Maintenance Procedures - ESD System Maintenance Procedures

ESD System Maintenance and Repair Procedures

1. General Principles

(1) Main Content and Scope of Application This specifies the specific technical requirements and implementation procedures for the maintenance, inspection, and safety precautions of the ESD system.

(2) Basic Principles It is the most advanced-tolerant controller based on a triple-modular redundant structure. It integrates three isolated and parallel control systems (each called a sub-circuit) and extensive diagnostics into a system, providing highly perfect, error-free, and uninterrupted process operation through a 3-out-of-2 voting mechanism, which will not cause system failure due a single point of failure. Sensor signals are divided into three isolated paths in the input module, and through three independent channels, they are sent to three processors respectively. The TBUS bus between processors performs data voting according to the majority principle and corrects any deviations in the input data. This process ensures that each main processor uses the same voted data to the application.

(3) Preparations and Requirements for Maintenance Personnel 1. Other standard test instruments such as multimeters and general commonly used maintenance tools; . Familiarity with the system drawings and related technical data, and on-site equipment with related interlocking diagrams and I/O tables; 3. Master the correct number and position of each connection point of this system; 4. Understand the role of related process production in it; 5. Master computer technology, digital circuit technology, electronic technology, and automation; 6. Master the basic skills of maintenance, inspection, and commissioning of the system and common fault handling

2. System Hardware Maintenance Content

(1) System Cleaning Inspection, Recovery, and Environmental Maintenance Use safe instruments, to carry out cleaning maintenance of system hardware, the content is as follows: Remove all cards from the TRICON controller for cleaning, wear anti-static wristband, and the removed cards to record their original installation positions. The TRICON rack is not removed for cleaning, all baffles are removed for cleaning, the fan is removed for cleaning, power supply is cleaned, other integrated accessories are cleaned, and the overall cleaning is carried out inside the cabinet after removing some hardware. After cleaning, all hardware is cleaned with special agents, including control switch relays, connecting wires, and terminals, etc. After cleaning, all cards and other hardware are checked, checked for integrity, and restored and installed to the correctness and reliability of the hardware installation after recovery. 

(2) Power Supply Inspection Check whether the power supply working voltage is 24VDC, and the 24VDC indicator relay works and the alarm status is normal. 

(3) System Cabinet Accessory Inspection Check the air switch and other control switches check the corresponding connection situation, and check whether the terminal connection is firm and reliable. The intermediate relay connection and use are checked to work normally, and the fan works normally. 

(4) System Redundant Power Module and Mainframe Rack Battery, Key Switch Inspection Carry out power-off test on the redundant power module of each frame of system, record whether the alarm occurs during the test and whether the recovery is normal; whether the battery voltage of the system 3.6VDC is 3.6VD, whether there is an alarm, and replace it regularly according to its service life (about 5 years). Whether the key switch position is normal; it is generally set at program position in our company. 

(5) System Expansion ELCO Cable Connection and ETP Inspection Check whether the connection between each frame and the corresponding E through the ELCO cable is normal, and whether the connection is firm and reliable. 

(6) System Channel I/O Loop Detection Carry out detection on system channel I/O loop; check whether the input switch signal changes ESD. 

(7) Power Supply and Grounding Inspection Test whether the alternating voltage system 220VAC ± 10%, and the grounding resistance is less than 4 ohms.

3. Engineer/Operator Station Inspection and Maintenance 

(1) Backup of the application software of the engineer station/operator station computer in a dedicated folder

(2) Cleaning and environmental inspection of the engineer station/operator station computer; 

(3) System update maintenance of the engineer station/operator station computer; 

(4) Upgrade and application of the system software (if necessary); 

(5) Inspection of the communication connection of the engineer station/operator station computer: perform program download communication and communication function test the DCS, the operator station communicates normally with the controller, and the controller communicates normally with the SOE, after each power outage maintenance, it is necessary to check bypass point from DCS to ESD one by one to ensure that the bypass is effective and normal.

4. 1131 Control Procedure

(1) Program Modification Based on the actual needs of the process, the software program should be continuously; before making any software modifications, a modification design should be prepared, the data table should be filled out according to the configuration requirements, and the configuration related list should be written. completing the software modification, a simulation test should be conducted to confirm that it meets the design requirements before it is put into operation, and attention should be paid to monitoring the operation. modified program should be backed up again; the modification data should be archived, and the modification of the software should strictly follow the operation ticket system. 

(2) Clock Synchronization Major Repair Period Due to the asynchrony of the clock between the host and the controller, it causes difficulties in event analysis. Set the host clock to the controller to make synchronous. 

(3) Login Permission Check and Arrangement Backup the login permission.

5. Shutdown Steps

(1) Backup data and software before shutdown.

(2) After the process is completed, ensure all personnel and materials are place, obtain permission from the dispatcher, and handle the necessary permits. 

(3) First, shut down the control station. Turn off the fan power switch, 2VDC power switch, power distribution switch of the cabinet, HUB power switch, and total power switch. 

(4) Shut down the operation station. Exit the 131 and SOE software systems, turn off the host power, and turn off the CRT power.

6. Power-on inspection of TRICON control system 

(1) Download the latest program to the controller and check its status. 

(2) Check the status of the indicating signal and whether any alarm light is on. 

(3) Check the communication status between the system and the operator station and DCS. Check whether the connection between ESD master and slave can be connected smoothly. Whether DCS can write data to ESD and whether ESD can receive it. (Whether the bypass button of ESD works in online state). It is necessary to test point by point to ensure the effectiveness of the bypass button. 

(4) Check the 1131 program of the operator station and the working status of SOE; whether 1131 can start normally, whether it matches the version of the controller, and whether the SOE recording function runs normally. 

(5) Use the TRICONEX dedicated diagnostic software to diagnose the system (controller & I/O card) and whether there are any alarms.

7. Acceptance Criteria 

(1) Parts are complete and meet the following technical requirements: 1. System hardware configuration meets technical requirements; 2 Radiator fans and air filters are complete and intact; 3. Nameplate marks should be clean and correct; 4. Connectors should be in good contact and fast should not be loose; 5. Terminal blocks should be firm; 6. Cabinet protective doors should be intact and undamaged.

(2) Normal operation meets the: 1. Operation is to achieve the specified performance indicators; 2. Indicator lights of all devices in the system indicate normally; 3. Host operation and display are; 4. Radiator fans operate normally; 5. The printer is connected normally and is in standby state; 6. Various AC and DC voltages meet the.

8. Daily maintenance 

The daily maintenance of ESD shall be carried out in accordance with the DCS regulations.

9、Safety Precautions 

(1) Safety Precautions for Maintenance and Repair 1: Maintenance and repair must be performed by more than two and a maintenance work ticket must be issued; 2: When opening the cabinet for equipment inspection, be careful not to touch the power connectors and various cards with your body;3: When inspecting electronic plug-ins, wear an anti-static wristband; 4: When inserting or removing cards, do so after power has been turned off; : During maintenance, place electronic plug-ins on an anti-static mat; 6: Spare plug-ins must be stored in anti-static bags; 7: performing software or hardware operations in an online state, it must be done according to the relevant technical requirements, and commands whose functions are not yet fully understood must not be used; 8: When repairing cards, the tools and instruments used must be well grounded; 9: When checking or dismantling terminal connections, prevent short circuits. 

(2) Safety Prec for Commissioning 1: Commissioning must be performed by more than two people; 2: Confirm that the equipment is in good standby condition; 3: Confirm that the power voltage and frequency meet the specifications; 4: After commissioning, observe the system operation. (3) Safety Precautions for Shutdown 1: Shutdown be performed by more than two people; 2: Shutdown operations must be performed with the consent of the process personnel.

10. Maintenance cycle 

This system undergoes maintenance every 12 months, usually coinciding with the annual overhaul.