METOR STA 2016 P1 E&I REPORT

8TH Nov 2016

YUSUKE INOUE
NOBUHIKO USAMI
CONTENTS

1. ELECTRICAL

2. INSTRUMENT
ELECTRICAL
Electrical Contents

1. Maintenance work of Electrical

Trabajos de mantenimiento de electricidad

2. Replace work of Electrical

Trabajos de reemplazo de electricidad
1.Maintenance work of Electrical
1-1.Switch gear and MCC
A switch gear (VCB) of TR-103A could not be
switched to power-off. After we tried several
times, SW of the switch gear body could be
power-off. It's after that, it's no problem by a
test. It's the cause, Operation mechanism
device of the grease was harder.

El interruptor del asociado al TR-103A no abria.

Sin embargo, despues de varios intentos, se
logró apagar el equipo. La causa de la falla es la
Middle-Voltage SWGR
solificación de la grasa mecanica. panel
1.Maintenance work of Electrical
1-1.Switch gear and MCC
Recommendation
It is very dangerous. If a protection relay is activated and the
switch gear can not power-off.
Es muy peligroso si un rele de proteccion se activa (bajo falla del sistema) y el
switchgear no puede apagarse
1.Maintenance work of Electrical
1-1.Switch gear and MCC
Recommendation
Grease up of operational mechanical device should be performed
with maintenance of VCB and VCS. For this kind of work, it is
recommendable to request manufacture service (TMEIC for
example). The cycle of vender recommendation is 6 years. The
Niigata factory cycle is 8 years.
La reposicion de la grasa del dispositivo mecanico de funcionamiento se debe
realizar con el mantenimiento del VCB y el VCS. Para este trabajo, es
recomendable consultar al fabricante (TMEIC por ejemplo). El tiempo
recomendado por el vendedor es de 6 años, el considerado
por Nigata es de 8 años.
1.Maintenance work of Electrical
1-1.Switch gear and MCC
The electric boards make a some designed hole. It is
possible that animal enters from the hole. If an animal
contact with the electrical circuit, the electrical e.g.：A snake invaded and short-
accident happened as a short circuit or arc. circuited in middle-voltage board.
Los paneles electricos tienen agujeros por donde pueden entrar
animales.Si algun animal hace contacto con el circuito electrico,
puede ocurrir un accidente por un corto circuito o un arco
electrico.

Kind of this trouble accounted for 4% of the electrical

accident in Japan.
Este tipo de problema representa el 4% de los accidentes
electricos en Japon Low-Voltage panel
1.Maintenance work of Electrical
1-1.Switch gear and MCC
Recommendation
Close the holes by board with clay, for instance, to avoid animal
entering.
Cerrar los agujeros de los paneles con arcilla, por ejemplo, para evitar la
entrada de animales
1.Maintenance work of Electrical
1-2.Transfomer

All transformers exceed of 24 years from installation. Furfural Analysis in

the oil have been performed from 2010. Furfural Analysis to estimate the
remaining life. However this analysis report didn’t write the remaining life.

Todos los transformadores sobrepasan los 24 años de instalación. El analisis de

compuestos furanos se realiza desde 2010. Este analisis se realiza con el fin de
estimar la vida remanente del transformador. Sin embargo, en el reporte no se
especifica el estimado de vida remanente de los equipos.
1.Maintenance work of Electrical
1-2.Transfomer
Recommendation
We will research your Furfural Analysis from JAPAN.
Investigaremos su Análisis Furfural desde JAPÓN.

＜Principle of Furfural Analysis＞

The life of the transformer is related to the deterioration of the coil insulating
paper. If it is degraded, Furfural is dissolved into the insulating oil.

＜Management in Niigata factory＞

First measurement: Commissioning stage.
Second measurement: After16 years operation.
1.Maintenance work of Electrical
1-2.Transfomer
The condition of the transformer is
no problem.
Los transformadores no tienen
problemas de condición

Visual inspection of the radiator is

important. If the radiator is
corrosion, lead to insulating oil
leakage.
La inspeccion visual del radiador es
importante. Si el radiador tiene e.g.： insulating oil leakage
corrosión, pueden haber fugas del
aceite aislante
1.Maintenance work of Electrical
1-3.UPS and 24VDC/125VDC PUWER SUPPLY
2016 STA, The UPS and 24VDC/125VDC power supply were replaced.

En STA-2016-P1 fueron reemplazados los sistemas de UPS, 24 VDC y 125

VDC

Recommendation
The vender inspection should be performed every STA.
According to vender instruction manual, periodical
replacement of parts (e.g. cooling fan, battery, etc.)
should be performed.
Recomendamos realizar una inspeccion por el fabricante
cada STA. De acuerdo al manual de instrucción del
vendedor, considerar el reemplazo periodico de las partes.
1.Maintenance work of Electrical
1-4. Maintenance Master-list
The list contains equipment ranking, remaining life, maintenance cycle,
etc. It’s marvelous!! Please continue the facility management.
La lista contiene la clasificacion de los equipos, la vida remanente, ciclos de
mantenimiento, etc. ¡Es una maravilla! Por favor, continuen con la implementacion del
facility management
1.Maintenance work of Electrical
1-5.Spare-Parts of Electrical
Common electrical device should be stored as spare parts.
For example, MCC of the magnet switch, thermal relay, contactors, etc.

Los equipos comunes deben tener repuestos almacenados. Por ejemplo, el

interruptor principal, relé termico, contactores, etc.
1.Maintenance work of Electrical
1-6. Others
・We propose to make operation standard（paper） of the bus A and bus
B for a power-on/-off operation for safety reason.
Por motivos de seguridad, proponemos se realice un procedimiento estandar
para el encendido/apagado de las entradas A y B.

・ A few days, maintained electric equipment was put on the floor. But it
was dirty. Insulation performance is degraded.
Los equipos electricos bajo mantenimiento se colocaron en el piso sucio por
algunos días. Esto degrada el aislamiento.
1.Maintenance work of Electrical
1-6. Others
・ The charging equipment was divided by red tape. Good be safe.
Los equipos con carga fueron divididos con una cinta roja de precaucion.
2.Replace work of Electrical
2-1.Switch gear
Switch gear on/off test unit is located in the
electrical room. The new switch gear (VCS)
and the existing switch gear (VCS) were
different in cable wiring. It cannot be used
for the test of the new switch gear.

La unidad de test de 125 VDC está

ubicada en la S/E Principal. El VCB/VCS TEST UNIT
conector de los contactores nuevos y
viejos es diferente. No se puede
realizar pruebas con este banco a los
contactores nuevos.
2.Replace work of Electrical
2-1.Switch gear
Recommendation
Please set up a new test unit. In this STA, New switch gear was broken
because cable connector was wrong.
Por favor configuren una nueva unidad de test. En esta STA, uno de los
contactores nuevos se daño porque el conector era el equivocado.
2.Replace work of Electrical
2-2.Concern for next STA

•MS-101 replacement project will be planned next STA. MS-101 is a long

term of delivery equipment. Therefore this project should be started after
this STA.
•El reemplazo del MS-101 está pautado como un proyecto para la proxima STA-
2019-P1. El tiempo de envío es largo, por lo tanto el proyecto debe iniciarse
despues de STA-2016-P1

•The VCS which was replaced this STA must be reused next STA
•Los contactores que fueron reemplazados en esta STA, deberían se
reinstalados en la próxima STA (con el tablero nuevo)
2.Replace work of Electrical
2-2.Concern for next STA

•Replacement all MCC and MS-101 will be planned at the same time. It’s
hard to work isn’t it? Please consider the work volume or budget in all STA
work.
•Se planifica reemplazar todos los MCC’s y el MS-101 al mismo tiempo. Es un
trabajo duro ¿No es así? Por favor consideren el volumen de trabajo y el
presupuesto para todos los trabajos de STA.
•If you plan to replace about MS or MCC, Please don’t forget to replace the
cable and bus duct between MS and MCC.
•Si se va reemplazar el MS o los MCC´s, por favor no olviden
reemplazar los cables y el ducto de barras junto a los tableros.
2.Replace work of Electrical
2-2.Concern for next STA

•The test items of all equipment are different between TMEIC and METOR.
Required test items should be contained in work pack.
•El protocolo de chequeo de todos los equipos presenta diferencias entre
TMEIC y METOR. Los puntos requeridos de chequeo deben estar incluidos en
el alcance de trabajo.
Thank you for your
kind attention.
Muchas gracias!!
INSTRUMENT
FINDINGS & RECOMMENDATIONS

・Valves

・SS tubes

・Local transmitters

・DCS equipments

・Others - Spare parts

- Data utilization of Smart Valve Interface

VALVES

XV & HV valves have some malfunction and

corrosion. For example,

・XV-111

・XV-203

・HV-204

・XV-302

・HV-205
XV-111

Rain water into the actuator, and corroded by

each part because of that.
XV-111
XV-203

Connection between air set and solenoid valve

was not correct.

These accessories added after delivery.

We modified correct connection.

XV-203

BEFORE AFTER

写真
XV-203

AFTER Solenoid valve;

Details of modification; Turn on

When a solenoid valve was turn on, ① − ② OPEN

Signal flows to port① from port②.

Valve was controlled with pneumatic signal from

E/P transmitter. SUP.
Air
① ②

SIG.
from E/P transmitter
XV-203

Solenoid valve;

When a solenoid valve was turn off, Turn off

Adjusted supply air flows to port① from port③. ① − ③ OPEN

It'll be the target position that was not concerned

with the just before state.

SUP.
Air
① ②

SIG.
from E/P transmitter
XV-203

BEFORE Solenoid valve;

When a solenoid valve was turn on, Turn on

Signal flows to port② from port①. ① − ② OPEN

It's different in a port, but the control is same as

before modification.

This case is OK.

②
But… ①
SUP. ③
Air
SIG.
from E/P transmitter
XV-203

Solenoid valve;

Case that needed the modify. Turn off

When a solenoid valve was turn off, ① − ③ OPEN

Keep the just before pressure of the blue line.

Keep the just before operate position.(Doesn’t

operate target position.)
②
Because adjusted supply air doesn’t flow to ①
positioner. SUP. ③
Air
SIG.
from E/P transmitter
HV-204

Actuator had crack on upper side.

We recommend to replace new actuator in next

STA.
HV-204

The temporary repairs was good. It was damaged, when dismantled actuator in this
STA. It doesn’t influence to control.
HV-205

Positioner feedback lever housing had crack by corrosion.

HV-205

We made a hole in this STA because the screw to We didn't dismantle feedback lever.
fixed a lever part.
HV-205

The housing cover was come off because Cover still come off after maintenance. We
housing was corroded. recommend to replace new actuator in next
STA.
XV-302

There were many corrosion and malfunction

because the first time maintenance.
XV-302

Actuator was replaced and disk was not bad, continuation usable.

There were not test flanges, so leak test wasn’t done.

We request to prepare two test flanges by each size for all size in next STA.

(Each one in the primary side and secondary side.)

HV-205

The part of SS tube that touches with another

tube was corroded.

This is a critical problem not only this tube.

SS TUBES

It is similar situation also connecting tube for transmitter.

CORROSION MEASURES FOR SS TUBES

After the sample brought back to MGC in 2014 was analyzed, it was judged as pitting corrosion
by chloride concentration.

We recommended a periodical flush by water or use of the duplex stainless steel.

CORROSION MEASURES FOR SS TUBES

Additional information

The Pitting Resistance Equivalent（PRE） is used as index. (for pitting corrosion-resistant)

PRE ≒ ％Cr + 3.3×％Mo + n×％N

Generally,

High PRE stainless steel have good properties for Localized corrosion-resistant by the environment
including the chloride ion.

Cr(Chromium),Mo(Molybdenum) and N(Nitrogen) improve corrosion resistance to pitting corrosion and

crevice corrosion.
CORROSION MEASURES FOR SS TUBES
CPT=Critical Pitting Temperature
CCT=Critical Crevice Temperature
This graph shows the relation of the pitting
corrosion and crevice corrosion occurrence Caution! : Not all duplexes are effective.
temperature with PRE of each stainless steel and
Nickel base alloy
nickel base alloy.

Pitting corrosion generates 316L by more than 10

Duplex

Temperature[℃]
℃.
Austenitic
Tubes don’t touch with each other, Because crevice
corrosion happens even if it's colder than pitting
corrosion.

Chemical components and PRE of stainless steel

and alloy shows in the next page.
Temperature in Venezuela
 Steel type UNS No. Group Other composition PRE

316 0.08 - 16.0-18.0 11.0-14.0 2.0-3.0 - 23

Sorry,
NO INFORMATION
Alloy of previous page

Chemical composition and PRE

of stainless steel
(Austenitic and Alloy)
 Steel type UNS No. Group Other composition PRE

Chemical composition and PRE

of stainless steel.
(Duplex)
SS TUBES

Other situation；

Painted part,

Of course doesn’t corrode.

CORROSION MEASURES FOR SUS TUBES

Please consider how to measure.

・Flush periodically

・Change quality of material

・Paint

・Replace periodically
LOCAL TRANSMITTERS

Pneumatic - Electric converter needs overhaul and calibration same as pneumatic transmitters.

We recommend to replace filter and to clean throttle mechanisms of control relay.

Filter

Filter

Control
relay
DCS EQUIPMENTS

Replaced motherboard and HDD in this STA.

I think that it was good that might be possible to minimize the cost by replacing partially, not to whole.

When if whole replace, Windows XP can't be installed into current model PC, that means so also to have
to replace YOKOGAWA software(CENTUM CS3000→CENTUM VP), It’s a large amount of cost.

It could make remainning life longer in this STA, We recommend to improve the installation environment
so that dust doesn't enter in PC.(Desk modification example is already introduced in 2014.)

Even if it can be clean periodically in the desk, it can't be clean to the inside of a PC.

When dust collects on a electrical-board, internal temperature rises and may shorten the life of the PC.
 DCS EQUIPMENTS

Current situation (before cleaning)

Inside of a desk Inside of a PC

OTHERS

Spare parts management

Actually, spare parts quantity isn’t sometimes equal to input value of SAP system.

Everyone think enough spare parts and dismantle instrumentation, If don’t have that actually, it can't be
restored.

We recommend to decide who manages clearly, and input person and a quantity of spare parts
confirmation person are same.

If can't do that, to arrange it will be able to double-check.

OTHERS

Data utilization of Smart Valve Interface

These are some of the data in the maintenance

report of the valve positioner by SERVALCON.
DATA UTILIZATION

SVI-II offers three types of diagnostics. Continuous Diagnostics

— continuous, offline, and online. Cycles (valve reversals)

Positioner and valve alerts

Travel (distance traveled)

Hours of operation - Time closed

- Time near closed

- Time open
DATA UTILIZATION

Offline Diagnostics

Single or multiple-step response (position vs. time)

Positioner signature (position vs. command signal)

Valve / Actuator signature (actuator pressure vs. travel)

DATA UTILIZATION

Online Diagnostics

Valve position, input signal, supply pressure,

actuator pressure, I/P pressure

Pneumatic system performance

Circuit board health

Device temperature (actual, high, low)

Valve performance (requires ValVue OVD)

Friction (requires ValVue OVD) *Valvue OVD;online valve diagnostics software by DRESSER
DATA UTILIZATION

・・・・・How would you be able to utilize these many data?

 It is easy to understand that to visualize data.

For example,
DATA UTILIZATION

•Cycles (Turn operation from upside down)

Utilization of a diagnostic Total

cycles

It helps to decide replacement cycle of slide

parts according to total cycles.

…such as ground packing.

Days
DATA UTILIZATION

•Travel (distance traveled)

Utilization of a diagnostic Total

[%]

It helps to decide maintenance or replacement

cycle of ground parts and packing according to
total distance.

It helps to confirm control tendency.

Days
DATA UTILIZATION

•Distribution of step response (position vs. time)

Time
Utilization of a diagnostic (Proportion)
[%]

It helps to confirm of the correctitude of the

valve sizing.

It helps to find of the blockade tendency of

inside the valve and the pipes.
Position[%]

It helps to prediction of trim damage by low

operation position.
Thank you for your
kind attention.
Muchas gracias!!