COMMISSIONING, OPERATION & MAINTENANCE · 2019-04-01 · 6 COMMISSIONING, OPERATION & MAINTENANCE...

COMMISSIONING, OPERATION & MAINTENANCE

COMMISSIONING, OPERATION & MAINTENANCE2

OVERVIEW

Pre-Commissioning Checklist

• Pressure and Vacuum Test• Working Fluid Transfer and Filter Dryer install• Drive Coupling Alignment (S6000)• Electrical Connections and Inspection• Test-Manual-Auto Switch• HMI Setup

Commissioning

• VPN Internet Router• Remote Access• Data Acquisition

Internet Setup

• Controls• HMI Screens

Startup

Maintenance


• Working Fluid and Transfer equipment scheduled• 180 kg (400 lbs) Honeywell Genetron R-245fa or

ElectraTherm approved equivalent• Nitrogen, N2 for leak checking and pressure testing• Vacuum and Refrigerant Transfer pump

• Electrical Connections• Earth Ground per local codes• 380-500VAC / 3 Phase / 50 & 60 Hz power terminated to

machine• Site interface wiring complete (Customer Terminal Strip)

• Mechanical and Plumbing Connections• Hot and Cold water manifolds connected and properly

supported• Heating and Cooling systems filled, purged and operational• Hot Water Bypass installed• Auxiliary Heat Dump installed (if required)

• Internet and Remote Communication configured

PRE-COMMISSIONING CHECKLIST


COMMISSIONING


COMMISSIONING OF POWER+

4400 in England, UK(2016)

GTMO, DOD Project(2015)


• Nitrogen Pressure Test• Shipped with 15 psi N2 charge• Pressurize system to 7 bar (100 psi)• Verify after one hour that pressure is

above 6.75 bar (98 psi)• Leak check if necessary

• Vacuum Test and System Drying• Connect vacuum pump and digital

vacuum gauge• Draw down to minimum of 750 micron

(99.90%)• Allow pump to run for 30 minutes to

remove moisture from system• Verify vacuum holds for 30 minutes

COMMISSIONING OF POWER+PRESSURE & VACUUM TEST


• Transfer 180 kg (400 lbs) of R-245fa refrigerant into Power+

• Flow the refrigerant thru an inline filter dryer to ensure clean/dry gas is transferred

• Heat and/or a recovery pump will be needed to transfer all of the liquid and vapor

• Weighing the bottles prior to transfer can help confirm entire mass has been transferred

• Use Liquid Push/Pull configuration for transferring liquid gas from bottles

• Use Vapor Recovery configuration to draw remaining vapor until a vacuum is achieved and/or the bottle tare weight is met

COMMISSIONING OF POWER+WORKING FLUID SYSTEM


North American Tank ConfigurationLiquid & Vapor ports

European Tank ConfigurationSingle Port with Liquid & Vapor Valves

COMMISSIONING OF POWER+WORKING FLUID SYSTEM


Onsen Bottle Bath

COMMISSIONING OF POWER+WORKING FLUID SYSTEM – HEAT IS YOUR FRIEND

Torpedo Heater (Don’t melt the bottle paint!)


• Installation of Filter Dryer on a 4000 • Installation of Filter Dryer on a 6000

COMMISSIONING OF POWER+WORKING FLUID SYSTEM – FILTER DRYER INSTALL


COMMISSIONING OF POWER+S6000 DRIVE COUPLING

Coupling installation/alignment for S6000 Power+

Shim skid before bolting to foundation

Check alignment of Expander and Generator shafts with orange coupling removed

Adjust Generator Horizontal and Vertical position to within spec for Howden 163 Expander. (Precise alignment will extend the life of rotating equipment!)

Record final measurements on Commissioning Checklist


COMMISSIONING OF POWER+S6000 DRIVE COUPLING

SKF TKSA 31 Laser Alignment Toolw/ TKSA 41-EXTCH chains

Maximum misalignment per Howden Service Manual

Radial 0.10mm (0.004”) TIRAxial 0.10mm (0.004”) TIR


• Check 3-Phase + Ground electrical is terminated to the machine main power connection

• Visually inspect all electrical cabinet wiring• Check that all field devices cables and wiring are

connected

COMMISSIONING OF POWER+VERIFY ELECTRICAL CONNECTIONS


• Cooling Enable 1 Relay N.O.• Cooling Enable 2 Relay N.O• Hot Water Relay #1 N.O.• Hot Water Relay #2 N.O. (optional delay)• On Grid Relay N.O.• External E-Stop 120VAC N.C. (jumper)• External E-Stop Alarm 24VDC N.O.• 24VDC Supply• Customer Grid Protection Relay 24VDC N.C.

(jumper)• Remote Start Button 24VDC N.O.• Remote Stop Button 24VDC N.C. (jumper)

COMMISSIONING OF POWER+CUSTOMER CONNECTIONS

• 24VDC Supply• MODBUS• Air Cooled Condenser Fan Speed 4-20mA

Output• Ambient Air Temperature RTD• Enclosure Temperature RTD− Installed by ElectraTherm on S4000 Skin

Package for Exhaust Fan Controls


Verify three Jumpers are installed if not used by customerTerminal Blocks 11 – 12 (External E-Stop)Terminal Blocks 22 – 23 (Customer GPR)Terminal Blocks 22 – 25 (Remote Stop)

COMMISSIONING OF POWER+CUSTOMER CONNECTION TERMINAL STRIP (S4000)


COMMISSIONING OF POWER+CUSTOMER CONNECTION TERMINAL STRIP (S6000)

Verify three Jumpers are installed if not used by customerTerminal Blocks 11 – 12 (External E-Stop)Terminal Blocks 22 – 23 (Customer GPR)Terminal Blocks 22 – 25 (Remote Stop)


Using a Multimeter verify 100-120VAC power at the 24DC power supply primary side

Using a Multimeter verify ~24VDC power at the 24DC Power Supply

COMMISSIONING OF POWER+POWER ON MACHINE AND CHECK CONTROL VOLTAGE


Power+ has three Operating settings controlled by a 3 position switch

• Test (left position) is used for Power+ test functions and system setup

• Manual (mid position) is for operation of the Power+ but has disabled the auto-restart capabilities

• Auto (right position) enables auto-restart of the Power+. Upon a shutdown the machine will automatically restart if all safety alarms are clear and the machine is within the startup parameters

COMMISSIONING OF POWER+TEST – MANUAL – AUTO SWITCH (TMA SWITCH)


The Power+ has Factory settings that are pre-programmed by ElectraTherm engineering during the Factory Acceptance Test (FAT)

Additional settings that are site specific and can be adjusted at commissioning for your site

COMMISSIONING OF POWER+HMI SETUP


Main Screen set units and confirm in TEST mode


Display Options set Language, Date/Time and Panel Brightness


Screen Select allows access to operator screens


Electrical Info verify Phase voltage and grid frequency


Setup allows access to site commissioning setup screens


1 – 2 – 4 – 8 Password for access to Setup Screens


Setup – Site Options set the minimum net Power, Serial # and Site Name


Setup – Startup Parameters setup start delays, temp conditions and restart functions


COMMISSIONING OF POWER+HMI SETUP – TEST FUNCTIONS• Test HW and CW relays if used for site

controls• Test Working Fluid Valve operation• Verify all Indicators operational• Test Air Tank Purge• Test Panel and Exhaust fans• Run VFD Test Run at 30 Hz speed for

20 minutes to mix the Working Fluid and Oil


INTERNET SETUP


• No required changes to site network for standard functionality

• Eliminates requirement to change Power+ software if site network changes

• Provides remote access for Power+ software upgrades and troubleshooting

• Easy configuration• Isolates Power+ from site network• Optional built-in 3G/4G cellular modem for

remote sites

VPN ROUTER FROM KEB AMERICA


• Connect the LAN port to the Ethernet switch in the Power+ control cabinet

• Connect site network with internet access to WAN port

• THAT’S ALL!

• Some additional configuration of the site network is required to provide SCADA and/or remote access to the Power+

VPN ROUTER FROM KEB AMERICASITE REQUIREMENTS

LAN Port

WAN Port

Power LED

USB Plug

Reset LEDRun/Stop

LED


• Request VPN credentials from ElectraTherm

• Only ElectraTherm personnel and authorized site users can access the VPN

• Sign in to the ELECTRATHERM domain• Authorized routers appear in a “file tree”

structure, or as pins on a map• Double-click on a router in the file tree to

connect to it• Once connected, access the HMI like

you’re standing at the Power+!

VPN ROUTER FROM KEB AMERICAVPN CONNECTION


STARTUP


STARTUPCONTROLS

Power+ Lights• Red MCR enabled• Yellow startup and/or caution• Green On-Grid

Power+ Buttons• Black Enable• Green Start• Red Stop• Emergency Stop

Runtime MeterHMI ScreenTMA Switch• Test• Manual• Auto

Panel Power Switch


STARTUPHMI SCREENS

Operator Screens• Main Screen• Auto Controls• Alarms• System Status• Fan Controls• VFD Status• Electrical Information• Logging• Contact Information

Setup Screens• PLC Digital I/O• PLC Analog I/O• Site Options• Startup Parameters• Veris Setup• Custom Alarms• Test Functions• Log File Test• Soft Starter Setup


MAINTENANCE


QUESTIONS?

COMMISSIONING, OPERATION & MAINTENANCE · 2019-04-01 · 6 COMMISSIONING, OPERATION & MAINTENANCE...

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Transcript of COMMISSIONING, OPERATION & MAINTENANCE · 2019-04-01 · 6 COMMISSIONING, OPERATION & MAINTENANCE...