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Framo

Control System

System maintenance procedure

CONTENTS
1 Preface
2 Electric panels / motor starters
3 Alarm check
4 Trip verification
5 Instrument set-point adjustment

No. 1400-0181-4
Rev. B 23May06

FRAMO CONTROL SYSTEM


System maintenance procedure

No.
Date/sign.:
Page:
Rev. B:

1400-0181-4
09Nov95/AAJ
2 of 6
23May06/AAJ

PREFACE
It is recommended that a functional test is carried out at regular intervals to verify that the
control system and related instrumentation is operating according to specification. Mechanical
components may change their characteristics, electronics are drifting or a limit switch may not
be working simply because it is covered by paint. Malfunction of a component may cause
severe damage to equipment as well as personnel. This can be avoided if the hydraulic system
is included in a periodical maintenance program.

ELECTRIC PANELS / MOTOR STARTERS

2.1 Visual inspection


- Check the cabinets, inside and outside, for physical damage and corrosion.
- Keep the cabinets clean and dry.
- Components and ventilation grids must be free of dust.
- Assure that there are no loose objects/tools which may cause damage or short circuits.
- Observe if there are abnormal temperatures.

2.2 Electrical
- Measure supply voltage /frequency and check that the readings are within tolerances.
(Voltage: +\- 10%, Frequency: +\- 5%).
- Measure internal regulated voltage(s) and check that the readings are within
tolerances.(+/- 1V).
- Check PLC status indication:
Running lights
Error lights
Battery lights **
Memory and I/O lights
**

For PLC's containing batteries, please note the following:


- The batteries should be changed every five years.
- Genuine spare battery must be used.
- New battery must be installed within 20 seconds after removal of old battery to avoid loss
of memory.

2.3 Mechanical
Check that all screws on electrical termination points are properly tightened. This applies to
power circuits and control circuits.

FRAMO CONTROL SYSTEM


System maintenance procedure

ALARM CHECK

No.
Date/sign.:
Page:
Rev. B:

1400-0181-4
09Nov95/AAJ
3 of 6
23May06/AAJ

(Note that it will be time saving to carry out this test


simultaneously with item 5).

Alarm status is indicated visually and audible as follows:


a)

Alarm on

==>

Indication lamp flickering


Buzzer activated

b)

Horn silence

==>

Buzzer off

c)

Acknowledge button activated

==>

Steady light

d)

Alarm off

==>

Light off

Activate all alarms as described below and verify that status indication is correct.
In addition, it must be observed that the common alarm relay for remote alarm indication
operates as specified.
Note! Refer to the instrument list for alarm set points (alarm limits), required running conditions
and time delays.
Note the time delays during testing.

3.1 Oil level high


-

Operate the 3-way valve and vent the transmitter to atmosphere.


Connect a transparent hose to the hose nipple.
Fill up the hose with hydraulic oil.
Verify that alarm is initiated when positioning the level in the hose relative to the transmitter
at the set point described in instrument list.

3.2 Oil level low


Refer to procedure in 3.1.
- Verify that alarm is initiated when positioning the level in the hose relative to the transmitter
at the set point described in instrument list.

3.3 Wear indication


Remove the connector ant take out the magnetic debris switch. Put back the connector and
short circuit the poles by means of an metallic object. Most systems has got one wear indicator
for each power pack.

3.4 Oil temperature high


Remove the sensor from the pocket. Apply a reference temperature lower than the set point and
slowly increase the temperature. Verify that the alarm is initiated at correct temperature.

FRAMO CONTROL SYSTEM


System maintenance procedure

No.
Date/sign.:
Page:
Rev. B:

1400-0181-4
09Nov95/AAJ
4 of 6
23May06/AAJ

3.5 Protection pressure low/ Dirty filter (open systems)


The source of these alarms is the same pressure transmitter.
Low protection pressure :
Apply a pressure higher than the set point. Slowly reduce the pressure and verify that the alarm
is initiated at correct pressure. Measuring points and closing valves are provided on the
manifold.
Dirty filter :
Apply a pressure lower than the set point. Slowly increase the pressure and verify that the alarm
is initiated at correct pressure.

3.6 Protection pressure low (closed systems)


The source of these alarms is the same pressure transmitter.
Low protection pressure :
Apply a pressure higher than the set point. Slowly reduce the pressure and verify that the alarm
is initiated at correct pressure. Measuring points and closing valves are provided on the
manifold.

3.7 Dirty filter alarm (closed systems)


Remove the differential pressure switch (DPS) and plug the hole to prevent oil spill.
Connect the special adapter included in the toolbox to the DPS. Apply a pressure lower than the
set point. Slowly increase the pressure and verify that the alarm is initiated at correct pressure.

3.8 Local suction valves


Close the individual suction valves for all power packs. Verify that the corresponding alarm is
initiated as soon as the valves leave fully open position. Observe that the alarm affects
corresponding stop relay only.

3.9 System pressure low


Apply a pressure higher than the set point. Slowly reduce the pressure and verify that the alarm
is initiated at correct pressure. Measuring points and closing valves are provided on the
manifold.

3.10 HPU leakage


Most systems are provided with "vibration fork" type switches. Check that alarm is released
when touching the fork by hand.

3.11 HPU shielding (open systems)


Remove the shielding and check that the alarm is initiated.

FRAMO CONTROL SYSTEM


System maintenance procedure

TRIP VERIFICATION

No.
Date/sign.:
Page:
Rev. B:

1400-0181-4
09Nov95/AAJ
5 of 6
23May06/AAJ

(Note that it will be time saving to carry out this test


simultaneously with item 5)

Trip status is indicated visually and audible as follows:


a)

Alarm on

==>

Indication lamp flickering


Buzzer activated

b)

Horn silence

==>

Buzzer off

c)

Acknowledge button activated

==>

Steady light

d)

Alarm off

==>

No change

e)

Reset button activated

==>

Light off

It is of great importance to verify that trigging an emergency stop relay really trips the
corresponding motor. On most systems, the power packs will trip in sequence. This can for
example be tested by starting all power packs and operate the emergency stop button. This test
should be carried out without any consumers, i.e. no flow and minimum pressure. If this test is
successful, it is sufficient to verify that all emergency stop relays are influenced by the trip
functions. Note that the emergency stop relays are energised during normal operation and deenergised in trip condition.
Activate all trip functions as described below. Verify correct operation of emergency stop relays
and that status indication is correct.
Notes: In addition, it must be observed that the common alarm relay for remote alarm
indication operates as specified.
Refer to the instrument list for alarm set points (alarm limits) and time delays.
Note the time delays during testing.

4.1 Oil level alarm low low


Refer to procedure in 3.1.
Verify that alarm is initiated when positioning the level in the hose relative to the transmitter at
the set point described in instrument list.

4.2 Feed pressure low (closed system)


Apply a pressure higher than the set point. Slowly reduce the pressure and verify that the
system is tripping at correct pressure.
Measuring point and closing valve is provided on the manifold.

FRAMO CONTROL SYSTEM


System maintenance procedure

No.
Date/sign.:
Page:
Rev. B:

1400-0181-4
09Nov95/AAJ
6 of 6
23May06/AAJ

4.3 Return line valves


Close the return line valves, i.e. up- and downstream the filter. Verify that the alarm is initiated
as soon as the valve leaves fully open position.
Note that some systems allow running the feed pumps in low capacity mode when these valves
are closed. Verify that the feed pump is automatically switched to low capacity mode when the
main power packs are stopped.

4.4 Emergency stop switches


All systems are provided with several emergency stop switches. Operate all switches and verify
that shut down is performed.

4.5 External trip functions (e.g. inert gas pressure low low)
Simulate alarm condition and verify that power packs/pumps are tripped as specified.

INSTRUMENT SET-POINT ADJUSTMENT


Refer to instruction no. 1400-0180-4 for adjustment of pressure transmitters/-switches and
temperature transmitters/-switches. Following instruments to be readjusted at regular intervals:
ALL SYSTEMS:
- Pressure transmitter for system pressure.
- Temperature transmitter for hydraulic oil temperature.
- Oil level transmitter for hydraulic oil tank level monitoring.

CLOSED SYSTEMS:
- Pressure transmitter for feed pressure / protection pressure, pressure switch for dirty filter.

OPEN SYSTEMS:
- Pressure transmitter for protection pressure / dirty filter.