i & c maintenance manual.doc

8/15/2019 I & C Maintenance Manual.doc

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Preface

This I & C Maintenance Manual is based on I & C equipment instruction and related drawings. It

is only for the maintenance of I & C equipment in Pacitan 2×3!"# coal$fired power plant%

Indonesia.

The manuals will be reised and improed with the pro'ect progress deelopment.

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Content

1.1 MAINTENANCE OF I/A SERIES CONTROL SYSTEM.........................................................5

1.1.1 S YSTEM HARDWARE INSTALLATION AND ENERGIATION.............................................................................5

1.1.! S YSTEM MONITOR SOFTWARE.......................................................................................................................7

1.1." DAILY MAINTENANCE....................................................................................................................................11

1.1.# OPERATION AND MAINTENANCE OF I/A$S S YSTEM.....................................................................................14

1.1.5 COMMON FA%LTS AND SOL%TIONS FOR I/A SYSTEM.................................................................................19

1.1.& THE MAINTENANCE MANAGEMENT OF THE I/A S YSTEM E'%IPMENT.......................................................21

1.! DIGITAL ELECTRO(HYDRA%LIC SYSTEM )DEH*............................................................##

1.!.1 DEH S YSTEM GENERAL DESCRIPTION.......................................................................................................44

1.!.! COMPOSITION OF DEH CONTROL S YSTEM HARDWARE............................................................................44

1.2.3 MAIN FUNCTIONS OF DEH CONTROL SYSTEM..........................................................................................61

1.!.# +ASIC MAINTENANCE ITEMS AND TECHNICAL RE'%IREMENTS................................................................621.!.5 DEH S YSTEM F%NCTION TEST....................................................................................................................66

1.!.& FA%LT DIAGNOSES AND COMMON TRO%+LE SHOOTING...........................................................................70

1." TSI SYSTEM MAINTENANCE............................................................................................,!

1.".1 TSI SYSTEM O-ER-IEW................................................................................................................................72

1.".! TSI S YSTEM F%NCTIONS AND COMPONENTS.............................................................................................72

1."." TSI S YSTEM OPERATION MONITORING.......................................................................................................79

1.".# TSI S YSTEM START%P..................................................................................................................................79

1.".5 TSI TEST.......................................................................................................................................................81

1.".& LOCAL MAINTENANCE AND TECHNICAL RE'%IREMENTS...........................................................................81

1."., T YPICAL FA%LT ANALYSIS TRO%+LE(SHOOTING OF TSI S YSTEM........................................................82

1.". CA%SES OF A0IAL DISPLACEMENT AND PROTECTI-E METHODS..............................................................83

1.". CA%SES OF E0CESSI-E E0PANSION DIFFERENCE AND MONITORING MEAS%RES...................................84

1.".12 CA%SES OF T%R+INE O-ER(SPEED AND PROTECTI-E MEAS%RES...........................................................85

1.# ETS SYSTEM MAINTENANCE...........................................................................................&

1.#.1 S YSTEM DESCRIPTION..................................................................................................................................86

1.#.! WOR3ING PRINCIPLE....................................................................................................................................86

1.#." MAINTENANCE ITEMS AND TECHNICAL RE'%IREMENTS OF ETS..............................................................87

1.#.# TEST PRIOR TO %NIT START%P...................................................................................................................89

1.#.5 OPERATION AND MAINTENANCE OF ETS....................................................................................................89

1.#.& COMMON FA%LTS AND TRO%+LE(SHOOTING OF ETS................................................................................90

1.5 ELEMENT AND INSTR%MENT FOR IC MEAS%REMENT...............................................1

1.5.1 INSTR%MENT FOR TEMPERAT%RE MEAS%REMENT.....................................................................................91

1.5.! PRESS%RE MEAS%RING ELEMENT AND INSTR%MENT................................................................................96

1.5." ELECTRIC CONTACT WATER LE-EL GA%GE.............................................................................................100

1.5.# ROTATION SPEED MEAS%RING E'%IPMENT..............................................................................................101

1.5.5 IRCONIA ANALYER..................................................................................................................................102

1.5.& F%RNACE FLAME MONITORING S YSTEM...................................................................................................104

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1.5., DR%M WATER LE-EL T- MONITORING S YSTEM......................................................................................105

1.5. +OILER SOOT +LOWING PROGRAM CONTROL S YSTEM..........................................................................107

1.5. MAINTENANCE OF %NI-ERSAL SMALL SIE RELAY.................................................................................109

1.5.12 MAINTENANCE OF TRA-EL SWITCH...........................................................................................................109

1.5.11 ELECTRIC ACT%ATOR.................................................................................................................................109

1.5.1! AI(MI SERIES ELECTRIC ACT%ATOR.........................................................................................................110

1.5.1" PNE%MATIC ACT%ATOR...............................................................................................................................110

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1.1 Ma4ntenance of I/A Ser4e Contro6 S7te8

1.1.1 S7te8 Har9:are Inta66at4on an9 Ener;4


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Push module into slot. 8asten fi1 screws with the 0e1 rier.

Press terminal cable soc)et of e1ternal equipment with one hand slightly. ;n the

top of module% there is an e1ternal equipment loading,unloading screw. *se the

0e1 rier to drie this screw for ,2 circle till contact pin contacting with soc)et.

...2 Installation of -#3


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7otice

. Please install I,- series modules according to 5ystem Installation rawing

carefully.

2. Connect wires carefully. -rrange wires in order.

3. uring installation% please do not hurt equipment contacts pins.

...3 Power on procedures

-fter installation% it can be energi>ed. (efore 6nergi>ation% please chec) and ma)e

sure urban power and *P5 are normal. 6ach power wire is connected correctly.

-fter chec)% offer power to C?T% printer% etc. for self$inspection% and then% energi>e

equipment with modules. -ctiate -# wor) station. Chec) the green and red

lamps of 7(I or 7(@ module of -#. -t the beginning% red lamp is on% green

lamp blin)s regularly. -fter module self$inspection% wor) station will load wor)software. -t this moment% only green lamp is on. 7e1t% actiate other wor) stations

and 8(" cabinets. -fter self$inspections and startup% all the green lamps of

module are on while all the C?T displays. That is to say% system starts to wor)

normally. Please set cloc) after system startup. etailed information about cloc)

set please refers to 7otice when energi>ing cabinet% turn on main power source

firstly and then secondary power source

...A 5hutdown procedures

;peration system for I,- is a multi$customer multi$tas) system. Therefore% do not

cut off power randomly een there is nobody using computer. 5hut down it

according to following procedures. ;therwise% file system or hardware may be

damaged.

-#,#P shutdown enter into process control engineer station% select B5ft"nt% and

5hutdownD-#. #ait and then cut off power if handing it.

Clic) 5tart button at left corner of #indows @P display and get a menu. o not use

its last item 5hut own to turn off computer. 5ince that menu only closes @P in C

but not close I,- in and it may cause computer crash.

1.1.! S7te8 Mon4tor Soft:are

I,- system proide one set of software pac)age to monitor wor)ing condition of the

system. #e call it 5ystem "onitor. -fter actiation of I,-% the software will put into

serice automatically. (y using the software and its ""I% we can )now and

respond system equipment operation and system communication conditions.

..2. 5tart ""I

"oe the cursor to the 5E5 on menu% and clic) mouse left )ey. The pull$down

menu will appear.

8ind 5ysD"7t and select it+ after seeral seconds% one display pops up. /5ee $3.

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5elect station Config select module. -t this time% the bottom will appear

6J*IP I78; button+ press it and then -CH button to confirm module alarm.

..2.2 Time setting

Choose TI"6 )ey which is at the bottom of human$computer display. The display%showing in K$L% will display. Clic) the big or small arrows to ad'ust time.

Choose ?6T*?7$56T% confirm time you set and get bac) to preious display.

Choose ?6T*?7$C-7C64+ get bac) to preious display without changing system

original time.

图－A

8ig $A

7otice *se time setting function to confirm time after I,- system startup to )eep

time of entire stations are the same. ;therwise% een if the times are correct% some

software still can not be actiated% li)e CI; configuration deice etc

..2.3 8ault response

-ny equipment in system fails to wor)% li)e printer cable comes free% the intelligent

transmitter can not communicate with I,- system% may actiate system monitor software alarm. 5E5 )ey >one on the I,- menu will turn to red and flash. -t the

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same time% the preset printer will send out alarm signal. 5E5 >one e1ists in any

cases. It has four )inds of color to indicate present condition of different system

hardware.

5table green 7ormal

(lin)ing green 5ystem had fault but get bac) to normal now /without

ac)nowledgement

(lin)ing red 5ystem had fault /without ac)nowledgement

5table red 61isting fault hae not been sole yet /already ac)nowledged

..2.A 8ault location

The system monitor software indicates equipment present condition and system

communication condition according to 4etterbug color changing and frame color

changing situations in each monitor display.

#hite frame 7ormal condition+ system communication is normal

?ed frame 5ystem has communication fault

=rey 4etterbug this module should not be in the system

#hite 4etterbug "odule wor)s normally

Eellow 4etterbug 5ub$equipment of the modules or one part of redundant

modules may wor) abnormally

?ed 4etterbug The module has fault.

The shining letters and asteris)/＊ means that there is un$ac)nowledged faults in

system. If MNO appears at the bac) of equipment name% it means the alarm for

equipment is forbidden artificially. This -larm can be restored in 6J*IP C0=.

-fter system alarming% enter ""I of the equipment monitor software. *se the

76@T 4664 and double$direction arrow interchangeably% find out failed

equipment according to the aboe color definition. iagnose the problem and find

out fault causes. -s for the possible causes and solutions% see (:


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-c)nowledge indiidual equipment alarm in eery equipment 6J*IP I78;

display% choose the -CH to confirm the alarming. -fter that% the alarming color will

not blin).

1.1." Da467 Ma4ntenance

..3. I,- 5eries system wor)ing enironment requirements

I,- system wor)ing enironment must meet some requirements that related to

power supply% temperature% humidity% grounding and the air particle.

..3.. Power supply

I,- system requires that the power supply should be continuous and stable and

hae ability to supply power with battery to deal with the accident happens to the

municipal electricity line. It is suggested that the *P5 which is constant power

supply with isolation should be used. *P5 capacity should be decided by I,-system si>e. *sually% .!H- is enough for one cabinet plus one operating plat.

The battery is required to supply the power for !$3: min.

..3..2 =rounding

I,- system must be supplied with one isolated grounding sta)e. The grounding

resistance is smaller than !Q /in power plant it is Q. I,- system safety protection

area% -C power supply area and the inner signal logic area should be connected

with sta)e. -ny equipment belongs to I,- can not be connected with the sta)e

during the grounding.

..3..3 Temperature

The temperature in control room should be controlled in the range of !～3:℃. In

order to calculate the ability of air conditioner% the radiating amount of the

equipment in I,- system has the detailed number in manual. Please refer to the

5ite Planning in (;


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build up a I,- spare parts store. The customer will prepare some spare parts for

some components according to the system condition and some spare part for the

components that are easily bro)en /li)e mouse% ribbon% and purchase some tapes

and dis)s. -ll these are necessary. -nd the customers should store the 8;@(;?;

company material% drawing and dis) which are attached with the computer. Theywill play important roles in future.

If the fault equipment is found% and there is spare part% change it soon. uring the

installation of spare part% please use 4etterbug Tool change the 4etterbug. Till the

new component green light shines% the component name can be seen in the

system managing software in white that means the spare part has already wor)ed

normally. #hen the component is disassembled% release the Me1ternal equipment

assembling screwO first /see 9$3% and then screw off the assembling bolt. The

installation step is 'ust opposite.

..3.3 "aintenance of software

-s for the maintenance of software% the main wor) is to ma)e the bac)up of the

software and resume the damage,lost software and to monitor the condition of

system hard dis). If possible% it is better to ma)e a tape bac)up of hard dis). #hen

the system is in normal operation% please do not change% delete or add the system

content. Please )eep the secret of the code and memori>e the code. If the system

is change for necessity% the changing part must hae the bac)up. Please gie clear

indication on the dis) with the date and method and )eep it well.

..3.3. 5oftware bac)up

(ac)up wor) has two types ma)e the bac)up to small amount of files and ma)e

bac)up to the entire hard dis).

..3.3.. 8iles bac)up

The sae path of this system bac)up file is SoptSnwStools. Ciosae command can

be used to sae bac)up file /ciosae command only can be used in commissioning

period. It should be deleted when unit is normal.

dSoptSnwStools

cd,opt,nw,tools

ls

ciosae

..3.3..2 0ardware bac)up

9: system operation system uses @P system and its bac)up method is the same

with #indows. ;nly using C;PE and 5TICH is o).

..3.3.2 ata bac)up of control processor 8CP

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5ae$all command can be used to sae the data of control processor 8CP to dis).

start

run

cmd

d：

sh

cd opt,fo1,ciocfg,api

sae$all cp2:: ,opt

..3.3.3 *se bac)up to download the data of control processor 8CP.

4oadDall command can be used to download the bac)up file in dis) to controlprocessor 8CP.

start

run

cmd

d：

sh

cd opt,fo1,ciocfg,api

lood$all cp2:: ,opt

..3.3.A 5ystem software reloading /-E; reloading

To ensure the completeness of these teaching materials% the installation of bare

computer Bcomputer without software should be introduced. (ut if it is not

necessary% -E installation should not be used. #e suggest that bac)up tape is

used to restore the hard dis).

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but if it is not% please install the show$card drie software+ otherwise% the I,- can

not be installed. The display resolution is required as :2A×9LK.

Chec) to ma)e sure the networ) card is installed well.

..3.3.A.2 I,-s software installation

Put I,-s software C into C$?;"% and enter into the C through -irows 61plore

and then e1ecute the 5etup file in C.

Then the installation display and the corresponding dialog bo1 appear. #hen the

first Juestion dialog bo1 appears% choose Ees to build the 8o1 customer. Then the

ne1t dialog bo1 ?estart 7ow appears and choose Ees% I want...% press ;H button.

-fter the computer restart% repeat the operation of a.

#hen the dialog bo1 Committed Install 8iles is) I U : appears% put the

prepared Commit dis) into 8 and press 4oad button and then the installation will

continue.

-nd then the dialog bo1 on the main networ) card selection will appear% -#9:

should choose networ) card of PCI bus wire+ #P9: should choose networ) card of

I5- bus wire. #hen the networ) card is selected% press 7e1t button to continue the

installation.

#hen the dialog bo1 ?elease 4eel is)ette is) I U :: appears% put the

matched dis) into 8 and press 4oad button and then the installation will continue.

?epeat the process till the U::! dis) finishes the installation.

If it is not PC$8(% there is no this step. The dialog bo1 PC8( Card 5ettings

appears% set the I?J as % Port as 3A: and 5hared "emory as K:::% and then

press ;H button.

-t this time the dialog bo1 5etup Complete appears and press iew 4ogs button+

the details of the software installation will appear and chec) whether there is

warning /yellow te1t or fault /red te1t appears during the installation. Press the @

button on the right corner of screen to close the bo1.

Ta)e all of the magnetic dis) and the C out of the drie and choose ;H. I want torestart my computer now appears and then press 8inish button.

7ow the I,-Fs software installation finishes.

7otice do not close e@ceed% 8o1Panels% ?54in1 or any other I,-Fs icons.

1.1.# O=erat4on an9 Ma4ntenance of I/A$ S7te8

..A. Chec) before actiation

..A.. The enironment temperature% humidity and cleanness of computer equipment

should meet the operation requirements.

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..A..2 The air condition entilation hole aboe the electrical equipment cabinet should

ta)e measurements to preent the water lea)ing.

..A..3 The power supply fuse should meet the regulations.

..A..A The controlling cabinet and the intermediate terminal number and name shouldstri)e the eye+ terminal bloc) wiring diagram should be put into the cabinet and

lightening is good+ the wiring of common power supply wiring% earthing wire% light

wire and measurement loop wire should be correct and fastened.

..A..! The signal wiring and signal shielding grounding wire which get into the

intermediate terminal cabinet and the controlling station cabinet from the site

should be connected correctly% stably and good$loo)ing. The cable number and the

wiring number should be complete and clear.

..A..L Chec) the following items one by one which should meet the requirements

：

Control station

. The power supply module% main controller and the functional module and

other equipment in cabinet should be reset and installed correctly and stably.

2. The signal wiring% power supply wiring% grounding wire and the connecting

cable in cabinet should be connected correctly% stably and perfectly.

3. The redundancy communication cable connect with seeral stations should be

connected correctly% stably and perfectly.

A. The data communication wiring in the controlling station and the

communication wiring between seeral controlling stations should be

connected correctly% stably and perfectly.

!. Connecting cable between functional module and the corresponding terminal

plate in intermediate terminal cabinet should be connected correctly% stably

and perfectly.

;perator station% engineer station and serice station

. The power supply of the computer% display and printer of eery station should

be connected well.

2. The connection between )eyboard% mouse% display signal wiring and the

printer wiring and the computer should be correct and perfect.

3. The data communication wiring between stations should be connected

correctly% stably and perfectly.

..A.2 C5 system operation patrol

..A.2. uring system operation% do not use the radio in the 3m area around computer

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..A.2.L The enironment inde1 of equipment room% engineer station room and control

station room should meet the requirements of the manufacturer.

..A.3 Periodic maintenance during operation of C5

Periodically chec) and test the following items during the operation

. The operating condition of operator station% communication interfaces% main

controller% communication networ)% system switchoer% and main bac)up

power supply+

2. 0istorical data storage deices should be actie or in default status. C% hard

dis) and cassette tapes should be replaced if it has insufficient spare space. -

cleaning tape should be frequently used to clean the magnetic heads during

the using of cassette player+

3. *se a special cleaning dis) to clean the C drier about once a month+

A. Chec) whether the cooling fans wor)s properly i.e.% rotates normally% no

abnormal sounds% etc. If it does not wor) properly% find out the reasons and

handle the faults immediately.

..A.A "aintenance during normal shutdown and long term shutdown of C5 system

..A.A. 5hutdown computer control system

..A.A.. 7ormal shutdown of the computer control system

. The computer control system should be continuously powered. The power supply to equipment being repaired should be cut off+

2. (efore the computer control system is shut down% confirm the releant

production processes hae been ta)en out of serice or releant isolation

measures hae been conducted. If not% do not shut down the computer control

system+

3. -ll of the required chec)s% processing and information storage hae been

finished+

A. -ll of the subsystems related to the equipment to be power off should beconfirmed to be out of serice and that power to this system is allowed to be

turned off+

!. Confirm no personnel are wor)ing within the system and all power off

procedures are complete.

..A.A..2 4ong term shutdown of computer control system

. Thorough bac)up of all software and data should be conducted before long

term shutdown+

2. The ambient temperature% humidity and cleanliness should meet the

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requirements during long term shutdown+

3. ?egularly turn the system on and conduct releant chec)s and tests to ma)e

sure that the computer control system is in good condition.

..A.A..3 "aintenance and testing cycle of the computer control system

..A.A..3. The maintenance and testing of the computer control system should be conducted

in con'unction with the unit ma'or oerhaul. The releant maintenance should be

conducted on the basis of system status when the unit is undergoing minor

oerhaul.

..A.A..3.2 In the following situations% basic performance and functions of the computer control

system should be tested.

. 7ew computer control system is being put into operation+

2. The computer control system has updated hardware and software+

3. The computer control system has important modified hardware and software.

..A.A..A Power off sequence

Power must not be randomly switched off. It must follow the following procedures

. Turn off the main power supply of eery operator station+

2. Turn off the power supply of peripheral equipment% such as display monitor

and printer+

3. Turn off the local power supply of control station+

A. Turn off the system power supply of control station+

!. Turn off the power switch of control station.

..A.A..! Chec)s and quality requirements relating to system energi>ation

..A.A..!. irectly energi>ing the computer control system after it has been repaired or

shutdown is not allowed. The following procedures should be obeyed

..A.A..!.. Preparation

. Confirm there are no personnel wor)ing within the power circuits of the

subsystems related to the computer control system+

2. Conform all the subsystems related to the computer control system are

allowed to be turned on+

3. The procedures for the operation of the system are complete.

..A.A..!..2 ?equirements of Power －on Process

uring the Power$on process% eery circuit output oltage of power moduleand power equipment or system power oltage should be inspected one by

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one. #hen faults are found% it should be eliminated in time within the

speciali>ed range.

2 7e1t stage Power$on operations of equipment and system may undergo after

confirming power oltage of Power$on equipment and system whether it is

normal or not

3 Power$on of Control 5tation

） Close main supply switch of control station.

2） Close power supply switch in control station and Close field power supply

switch.

3） 5tart up control station to run automatic operation system. The indicator shows

a normal state% then run self$ diagnostic program to obsere.

A Power$on of operator station% engineer station and serice station

） Close mian supply% main power of engineer station and all serice stations.

#hen there is a display on the screen% entry the operation system and start

application program /or system stars automatically.

2 Close all the switches for peripheral equipment% including printer% hardcopy

unit and monitor.

3 Close the main power station switch of operator station. -pplication program

automatically starts after startups of all operator stations.

! 5tartup all computers one by one following stages aboe until the whole

control system hae started.

L Chec) the indicators of communication lin)% display and all running equipment

of the whole system. ?unning should respond to the actual statement. If not%

problems need to be eliminated. #hen needed% dedicated inspect tools and

soft wares can be used for a further inspection.

1.1.5 Co88on Fa>6t an9 So6>t4on for I/A 7te8

..!. Power 5ystem 8ailure Inspections and 5olutions

Indicators of power components should be inspected at required time eeryday.

#hen equipment operates abnormally and the light turns red% components should

be remoed immediately /components use matri1 power supply mode% and any

functional modules will not be affected. -nd then a new one should be changed.

-t the same time% chec) the normal alue of *P5% and confirm power supply within

stipulated range.

..!.2 8aults and 5olutions in #or) station Processor

. -ctiate with ?eboot in the menu on the top. If not% use b.

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2. Press CT?4D-4TD8 at the same time% and restart it.

3. 5tart it from other stations% and then entry 5E5$"gmt. 5elect fail #P and

choose ?eboot 5tation in 6quipment Change display.

A. If all aboe do not wor)% turn off main power of #P cabinet.Then power on%and start it.

..!.3 8aults of CP /Control Processor

..!.3. 5ymptom of failure #hen one of the redundant CPs operates in a normal

statement% oneFs red and green lights are all on or off ;ne CP runs normally% so it

does not effect normal control. 5o use the following stage to loc) CP）.

5olutions

6ntry 5E5$"gmt% and choose CP with faults. Then entry 6quipment Change% and

choose ?eboot 5tation to start this CP.

If a does not wor)% this CP could be inserted and remoed% then Power$on starts

/the other CP should not be remoed. If not% this CP should be replaced.

7ew ersion of hardware needs to be considered if a new CP does not wor). If

ersion marches% confirm that two redundant CPs are remoed synchronously% and

inserted again in accordance with production. If two CPs running at the same time

is permitted% onsite monitoring should undergo closely with technologist. If not%

maintenance personnel should obsere closely when a CP is running.

..!.3.2 8aults red light and green light of two sets of redundancy CP are both on /or red

light is on while green one is off

-nalysis at this time% the producing deice may out of control% so redundancy CP

should be started again. -t same time% inform technical personnel to monitor field

deice operation strictly.

5olutions

In order to restore CP control function as soon as possible% unplug CP with fault

immediately% if the CP still cannot wor) normally% replace these two sets of CP.

..!.3.3 8aults one module in some loop or one control loop cannot operate normally.

/6specially PI% PI6

5olutions

5witch this loop to manual mode immediately% and then withdraw the -;*T

module of this loop% which is used for technical personnel to control field operation

manually

6nter into CI;5 configuration% select module loop and edit all parameters if there

are any faults% quit if the parameters are correct.

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Choose 646T6 in the menu% delete this module% and then choose *7646T6 to

restore this module. In this way% module fault can be eliminated.

..!.A Input,output module% 8(" trouble$shooting

There are two state indicating lights on 8(" board. "aintenance personnel shouldpay attention to light state during daily inspection% and ta)e immediate measure if

there is fault.

..!.A. 8aults one 8(" state indicating light is abnormal red light is on /green light is on

or off.

5olutions

Inform technical personnel to monitor the field in 8(" area carefully.

2 ?eplace 8("

..!.A.2 8aults channel alarm of -I7 appears frequently% or the signal which is detected by

technical personnel is not correct.

5olutions

Chec) the meter once% and put it into operation if there is no fault.

2 If the loop is control loop% change to manual operation firstly% and disconnect

8(" channel terminal which connects with this detecting signal% use this

signal to chec) 8(" channel conersion accuracy. If this channel has fault%

connect 8(" channel terminal to the resered channel terminal. -t the sametime% reise CI; parameters or replace 8(".

..!.A.3 8aults

5een from operation interface% the loop can wor) normally% which means the output

parameters are consistent with that of original design. 0oweer% the parameter

which needs to be ad'usted does not change correspondingly. or there is I,;

channel alarm on operating interface.

5olutions

8irstly chec) whether ad'usting ale is bloc)ed% at the same time% chec) accuracy

of positioner. If there is no fault% use "- ammeter to chec) whether the

corresponding 8(" output channel can complete ,- signal conersion correctly.

In this way% we can 'udge whether the output channel has fault or not. If there is

fault% as) technical personnel to operate at local immediately% and e1change with

resered 8(" channel% meanwhile reise CI; or replace the 8(".

..!.! 5ystem crash

Phenomenon C5 display cannot be refreshed+ the panel cannot be operated and

data indication shows no changing.

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5olutions close the host computer power of crashed system% after waiting for three

minutes% supply host computer power+ after P-55#;? interface shows% input

gnomes to restore the system.

1.1.& T?e Ma4ntenance Mana;e8ent of t?e I/A S7te8 E@>4=8ent

..L. (asic maintenance items and quality requirements

..L.. Chec) up before shutdown

Chec) the condition of the computer control system% ta)e a record of the

abnormal conditions for further maintenance.

2 Chec) the operating condition of the hot air fans

3 Chec) the power supply oltage of the uninterrupted power supply /*P5 and

the power supply oltage of each cabinet% chec) the oltage of C power

supply and the operating condition of each power module.

A Chec) the wor)ing condition of each module in the cabinets% chec) the

conditions of each channel and the operating condition of each operator

station% control station% serice station and the communication networ)% etc.

! Chec) alarm system% ta)e a detailed record of the crucial abnormal

information /such as redundance loss% abnormal switch% loss of important

signal% data spill% frequent bus switch% etc..

L Chec) aried printing records and hard copy records.

9 "easure the temperature and humidity of control room% engineer station and

electronic equipment room.

K Chec) the operation log and the data base alarming log of the computer

control system.


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computer control system. Cut off the power supply!pull out the plug of the

equipment which needs to be repaired.

2. The air conditioner system inside electronic room% engineer room and control

room should hae enough capacity. ad'usting performance of temperature and

humidity are good. the ambient temperature! humidity and cleanness shouldcomply with =(2KK9 or the regulation of the manufactory.

3. The fuse of all the power circuit and channel fuse of module should comply

with the requirements of equipment operation. If any damage is found% ta)e a

record of it% and after erifying the causes of the damage!ma)e replacement

with the same capacity and mode of the fuse.

A. The computer equipment should be complete% without rust corrosion%

deformation or distinct damage.

! Confirm the computer equipment are in order and the mar)s are complete and

clear.

L Clean the equipment after electricity of system or equipment is cut off.

9 8or the equipment with antistatic requirements% anti$static measures must be

made before maintenance. "aintenance personnel must wear antistatic

grounding bracelet and )eep away from circuit. The disassembled equipment

should be laid on anti$static plate% and the compressed air gun used for purge

should be grounded.

K The compressed air for purge should be dry and without oil dirt% and the

pressure should be controlled around :.:!"pa. the power of cleaner should

be big enough to absorb the dust% and special detergent must be used for

cleaning equipment.

< The parts inside and outside cabinet should be installed firmly% all screws are

in place. The bolts of connection terminal board and grounding bus are tight.

: The connection cable and lead in the computer equipment room should be

complete and and in good order% and the mar)s should be complete and clear.

..L..2.2 The hardware maintenance of operator station% engineer station and serice

station.

. Confirm the power of the equipment which needs to be repaired has been cut

off% and then open the coer of the cabinet.

2 There is no clear mar) of damage or burning in circuit board% the elements of

circuitry plate has no weld loose. There is no line brea) of the connections or

connection cable% and the fi1ing of the inner equipment% cards and the

connection parts are tight% the fi1ing bolts are complete.

3. Clean the inside and outside parts of the coer and radiator fan% after the

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clearing% the radiator fan should run fle1ibly

A. Install the coer of the cabinet% and confirm that the power supply oltage

grade is set correctly.

! -fter the power is supplied% equipment can be started normally and enter theoperation system% the equipment has no abnormal sound or smell. There is no

incorrect information in the process and the status indicator lights and

interface displays of the are normal. Chec) the radiator fan runs normally and

the rotate direction is correct. 8or the serice station that has no display or

operating equipment /such as )eyboard or mouse in normal wor)ing

condition% display and operation equipment can be connected for inspection.

..L..2.3 The maintenance of the control station

Corresponding equipment of unit and computer control system are stopped%

the control system is stopped as well. 5top the sub$system and power supply

of the equipment that is to be repaired.

2 Ta)e an detailed record of the module cabinet % slot number and the 'umper

wire setting that need cleaning.

3 Clean the module and heat radiator fan% and confirm ther are no dust% dirt%

damage and burn. The module has no corrosion and contact pin or the finger

has no bend and crac). the assemblies in the module are firmly fi1ed% the

setting of 'umper wire and the pin are correct% the connection is reliable. The

type and capacity of module are correct. all the mar)s of the module are clear.

A Chec) the power$fail protection switch of the module of control station and the

'umping wire setting are correct. 8or the module with standby batteries% the

batteries should be e1amined and replaced in accordance with the releant

regulation and requirements of the manufactory. #hen replacing the batteries%

ma)e sure that the electricity loss time is within the permitted range.

! -fter clean and inspection% restore cabinet% frame and slot of module

accroding to the number% and the position should be correct.

L #hen the module is in place% chec) and ma)e sure that the connection cableof the module /such as the flat connection cable are inserted at the proper

position and the installation is firm% and tighten the fi1 screw and bolts if

necessary.

9 (efore energi>ation of the module% chec) the fuse and capacity of module.

after energi>ation% the indication of indicator light should be correct and the

heat radiator fan runs normally.

K 8or the control station with display or )eyboard or mouse interface% connect

display and operation equipment /)eyboard% mouse for chec)up if necessary.

..L..2.A "aintenance of computer e1ternal equipment.

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..L..2.A. The maintenance items of indicator

Cut off the power supply of indicator.

2 Clean the inside and outside of the display% and clean the display screen with

speciali>ed lotion. -fter maintenance% the appearance should be clean. Chec)the elements inside circuit plate to ma)e sure that the connection lines and

plugs are correct and without brea)e and loose% tighten the elements if

necessary. Chec) the signal cable inside indicator to confirm there is no short

circuit% brea)e or crac). The insulation of equipment should be measured

qualified.

3 6nergi>e the display for chec)up after the maintenance% the display menu

should be clear% without twin)le% twitter and abnormal color. The button

function of brightness% contrast% color temperature% focus and positioning are

normal. -d'ust big screen display carefully to ma)e sure the brightness andcolor are een.

A The running of heat radiator fan of the big screen display should be normal.

..L..2.A.2 The maintenance items for printer

Turn off the power of printer% and disconnect the power plug.

2 Clear out the wastepaper inside the printer% and clean the paper coneyer and

paper coneying channel. Confirm the printer has no dust and dirt% and the

elements of inner inner circuit plate has nothing abnormal. the connection

parts or connection wires are correct and without loose and brea)s% tighten the

elements if necessary. The insulation should be measured qualified. add oil to

the mechanical rotating part of the printer accordingly.

3 ?ecoer the printer% and chec) the switches% 'umper wire and the setting of

releant parameters are correct.

A 8or the stylus printer% the paper thic)ness ad'usting bar should be read'usted

according to the thic)ness of the printing papers. after energi>ation of printer%

the automatic test program will be carried out to ensure that the characters are

correct and clear. If there is brea)% replace typing head or ribbon.

! 8or the in)$'et printer% after energi>ation% the self$test program will be carried

out to ensure that the characters are correct and clear% and there are no

deformed character% line loss or in) drop. when replacing the in) bo1% its type

must match the printer.

L 8or the laser printer% after energi>ation% the automatic test program will be

carried out to ensure that the characters are correct and clear% and there is no

character deformation% blac) lines or loose in) powder.

..L..2.A.3 "aintenance items for the trac) ball and mouse

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-fter deenergi>ation% pull out the connection between the trac) ball and the

computer or between mouse and the computer.

2 Clean the trac) ball and mouse carefully% including the ball% the pulley and the

light mouse glistening board.

3 Confirm the elements of the circuit plate are normal% the connnection wire is

correct and there is no wire brea) and wire loose. fasten the fi1ing screws if

necessary.

A ?esume the connection with system% after energi>ation% the operation for the

trac) ball and mouse should be fle1ible.

..L..2.A.A "aintenance items for the )eyboard

;perate each )ey under safety condition% if there is any )ey that moes not

fle1ibly or has no respond or wrong input% record its position.

2 Turn off the computer% pull out the connection between the )eyboard and the

computer to clean the )eyboard and shoot the trouble of )eyboard% especially

the )eyboard which record with defects preiously. The elements of circuit

plate should be under good condition after maintenance% and there is no

connection loose or cable brea).The contact point of )eyboard and the

connection of the computer should be good and without dust or dirt.

3 ?esume the connection with the system% and test each of the )eys again after

energi>ation to confirm that responses of the )eys are quic) and correct.

..L..2.! "aintenance of the networ) and interface

..L..2.!. The maintenance items for communication networ)

#ithdraw system

2 ?eplace the cable and fiber optic cable with fault% the communication cable

has no damage and brea) after the maintenance% and the cable or fiber optic

cable are well fi1ed and without bend.

3 Chec) the grounding condition of metal protectie bushing of communication

cable /the metal protectie bushing applied for local installation

A "easure the insulation resistance% and the impedance of the terminal matcher

to ma)e sure they can meet the requirement.

! Tighten all the connectors /or connector firm screws% all the insert connectors

/such as ?VA!% -*I% (7C% etc. and the terminal connection. -fter

maintenance% test each of the connector% plug$in connector and terminal

connection by pulling slightly to confirm there is no loose.

L -fter energi>ation% chec) the module indication lamps or ia system diagnosisfunction to confirm that the state of the module and the communication bus

Page 26 of 112


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system can wor) normally. The redundant bus should be at wor)ing condition%

and the indication of the indicator lamp of the e1changer% the collecting tray%

the coupling% the transponder and the bus module are normal after

energi>ation .

9 Chec) the control subsystem% I,; channels and the communication indications

ia the system diagnosis or other methods proided by manufactory.

..L..2.!.2 The chec)up items of networ) interface equipment

(efore inspection% cut off the power supply of all equipment and mar) the

connection cable and fiber optic cable% then disconnect the connection cable

and fiber optic cable% and wrap the connector of the fiber optic cable which has

been disconnected to preent it from contamination.

2 Clean and repair the inside and outside of the networ) equipment% such as the

e1changer% the collecting tray% the coupler% transmitter and the fiber optic

conerter. tighten wire connection if necessary. The equipment should be

clean and without dust or dirt after maintenance. the elements inside circuit

plate has no abnormal condition% and the wire connection or the cable

connection should be correct and without loose or brea). all plugs should be

under wor)ing condition% and the insulaton test for fans and other equipment

should be qualified.

3 Carefully chec) the optical cable connection% ?' A! interface or (7C interface

to confirm that there is no brea)% crac) or deformation.

A ?estore the coer and supply power to confirm that the rotating direction of the

fan is correct% and there is no abnormal sound and smell. The automatic test

has no fault% and the indication of the light is normal.

..L..2.L "aintenance of power supply equipment

..L..2.L. "aintenance items of module power% system power and cabinet power supply

..L..2.L.. Cleaning and common test

5top releant system% mar) the power plugs or wire connection before pulling

out.

2 Clean power supply equipment and fans% pull out the inner pieces of the power

supply carefully% confirm that there is no burning mar) in inner printed circuit

plate. The elements are normal% the connection wire% connection cable% signal

cable% power line and grouding cable hae no brea) or loose% tighten again if

necessary. The big capacitance inside the power supply should hae no

e1pansion% deformation or lea)age% otherwise% replace the capacitance with a

new one with the same type and mode. Chec) the fuse% if there is any

damage% replace with the same type and mode.

3 "easure the insulation resistance between the primary side and the secondary

Page 27 of 112


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29/111

. 6nergi>e each computer% start the display menu and the self$test% if there is

wrong information hint% ta)e corresponding measure.

2. =enerally% there is no wrong information hint during energi>ation and self$start

process of the operation system% and if there is erro% the error will be repaired

automatically. ?estart operation system to chec) there is no error indication%

otherwise% consider bac) up resume or reinstallation.

3. -fter startup of the operation system% the entire application document should

be closed. 5tart the dis) testing and repairing program to test and repair the

dis) error.

A. Chec) and calibrate the system date and time.

!. 5earch and delete the temporary document in the system% clear up the recycle

bin+ for the computer station without the function of the automatic deleting of

the data document% clear up the useless data document manually.

L. Chec) each user authority% the account command% the auditing and clientage

relation and the setting of the area and group are correct% and meet the

requirement of system. Chec) the authority set for the equipment or the

document% the document share and the access of document should be right

and meet the requirement.

9. Chec) the residual space of the dis)s and ma)e sure there is some spare

space. The dis) chip tidying program should be started to optimi>e the dis).

..L..2.K.2 The application software and the integrality test

. -fter modifying of the computer control system logical configuration% bac) up

the software again.

2. Chec) the integrality of application software according to software list supplied

by manufacturer.

3 Chec) and confirm system integrality according to system startup conditions

A. There are no abnormal and error indicates during startup of application system

software /as for energi>ation auto start system% it will start after startup of operation system

!. 5tart other software of operation station% engineer station and serice station

separately% and there are no faults.

L. 5can and chec) the integrality of the software system by employing the utility

program deice that is proided%

9. 5tart the self$monitor% fault searching% and self$diagnosis software of computer

control system to chec) whether the function can meet the regulation of the

manufactory%

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..L..2.K.3 Chec) the authority setting

. Chec) the setting of userFs authority in each operator station% engineer station

and serice station to ma)e sure the settingcan meet the requirement of

management and safety regulation.

2. Chec) the userFs authority setting of the interface station networ) or the

gateway to ma)e sure they can meet the requirement of management and

safety regulation.

3 Chec) the net wor) interface station or end I serice setting of gateway% and

stop the end I serice that is not used.

..L..2.K.A ata base chec)up

. The setting of data base isitation authority should be correct and meet the

requirement of management and safety regulation.

2. 61plore the data base% and the releant information of data base and sheets

should be correct.

3. If the record of the data base diary is full% bac) up immediately and then delete

it.

..L.2 The test after small repair and oerhaul of C5

..L.2. 8or the computer control system after maintainance or upgrad% the performance

and functions of its system should be tested according to releant requirements.

..L.2.2 8or the computer control system after maintainance or upgrad% if the test of the

performance and function of the equipment is normal% do the off$line operation for

92 hours to test the stability of the system% only when the stability of the system

meet the requirements can the system be put into on$line operation.

..L.2.3 The C5 system redundant switch test

..L.2.3. The redundant switch test of the module% system and cabinet power supply

..L.2.3.. 8or the self power supply or redundant power supply system of the module% control

system and computer cabinet% do the following redundant switch test：

） isconnect the wor)ing power circuit to chec) that the stand$by power supply

is automatically put into serice+

2 8or redundant power supply% cut off any circuit of the power supply.

3 o the reerse switch test for the aboe and 2 in the same way.

..L.2.3..2 ?ecoer the system into normal status.

..L.2.3..3 uring the aboe test% the control system should wor) normally% no loss of the

middle data and the accumulated data% and the fault diagnosis indication should be

correct. There should be no fault% or other abnormal condition e1cept I&C

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equipment fault alarms.

..L.2.3.2 The redundant switch test of the operator station and the serice station

..L.2.3.2. 8or the equipments that are in parallel operation% the operator station% for e1ample%

shut down one of the equipment or one part of the equipment% and this should notinfluence the normal operation of the whole computer control system.

..L.2.3.2.2 8or the equipment with redundant switch% when the main operation equipment is

shut down by cutting off the electricity or by shutting down the application software%

the subordinate operation equipment should be automatically started or switched

into main operation status.

..L.2.3.2.3 o the reerse switch test in the same way.

..L.2.3.2.A ?ecoer the system into normal state.

..L.2.3.2.! uring the aboe test% the fault diagnosis indication should be correct% there should

be no fault% or other abnormal condition e1cept there is fault alarms from the I&C

equipment releant to this test.

..L.2.3.3 The main controller and module redundant switch test in the control station

..L.2.3.3. (efore energi>ation of the main controller and the module% chec) the fuse to

ensure that it is fine and complete% and the capacity is correct.

..L.2.3.3.2 -fter energi>ation of the main controller and the module% ma)e sure that the

indication of the indicating light matches the normal practical condition.

..L.2.3.3.3 5elect the following methods to do the redundant switch test of the main controller

and the module.

. Ta)e out the fuse of module and main controller under operation

2. ?eset the main controller and the module in main operation.

3. Pull out the main controller and the module in main operation /the module can

be pulled out or inserted when it is lie

..L.2.3.3.A o the reerse switch test in the same way.

..L.2.3.3.! ?ecoer the system into normal state.

..L.2.3.3.L uring the aboe test% the system should be able to be switched into the operation

of the main controller and module in the subordinate operation% or is able to

change the main controller and module from the subordinate operation into the

state of main operation. the fault diagnosing indication should be correct. There is

nothing abnormal in the system e1cept the alarm for module fault and the

redundant loss occurs.

..L.2.3.A The redundant switch test of the communication bus

..L.2.3.A. Chec) the following items before the test

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. There is no damage or brea) in the bus cable+

2. The connect and insert deices should be firm% the contact should be good%

and the end connection should be correct and firm.

3. Chec) the resistance alue in the bus terminal is normal% the connection isfirm and the indication of the e1changer% the collecting tray and the bus

module indicating lampare correct.

A. Chec) that system wor)s normally through system diagnosis and bus module

wor) indication. ?edundant bus should be in redundant wor) condition.

..L.2.3.A.2 -ctiate or deactiate the equipment on any node of the communication networ)%

the communication of the bus should be normal.

..L.2.3.A.3 Cut off the communication connection between the node equipment and the bus

communication networ) in turn% there should be no fault% crash or other abnormalcondition in the system.

..L.2.3.A.A Ta)e the following methods to do the redundant switch test of the communication

bus

Cut off the power supply for the main operating bus module+

2 Pull out the plugs of the main operating bus+

3 isconnect the main operating bus cable or the terminal matcher+

A 5imulate other conditions.

..L.2.3.A.! o the reerse switch test of c and d in the same way.

..L.2.3.A.L ?ecoer the system into normal condition.

..L.2.3.A.9 uring the test% the communication bus should be switched into redundant bus

operation automatically.The indication of the indicating light and the system should

be normal% and there is no system data loss% at the same time% confirm the

communication is not interrupted% the fault alarm of I&C instrument is correct and

the diagnosis menu display matches the practical condition.

..L.2.3.! Control loop redundancy switch test

..L.2.3.!. Put the computer control system as well as the main controller and modules

related to the control loop into serice normally.

..L.2.3.!.2 5elect one of the following methods to conduct the control loop redundancy switch

test

*se a manual operating deice or other equipment to manually ma)e the

control loop to output a static alue or status. Then reset or turn off the

corresponding main controller or output module that run in the main operationstate+

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2） irectly reset or turn off the corresponding main controller or output module

that run in the main operating mode.

..L.2.3.!.3 The same method is used to conduct control loop reerse redundancy selecting

test.

..L.2.3.!.A ?estore the system.

..L.2.3.!.! ;bsere the control loop output during the test. There should be no changes or

disturbances. Chec) whether the operating mode of standby main controller or

output module is right.

..L.2.3.L 8ault tolerance performance test of the system

..L.2.3.L. #hen any undefined )eys are operated on the )eyboard of the operator station or

a series of illegal orders are inputted on the operator station% faults% crashes or

other abnormal situations of the operator station and control system should not beoccurred.

..L.2.3.L.2 Conduct the reset test on the part of system and peripheral equipment

5hut off the system power supply of control station% and shut off all of the

power supply when the configuration is redundant. Turn it on after 3: seconds+

2 5hut off the running display monitor% and then turn it on again+

3 5hut off the running main computer of the operator station% and then turn it

bac) on+

A 5hut off the running main computer of the communication station% and then

turn it on+

! 5hut off the printers respectiely then turn them on. This operation should be

conducted both when the printer is wor)ing and when it is not wor)ing+

L The control system should wor) normally and there not produce abnormal

situations during the test. The displaying of fault diagnosis should conform to

the actual situations.

..L.2.A *P5 power auto actiation and switch test

..L.2.A. *P5 test

..L.2.A.. *P5 performance test

..L.2.A..2 Connect the *P5 current input terminal to the output terminal of :$2!:# -C

regulator. Connect the regulator input terminal to the 22: -C power supply% then

turn it on. -ccording to the *P5 manual% the current of oltage regulator should be

ad'usted to -C


34/111

..L.2.A..3 Connect the *P5 power supply to -C 22:. 5tart the computer system powered

by *P5 power supply. Conduct the power switchoer test and standby time test

Connect the testing circuit to oscilloscope.

2 Confirm the charging indicator of *P5 power supply is off. #hen the switchedoltage is equialent with the output oltage ad'usted by the oltage regulator%

*P5 power supply should be switched to battery supply. "easure the output

oltage of *P5. It should in the -C range of /W!"×22:.

3 5hut off the e1ternal power supply of the *P5 and switch the *P5 to battery

power until the computer system is automatically shut down% then correctly

shut down the computer.

A Chec) the standby time of the *P5. It should not be less than the required

time stated in the manufacturerFs manual. =enerally% 3: minutes of continuous

supply should be guaranteed+

! ?estore the *P5 e1ternal power supply. 5witch the power supply from battery

power to e1ternal power supply+

L ?ecord the switchoer time of the *P5 power supply. It should be less than !

mins+

9 ;bsere the switchoer process to chec) the corresponding sound and light

alarms% fault diagnosis displays and printing information. There should be no

abnormal situations occuring in the operation of computer control system and

other equipment. If there is% the *P5 power supply should be repaired or

replaced.

..L.2.A..A Inspection of communication between *P5 and computer

..L.2.A..A. Chec) the communication between *P5 and computer is in a normal state. 5tart

self$chec) of the *P5% and inspect the self$chec) report. It should be normal and

with no fail information.

..L.2.A..A.2 5tart up *P5 power test program from the computer% and chec) the

communication with *P5 is normal.

..L.2.A..A.3 Cut off the *P5 e1ternal power supply and transfer to battery supply% or cut off the

power before the computer shutdown and there should be releant alarm

information.

..L.2.! Inspection and test of I,; module

..L.2.!. 0ot insertion and remoal test of modules

Confirm the modules which will be tested hae hot insertion and remoal

functions.

2 ?emoe one module% and there is an error state on the display. Then the

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control system or equipment should automatically carry out releant handling

/such as transferring to manual operation% actuator holding its position% etc.

uring insertion and remoal% other functions of the control system should not

be affected.

3 #hen current signal is inputted into one I,; module channel and remains

constant% insert and remoe this electrified I,; module twice. It should not

affect the system operation% process control and other inputs. Then the display

should show corresponding state when the module is inserted and remoed.

The displayFs corresponding physical quantity alue should remain constant

both before and after the test.

..L.2.!.2 ?eal$time Test of 5ystem

..L.2.!.2. isplay response time continuously switch display of the operator station :

times% and test the time from the last operation to all contents of eery displaythrough program or stop watch. Then calculate and the aerage response time

should be less than .!s. 8or normal displays% the time should be less than

second% 2 seconds for comple1 displays. The time should also not be lower than

the manufacturerFs standards.

..L.2.!.2.2 ate refresh time in the display obsere process ariable real$time data and

operation state change in the display. Then test 2: times ia program or stop

watch. isplay real$time date and operation state refresh period should be s.

Titles and display colors should change as the process changes.

..L.2.!.2.3 ?ealGtime function of on$off ariables acquisition select seeral on$off ariables

channels% connect seeral test signals and alternately change state in accordance

with design on$off ariables acquisition cycle. Chec) the real$time function of on$off

ariables acquisition ia on$off ariables print function. The printing should be in

accordance with design acquisition cycle.

..L.2.!.2.A Processing cycle of controller module test analog quantity and on$off ariables

processing cycle ia program to confirm analog quantity control system is no more

than 2!:ms and on$off ariables control system no more than ::ms. In rapid

process loop% analog quantity control system should be no more than 2!ms and

on$off ariables control system no more than !:ms.

..L.2.!.3 Test of 5ystem ?esponse Time

..L.2.!.3. irect the switch alue operation output signal to feedbac) signal input of

operation ob'ect. Then record the response signal time which the operation station

panel gies the command to display. o it : times and ta)e an aerage. The

aerage response time should be not more than 2.:s.

..L.2.!.3.2 Put analog quantity alue operation output signal to response signal input of

operation ob'ect directly. Then record the response signal time which the operationstation board gies the commander to display /or select one analog quantity alue

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of engineer station as the detection point. ;bsere and record date change time of

the signal which is inputted through the )eyboard is sent to another display. -nd it

should be done : times and ta)e an aerage alue of the time. The aerage

response time should be not more than 2.!s.

..L.2.!.A Test of system memory space and loading rate

..L.2.!.A. *se the system tool or the method proided by manufacturer. Chec) the memory

and e1ternal memory capacity and usage of historical data station or the station

with function of historical data storage of eery control station. It should meet the

following requirements

The memory space should not less than A:R.

2 The e1ternal memory space should not less than A:R.

..L.2.!.A.2 *se the system tool or the method proided by manufacturer. Test the loading rateof computer control system and data commnication bus. The loading rate should

be tested ! times under the different wor)ing conditions and each test time is :

seconds. The aerage alue should meet the following requirements

The loading rate for all the CP* of control stations should not more than L:R

under the seere wor)ing conditions.

2 The loading rate for the CP* of operator station and serice station should not

more than A:R under the seere wor)ing conditions.

3 In the loading rate of data communication bus% ethernet should not more than2:R and other networ)s should not more than A:R.

..L.2.!.! Test of anti$'amming capacity

..L.2.!.!. The test of anti$'amming capacity should be conducted when the operating

enironment of the computer control system has been changed.

..L.2.!.!.2 Test that bring interference oltage into onsite

*se the transformer as interference source. (ring the common$mode

disturbance oltage and differential$mode disturbance oltage from the singal

loop of onsite current% thermocouple and thermal resistance. "easure the

actual common$mode disturbance oltage and differential$mode disturbance

oltage on the input terminal of I,; of control station /see the method in

-ppendi1 C.

2 If the test condition that bring the interference oltage from the onsite is not

meet the requirement% "easure the actual common$mode disturbance oltage

and differential$mode disturbance oltage brought from the onsite on the input

terminal of I,; of control station when the accuracy of analog signals being

tested.

3 -ctually measured ma1imum common$mode disturbance oltage alue should

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less than L:R of common$mode disturbance oltage restraining ability.

*7 R,/:7"? , 2: X:.:! ）

A） -ctually measured channel error caused by the differential$mode singal should

meet the requirement of formula /

*7 R,/:7"? , 2: X:.:! /

In the formula

* R" $ The ratio of -C component pea) alue and full range of this point that

measured on the input terminal.

7 7"? $ ifferential mode re'ection ratio

..L.2.!.!.3 The test of radio frequency immunity *se the wal)ie$tal)ie with frequency of

A::"0>$!::"0> and power of !# as the interference source. Transmit the

singals to conduct the test that .! meters from the open machine cabinet% and the

computer system should wor) normally. The reading ariation range of recorded

testing singnals should not more 2 times than integrated tolerance of measurement

system.

..L.2.L -ccuracy test of module singal processing

..L.2.L. uring the accuracy test of module singal processing% the matching of impedance

between standard source G calibrator and module should be guaranteed and theinternal and e1ternal power supply should correspond with each other.

..L.2.L.2 Chec) the transfer coefficient of eery channel. It should meet alue conerting

requirement of the measurement system.

..L.2.L.3 -ccuracy test of analog input singal

8or newly$built or oerhauled unit% pointwise accuracy test should be

conducted on eery I,; channel of module. 8or medium and minor oerhaul%

$A channels could be selected randomly from eery module /see table .

2 The corresponding standard source is used to respectiely input

:R、2!R、!:R、9!R、::R of singal to the terminals that corresponding with

the measuring point. ?ead the displayed alue from the operator station or

energineer station G manual operator and compare it with the inputted

standard alue.

..L.2.L.A Pulse input /PI signal precision test

. *se releant standard signal source to input signals :R!2!R!!:R!9!R of

measuring range to the terminal of releant measurement point% compare the

indication of the measurement point in the operator station or engineer station

/manual operating deice with standard alue that has been put in+

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2. ?ecord the test data of each measurement point% calculate measurement

errors% and chec) the trigger leel+ they should meet the requirements in the

table . /;r meet the precision requirements of the manufacturer.

..L.2.L.! -nalog output precision test

. 5et the output alue of each point according to :R!2!R!!:R!9!R of

measuring range through operator station /or engineer station% or manual

operation deice% employ standard instrument to measure the indication alue

of the output signal in the releant output terminal of I,; station% and compare

this alue with output standard calculation alue+

2. ?ecord the test data and calculate measurement errors of each measurement

point+ they should meet the precision requirement in table 2.

Table the precision standard of output module channel

-; signal type (asic error ?eturn error

Current /m- W:.2!R :.2!R

oltage / W:.2!R :.2!R

Pulse /0> W:.2!R :.2!R

..L.2.L.L Pulse output /P; signal precision test

. 5et the output alue of each point according to :R!2!R!!:R!9!R of

measuring range through operator station /engineer station% or manual

operation deice% employ standard )ilometer to measure the indication alue

of output signal in the releant output terminal of I,; station% and compare this

alue with the output standard calculation alue+

2. ?ecord the test data and measurement the errors of each measurement point%

they should meet the precision requirement of the manufacturer.

..L.2.L.9 ;n$off /igital input /I correctness test

. Change the status of each input point separately by disconnecting source$free

contact point or by short circuit% or by adding or remoing leel signal% chec)

the status change of each input point at operator station or engineer station

/manual operating deice.

2. ?ecord the status change of each measured point and they should be correct.

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..L.2.L.K The correctness test for interruption type5;6）data input channel.

5end out 3Y! ;n$off signals by digital signal generator with time interal of

msY!ms to input terminal of 5;6 signal. Change the time interal of the signal

generator until the eent sequence record is undistinguishable. The resolution of

the eent sequence record should be equal or less than ms+ the alarm display%

the sequence of printing signal and the time sequence should be consistent with

input signal+ when printing again% the time sequence should not change+

If there is no ;n$off signal generator% input signals simultaneously to 5;6 signal

input terminal of different stations /for e1ample% to connect 5;6 signal terminal of

different station to the same switch% then open or close the switch. The display

and printing record in 5;6 alarm list of operator station should be consistent with

input signal. It is not suggested to print again during the interal between signal

generating and disappearing+ the time difference of signal actiation should be

equal or less than ms.

..L.2.L.< igital output;）correctness test

. 5et the output gien alue of and : through operator station /engineer

station or manual operating deice% measure the pass and brea) condition of

the terminal releant to I,; station. -t the same time obsere the status of

indicating lamp for digital output

2. ?ecord the status change of each measuring point% and ma)e sure the status

change is correct.

..L.2.L.: Test of channel output self$)eep function

. 5et an output alue for measured module channel at operator station%

measure and record the output alue of releant module output terminal at I,;

station.

2. Cut off the system power supply of I,; station firstly% and then switch on%

measure and record the output once again of releant output terminal+

3. The indications of the module output alue before and after switch off should

be within the precision range.

A. The ma1imum error calculated from half alue of the indications difference

before and after the aboe operation should not e1ceed the permissie error

of the module.

..L.2.9 (asic functions test for control system

..L.2.9. 5ystem configuration and on$line download function

. Confirm the authority setting for engineer station is correct and ma)e sure only

engineer can enter the engineer station.

2. ;pen the system configuration software at engineer station% build a

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configuration off$line according to configuration manual% carry out compiling if

the condition permits% and chec) that the functions of the configuration

software are normal.

3. #hen the computer control system is energi>ed% read the configuration of any

main controller or any functional module in control station bac) into the

engineer station+ then download this configuration / or modifying the

configuration and the conforming of it into the original main controller or

functional module. #hen the new configuration has been downloaded% system

original configuration will be refreshed automatically+ ensure that there is no

fault in the system or other abnormal conditions during operation process.

..L.2.9.2 Test for man$machine interface /""I function at operator station.

. Confirm the authority setting for the operator station is correct% and operator

can enter the operator station.

2. Confirm there is nothing abnormal on each process menu and parameter

monitoring menu.

3. ;perates deice with different functions and menus at operation station one by

one through functional )eyboard and mouse. Chec) that each display menu is

normal% each functional )ey or button% all connections of the functional menu%

the corresponding results of the operation should be correct. #hen operate

the )ey that has neer been defined% ensure there are no faults or system

crash.

A. Confirm that the main menus /such as the process menu% parameter

monitoring menu% real$time trend cure display menu% alarm displaying menu%

etc. indicate normally+ chec) that each of the dynamic parameters and the

real$time trend cure are refreshed automatically% and the refresh time can

meet the requirements.

!. Confirm each alarm display+ alarm window and the alarm confirming function

are normal% the connection of alarm clue and relating menu are correct.

L. Confirm historical data searching menu indicates normally% when input data

/such as measurement point name% measurement point number and time

period that need searching% the system should respond correctly and display

correct record /such as historical data report forms or the historical data cure%

historical eent report forms and the operation record% etc.. #hen applying for

printing% the print result is the same as displayed result.

9 Chec) system operating status menu /system self$diagnosis

information!and the display should be consistent with practical status.

K. Chec) that the help and,or the operation guide menu are normal.

..L.2.9.3 Test of report form printing function and screen copy function.

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. Confirm that the display of report forms management function menu is normal+

start periodic printing function of report forms% confirm the format% content and

time% and ma)e sure they can meet the requirements.

2. 5elect the report forms at operator station that need printing by functional

)eyboard and mouse% trigger the random printing function% the system should

print the selected forms immediately% and the format% content and time should

meet the requirements.

3. 5elect one flow chart display and actiate the screen copy function% chec) the

hard copy content and menu display are consistent.

A. -ctiate any data signal in the 5;6 report forms% chec) that the 5;6 report

forms are printed normally. The data and actiated data signal before or after

actiation should be correct.

..L.2.9.A 8unction test for historical data storage and search

. 5elect a group of record point from historical data base% the content include

analog% ;n$off ariable% operation record and system eent% etc.

2. "a)e configuration separately for the report forms and cure of the current

historical data% display and print the forms and cure. Confirm the data and

time of the forms and cures are correct and there is no fault alarm during the

process.

3. 5eparately configuration historical data report forms and cures that has been

stored into tapes or dis)s /long$term% and system should remind the necessity

of historical data tape or dis)s+ insert releant tape and dis)s% ma)e actiation%

and then display and print them. Chec) that the data and time of the forms

and cures are correct and there is no alarm during operation process.

..L.2.9.! Chec) the function of performance calculation

. Chec) that all the measurement points releant to the performance calculation

are correct% the calculation of the report forms% the display and the print of the

menu should be normal.

2. 5tart the application program of the performance calculation and there is no

alarm.

3. Cooperate with releant department to chec) the calculation precision of the

performance calculation% if it fails to meet designed requirements% ma)e

ad'ustment or modify the configuration.

..L.2.9.L Test on connection of communication interface

. 6nergi>e the system and the indications of indicating lamps in the

communication interface module are normal.

2. 5tart communication driing software% system should hae no incorrect

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information

3. *se networ) software deices or special communication test software deice

to ensure that the physical connection of the communication is correct and

effectie. Test data sending and receiing condition by using application

software or modulation method% the real time should meet the designed

requirements.

A. Confirm the connections of interface and communication between computer

control system and other special deices are normal and the communication

data is correct.

..L.3 Test and acceptance of maintenance

..L.3. Control system is in good condition

..L.3.2 The inspection and maintenance items in the control system can meet the qualityrequirements.

..L.3.3 The standby channels of measuring module hae been carried out with initial setup

according to the requirements for online operation channel.

..L.3.A The performance and function tests of control system hae been tested according

to test program% and the technical target can meet the requirements.

..L.3.! Test at local and confirm the operation of control sub system is normal.

..L.3.L The maintenance record and report.

The following maintenance record should be complete and in good order% the data

should be correct meet the quality requirements% ma)e a list for the items that fail

to meet the requirements

. Chec) the abnormal item record before shutdown and the conditions after

maintenance% confirm all problems hae been soled.

2. "easure insulation resistance% it should meet the requirements

3. The precision calibration record of analog I,; module is also attached with a

classification statistic table for calibration qualification rate of different type of modules.

A. Performance test and test record for computer equipment and system are

complete% and can meet the requirements.

!. The record for performance and function test of computer control system

should be complete and meet the regulated requirements.

L. The record for repaired parts or replaced parts of computer control system is

complete and detailed. /-ttached with reasons for maintenance and

replacements

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9. The record for inspection and modification of software should be complete and

detailed. /-ttached with detailed instruction and modification approal permit

K. The quality and quantity of software bac)up for computer control system can

meet the requirement.

e% and the printing paper is well fabricated.

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1.! D4;4ta6 E6ectro(?79ra>64c S7te8 )DEH*

1.!.1 DEH S7te8 Genera6 Decr4=t4on

.2.. The turbine 60 control system is made up of control part% 60 hydraulic pressuresystem and safeguard system. It is mainly used to control the rotation speed and

power of turbine generator. It adopts the adanced I,- 5eries open industry controlsystem of 8o1boro.

.2..2 *nder the automatic condition% the operator carries out the control operations andimage operations mainly through the mouse of the operator station. The operatorFscommand is transmitted to the control 8C5 through the operator station% and theI,; card will carry out the output control. The unit state and result will be displayedon C?T.

.2..3 8our goerning steam ales are equipped at the inlet of turbine 0P casing. Incommand to ensure the safety operation of the turbine% corresponding main stopales should be equipped. -ll of the ten steam inlet ales of turbine aboe$mentioned adopt oil actuator drien with the 0P fire$resistant oil as wor)ing

medium. The si1 goerning ales% C、IC and the 0P main stop ale "52 onthe right side is continuously controlled by the sero ale and the interface of the60 micro computer. The two$position control of 0P main stop ale "5 on theleft side and two IP main stop ale ?5 is carried out by the solenoid ale and60 interface.

In command to ensure the safety operation of turbine% there are redundantprotecting sleees in the hydraulic pressure system.

8ly ring and test solenoid ale

0P and 4P trip solenoid ale

;erspeed limiting solenoid ale.2..A 60 hydraulic pressure system includes oil feeding system% oil pipes% and oil motor.

60 oil feeding system also includes the emergency trip system which controls theoil motor emergency shutdown and the diaphragm ale. 0P fire$resistant oilsource is equipped with two redundant sets of pressure oil pumps to ensure thecontinuous oil feeding.

.2..! The emergency trip system includes ;PC solenoid ale% -5T solenoid ale anddiaphragm ale. The structure of ;PC solenoid ales is two ales parallelconnection. #hen the ;PC solenoid ale is energi>ed% release ;PC safety oil%and quic)ly close the goerning steam ale. The structure of -5T solenoid alesis four ales series,parallel connection. #hen -5T solenoid ale is de$energi>ed%

release -5T safety oil and ;PC safety oil% close all of the

i & c maintenance manual.doc

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