Home » Repair and Calibration Fixed Gas Sampling System MT SG Bahari PT Samudera Gemilang Bahari

Repair and Calibration Fixed Gas Sampling System MT SG Bahari PT Samudera Gemilang Bahari

IDENTIFICATION RESULT

Specification

Name Device

Fixed Gas Sampling System

Control Unit

Consillium Salwico SW2020

Analysing Unit

Pump

107 CCD20

15 l/min, 230V 50/60 Hz

Vacuum Guard

VCM 095

 

Flow Meter

Brooks 2700

0-300 l/h

Detectors

SIMRAD Optronics GD10

Filter/Pressure Reg.

N1204-D00

0 – 4 kp/cm²

Pressure Instrument

M043

0 – 4 kp/cm²

Filter

N204-F00

Choke Valve

SCO – 604 – 1/8”

Adjustable

Flame Trap Outlet

FTH – 6

Flame Trap Sampling Point

FTH – 8

Power Supply Unit

PSK – 4

220 VAC ± 10-15% / 24 VDC

Automatic Fuse

E21 12250

4A

Relay

E40 06823

24VDC 2P5A

Remote Input/Output PCB

RIOM – 40

Remote Output PCB

RIOM – 41

 

 

 

 

Problems Found

Fault

Fault indicators are caused by several points (see point: Solution and Action Taken)

Alarm Hi – Lo

For Sampling point 1 – 17

External Alarm

 

SOLUTION AND ACTION TAKEN

Problem Checker

Problem

Possible Causes

First Step

Result

Fault

 

 

Good

 

Noted

 

No. Good

Analyse pump, flow failure

Flow Check

PS detected that the pump pressure was normal. membrane pump and PS are working normally.

Bypass pump, flow failure

Flow Check

PS2 pressure switch is working normally. Scan cycle continues. The bypass pump is running at the time of the test.

Analyse Pump or Internal Leakage

Leakage Check

This control is automatically carried out every 24 hours by closing all sampling valves, running the analysis pump and checking that the VS1 vacuum switch is activated. VS1 works normally in 24 hour intervals.

Calibration

Follows the initial calibration results

Detector, (Gas type + type of detector fault)

Gas type check

Make sure to include Prophane sample gas, this is in accordance with the type of detector installed. And in this condition the gas status becomes correct.

Moisture in analysing unit

 

Normal indicates that condense water is sucked into the pipe system of the analysing unit.

High temperature in analysing unit

There is no temperature sensor installed in the cabinet or analyzing device

Power fault

Power Check

Power ready in system

Flow fault on SP #

Point Sampling Check

Point sampling is working normally. An automatic pipe cleaning function has been performed to eliminate causes of flow disruption by rinsing the sampling pipe for 15 seconds and then trying to obtain a new sample.

Fuse fault in control unit

Fuse Check

There are no broken fuses

Low 5 volt in control unit

Voltage Check

5 V voltage available

Repeater unit # no answer

Do not use a repeater unit

Repeater unit # booted

Analyse unit no answer

Communication Check

Control Unit communication with PCB – RIOK-40 worked fine. With a sign the communication signal indicator lights up.

Analyse unit booted

Boot Check

Normal, when resetting if something goes wrong.

No custom setup, using factory (or default) setup

Everything works normally, no need to do a factory reset.

Flash memory error in control unit

FM Check

flash memory is good. No exchange required

Negative drift, analyser (Abnormal condition)

Calibrate the detector.

Alarm Hi- Lo

Basic : Gas alarm panel is activated when a gas alarm situation is detected in the system. The sampling point number, alarm level (LO or HI) and the actual gas detector in alarm are displayed.

Hi-Lo limit parameter setting is incorrect

Parameter Check

Initial Parameters: Hi ==> 10% LEL, Lo ==> 5% LEL

External Alarm

Basic: external alarm reads an error in the sample installation, for example: dead-end pipe etc … But that doesn’t mean it comes from that. It could be from reading the wrong sensing sample.

 

Problem in Installation

Installation Check

Installaion Good, only some of the valves are disconnected and closed

 

Solve the problem in point 1 and 2 above.

Action Taken For Check Result

Check Result

Action Taken

Calibrated Detector

Detector Check

Basic: The detector checks by reading a 4 – 20mA signal as its output.

Result:

The amperage output is 5.8 mA, this value is not reasonable, the effect is on the percentage value sent to the control unit.

Based on the following table of scale:

NORMAL

0%

25%

50%

75%

100%

4mA

8mA

12mA

16mA

20mA

0%LEL

25%LEL

50%LEL

75%LEL

100%LEL

REAL

0%

25%

50%

75%

100%

5.8mA

9,35mA

12,9mA

18,85mA

20mA

1,45%LEL

29,23%LEL

53,75%LEL

88,36%LEL

100%LEL

 Solution:

  • Basically, the detector has to be replaced
  • Temporary solution: Adding an adjustment variable in the form of a variable resistor to the detector output signal to be able to set the signal at point 4mA.

Repair and Calibration Oil Discharge Monitoring and Control System Adding a Variable Resistor

Adding a Variable Resistor

Hi-Lo Parameter

– Hi-Lo Limit change parameter must enter at level 2

– Change the current alarm level for all sampling points.

Repair and Calibration Oil Discharge Monitoring and Control System Change the current alarm level for all sampling points

Choose the alarm level to change (High or Low) with F2 and . Continue with F1

Repair and Calibration Oil Discharge Monitoring and Control System Choose the alarm level to change (High or Low) with F2

Enter the new alarm level with a numeric input and . Exit with F1

Repair and Calibration Oil Discharge Monitoring and Control System Enter the new alarm level with a numeric input

External Alarm

External alarm will automatically disappear when both of the above problems are resolved

RESULT AND CONCLUSION

  1. All alarm status has disappeared, sampling point reads between 6 – 8% LEL.
  2. Fault status has disappeared with records, all requirements such as:
    • Power ready
    • Air pressure ready
Noted:
  • Calibration process is required, 100% LEL prophane gas sample is required
  • Replacement of the detector with the following specifications:

Name device

Gas Detector

Type

GD10

Brand

Simrad

Version

Version: 0-100%LEL C3H8, 5 sec. response time.

Detection method

IR-absorption, dual wavelength, dual path

Gases detected

Hydrocarbons, CO2

Nominal supply voltage

24 V DC

Operating voltage range

18-32 V DC

Star t-up current

0.3 A for 0.3 s.

Power consumption

~3.5 W

Electrical connection

3 wires (0.5 mm2-2.5 mm2)

Operating temperature range

-40 °C to +55 °C (-40 °F to +158 °F)

Storage temperature range

-40 °C to +65 °C (-40 °F to +149 °F)

Ambient humidity

0 to 100% RH (non-condensing)

Material Stainless steel

SIS2343

Colour

Black/silver

Weight

2.9 kg ± 5%

Cable inlet

M20

Ingress protection

IP66 DIN 40050

Ex proof housing main compartment

EExd IIC T6

Ex proof housing terminal compar tment

EExe

DOCUMENTATION

Photo

Video

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