cant Reset, Unit Unavailable Unplanned) Check wiring connection of Module Flex I/O ZF 2080 Check PLC by Software found error signal at ZF2081 N63 : 17 Active Node 8 Slot 1 Error active. Check Connection of ZF2081, OK Reset Power to ZF2081 and measure power to ZF2081, OK Suspected Module Flex I/O ZF2081 Problem (Alarm cant Reset)

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time 02-05-2009 GTGC A O & M Control Net not working Normally Replaced Net module with New Module Check and Monitoring PLC program performance.

Found Node 8 Slot 2 Error at Module ZF2082


Function Test of enclosure fan 1 & 2 with bypass module, found Enclosure Fan Normal Run Perform Program simulation

Function Test Relay related to Module I/O ZF2080 to ZF2083

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time 03-05-2009 GTGC A O & M Function test Equipment that is connected to ZF2082 (Post Lube Fan 1 and Fan 2) Replace Discrete Module and Combo Module Flex I/O Consult to Transavia,PT : Found the problem is that each replacement of the Net adapter module must be perform network reconfigure using software RS network for Control Net. (RS software progress on order)

04-05-2009

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time 07-05-2009 08-05-2009 09-05-2009 GTGC A O & M Try to communicate between PLC & RS network, failed. Reconfiguration Reconfiguration

10-05-2009 11-05-2009
12-05-2009

Reconfiguration Reconfiguration
Found Module 1794-ACNR ser A F/W rev D (Module Discontinue) PLC Obsolete Replaced Module 1794-ACNR ser A F/W rev D with Module 1794-ACNR ser A F/W rev E (Spare from Transavia,PT. Last stock no production yet)

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time GTGC A O & M 12-05-2009 Found No communication to Node 8 Address Module Recommendation from Transavia,PT: Need to Prepare upgrade the Control net adapter and PLC5/40C processor to Control net 1.5 Protocol or other option is change to control logix system. 05-10-2009 Upgrading PLC: Replace 7ea Control Net Adapter 1.5 ser C 1794ACNR 1.25 to ser C 1794-ACNR 1.5 Replace 1 ea PLC5 Programmable Controllers 1785-L40C 32 ser E to 1785-L40C 15 ser F

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time GTGC A O & M 05-10-2009 Reconfigure Control net network and download to processor. Testing Control net network, found only Chanel A working properly but Chanel B as redundant is not working properly. 06-10-2009 Try to using only 2 Module(2 node) installed, but the 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 C 1794-ACNR 1.5 to ser C 1794-ACNR 1.25 Switch back 1 ea PLC5 Programmable Controllers 1785-L40C 15 ser F to 1785-L40C 32 ser E

GTGC A, Node 8 Error, PLC product Obsolete


Shutdown Historical :
Date/Time GTGC A O & M 06-10-2009 Put back new PLC5 by Transavia,PT to claim to Rockwell

GTGC A, Engine Flame Out


Shutdown Historical :
Date/Time 02-12-2009 @11.39 08-12-2009 @11.39 09-12-2009 @11.37 11-12-2009 @11.37 18-12-2009 GTGC A O & M FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK Press Switch S349(PCD) calibration , retighten nut & bolt, and cable connection

PMV calibration, cable connection check and retighten, recondition CM switch


30-12-2009 @11.34 31-12-2009 @11.34 04-01-2010 FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK TPD 344 Test, EGF 344 function Test

GTGC A, Engine Flame Out


Shutdown Historical :
Date/Time 25-01-2010 @11.32 26-01-2010 @11.34 27-01-2010 @11.34 28-01-2010 @11.34 30-01-2010 @11.32 01-02-2010 @11.32 02-02-2009 GTGC A O & M FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK FN472 Engine Flame Out, Restart OK Monitor Voltage of DP Switch S349 (PCD) line from TCS(Control Room)JB(field) record voltage if shutdown happened (No Engine Flame Out)

03-02-2010 @11.32

FN 472 Engine Flame Out, and FL346 EGF344 Position failed, Restart OK

GTGC A, Engine Flame Out


Shutdown Historical :
Date/Time 04-01-2010 @11.32 05-02-2010 20-02-2010 GTGC A O & M FN 472 Engine Flame Out, and FL346 EGF344 Position failed, Restart OK PM 8K, Function Test EGF344 & PMV Surge Valve TCS Panel Often power loss suddenly Check physically TCS Batteries, Find 1pc Batteries burn out. Replaced Battery and Engine Flame Out Solved.

GTGC A, GP Over speed


Shutdown Historical :
Date/Time 21-11-2011 @22.59 22-11-2011 23-11-2011 @01.02 14-12-2011 @17.17 14-12-2011 @20.47 14-12-2011 @20.52 14-12-2011 @21.01 14-12-2011 @21.32 14-12-2011 20-12-2011 @21.41 21-12-2011 GTGC A O & M FN476 GP Over Speed, Restart OK Engine Wash FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK Check probe sensor, retighten cable connection line TCS-JB-Sensor FN476 GP Over Speed, Restart OK Replace Probe Sensor

GTGC A, GP Over speed


Shutdown Historical :
Date/Time 26-12-2011 26-12-2011 GTGC A O & M FN476 GP Over Speed, Restart OK Check measure frequency & voltage Test NGP sensor using tools FT51010 calibration:

NGP
Freq 24-01-2012 @00.21 24-01-2012 24-01-2012 @02.23 24-01-2012 @03.04 29-01-2012

100

75 ;

50 ;

25 ; 0

3000 ; 2500 ; 1500 ; 750 ; 0

FN 476 GP Over Speed, Restart OK Check cable connection at JB, retighten FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK FN476 GP Over Speed, Restart OK

GTGC A, GP Over speed


Shutdown Historical :
Date/Time 29-01-2012 29-01-2012 GTGC A O & M FN476 GP Over Speed, Restart OK Check probe sensor, retighten cable connection line TCS-JB-Sensor Calibrations Backup Over speed

Check cable sensor of PT


10-02-2012 11-02-2012 14-03-2012 FN476 GP Over Speed, Restart OK Swap Burrier from GTGC C to A FN476 GP Over Speed, Restart OK Check and measure shield grounding FN476 GP Over Speed, Restart OK

GTGC A, GP Over speed


Shutdown Historical :
Date/Time 14-03-2012 GTGC A O & M Dismantle and install new EGF Reconnected all cables and tubes Function test with RS logix5 program Test Crank failed, FN476 GP Over speed Replace module ZF2091, ZF2092 and ZF2093 with new module , RESET on PLC (as per solar suggestion) Start Failed, FN476 GP Over Speed Change the resistor on ZF2090 (from node 07 to node 05) from 10K ohm to 20K ohm(as per Solar suggestion) Start Failed, FN476 GP Over Speed

15-03-2012 28-03-2012

28-03-2012 30-03-2012

30-03-2012

GTGC A, GP Over speed


Shutdown Historical :
Date/Time 05-04-2012 GTGC A O & M Perform Troubleshooting with FSR: Checked ground system at Control Console (PE, IE, IS) Found that there is no connection between them wich mean that ground rod are not bonded together. Checked shield installation for NGP speed probe. Found that shield is not connect to IS ground bar but connect to other shield cables that connect to anywhere. Tracked shield of cable of the NGP speed and connected to IS ground bar.

Checked installation of the NGP speed probe

GTGC A, GP Over speed


Shutdown Historical :
Date/Time GTGC A O & M Found that shield that use wire marker of NGP speed probe come from cable Fuel Signal of EGF system. Ensure shield connection of EGF system are correct base on Electrical Schematic. Edit logic for temporary to capture spike at GP speed measurement inside the logic. 06-04-2012 Start GTGC Unit, collect data from Controller using Strip chart (using RS5 and External Strip chart).

Found unit run normally and there is no spike at GP speed

Gas Detection System Power Supply BA04, Gas Detector Product Obsolete

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