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BEST OPERATIONAL PERFORMANCE
BYMAINTENANCE
Building Automation System
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YAMATAKEGROUP
CORPORATEPROFILE
Since its founding in 1906, the Yamatake Group
has built on its core of measurement and control
technologies to maintain its position at the
forefront of Japans automation industry. To our
customers, Yamatake is a name to depend on for optimum solutions in
industrial automation, building automation, and factory automation.
As Japans leading supplier of
Building Automation, Yamatake
Building System Co., Ltd provides
integrated air conditioning, lighting,
sanitation, security, access, and fire
systems monitoring and control to
office buildings, hotels, factories, laboratories, schools, and hospitals.
Our highly advanced
products and systems can
improve the value of your
investment. Wether you operate
a refining plant, a factory or an
office building, Yamatake is
dedicated to helping you to enhance productivity, safety and
convenience while conserving energy usage and running costs.
Founded by Yamaguchi Takehiko
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OVERVIEW
PT. YAMATAKE BERCAINDONESIA
Yamatake has been serving the Indonesian
market since 1970s, together with PT. Berca
Indonesia. The commitment grows further in
strength in a joint venture between Yamatake
Corporation and PT. Berca Indonesia.
PT. Yamatake Berca Indonesia was formed in 1997 to enable us to
work more closely with Indonesian customers in engineering and
support of optimal automation solutions. Since its founding, we have
been serving Indonesian customers in a wide range of business, from
industrial control, building management, factory automation to control
components.
We grew in strength and versatility
after P.T. Berca Indonesia became
Yamatakes distributor, in 1974. Since then,
we have aided progress in such process
industries as oil refining, chemical, power, pulp & paper and food
processing. We have helped to improve built environments for hotels,
offices, factories, government and shopping centers.
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PT. Yamatake Berca Indonesia is commited to offering SOLUTION tothe Indonesian market, that is,
Solving complex problems in instrumentation by providing world-class consulting from the earliest stages of design andimplementation
Open and advanced technologies and state-of-the-art products forthe latest automation solutions
Larger variety of products and systems provided, such as sensors,controllers, control valve and open architecture systems
Utilizing customer investment at the best by offering completeafter-sales services
Total quality concept is tightly integrated in design, manufacturing,sales and service
Improving productivity, safety, profitability, comfort andenvironmental compliance in your plants and facilities
One-stop shopping for automation solution products at competitiveprices is our commitment to customers
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Never forget to compromise on energy and environmentalconservation
BUILDING AUTOMATION
PERFECTING ENVIRONMENTS
Building Automation is a system for
comprehensivelycontrolling and managing a variety of facilities in a building. Central
monitoring systems, which monitor the operating status and errors of
building facilities such as air handling, heat sources, plumbing and
power facilities plus what has up to now been called automatic control
equipment of air handling, have now been integrated into one
centralized piece of equipment with the advance of computer
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MAINTENANCE
Preventive maintenance refers to a series
of actions that are
performed on either a time-based schedule or a schedule based on
that of machine run time. These actions are designed to detect,
preclude, or mitigate degradation of a system (or its components). The
goal of a preventive maintenance approach is to minimize system and
component degradation and thus sustain or extend the useful life of
the equipment.
Building
automation integration of sensors for
temperature, humidity and comfort
measurement security devices, HVAC
controls, valves and actuators,and heat
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source control networked with a central control system, ensure
efficient, safe, energy cones.ving operations throughout the building.
To keep your investment operating at peak performance throughout its
lifecycle, PT. Yamatake Berca Indonesia offers a comprehensive service
and support program tailored for your particular needs.
One case for example to explain why
maintenance is very important in the
control system, its the control valve,
which is the most important
equipment in your control system that
constantly in contact with the process medium. Therefore the control
valve has a significant impact on your plants efficiency and if not
properly maintained, it will perform like a well tuned car with bad tires
capable of running but becoming very
dangerous during sudden braking.
Our engineers can assist the
condition of your control valve and provide
recommendation for service or overhaul.
Beside that the ability of an Energy Management Control System
(EMCS) to efficiently control energy use in a building is a direct function
of the data provided to the EMCS. The value of an EMCS in making
decisions is dependent upon the accuracy of the information in the
system. Therefore careful input of accurate, up-to date data is
essential.
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For a number of reasons, the calibration of
sensors is an often overlooked activity.
However, sensors should be calibrated
regularly as sensors out of calibration can lead
to enormous energy penalties. Furthermore, as with steam traps, these
penalties can go undetected for years without a proactive maintenance
program.
PURPOSE OF MAINTENANCE
Prevents functional disorder and failure
Enables detection of parts deterioration problems and trouble
parts
Replaces consumable parts, or parts which are judged likely to
break down
Enables calibration and readjustment of the sensors and
actuators
Keep the equipment in good working condition
BENEFITS OF MAINTENANCE
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Extends effective operational life of equipment
Generates energy saving
Prevents plant shutdown from unexpected accidents due to
instrument trouble
Increases the realibility, availability and safety of the
instrument
Enables making an efficient maintenance budget for parts and
service
Reduces equipment and/or process failure
KEY COMPONENTS
Modern control systems have three necessary elements : sensors,
controllers, and the controlled devices.
Component DescriptionSensors There is an increasing variety and level of
sophistification of sensors available for use
with modern control systems. Some of the
more common include : temperature, humidity,
pressure, flow rate, and power. Sensors that
track indoor air quality, lighting level, and fire
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MODIFICATIONS TO MEET NEW REGULATIONS AND
STANDARDS
With new legislation on quality and environmental management
come new burdens on manufacturing and building industries; we
can ease your burden by assuring compliance before inspectors
come by.
ANALYSIS OF FAILURE RECORDS
When things go wrong, our experienced service
engineers can pin point the problem from analysis
of the system status report and other records.
PARTS REPLACEMENT
Should unforeseen trouble occur, spare parts readily
are available. Any defective parts are replaced
according to service agreements, and detailed failure analysis are
presented as required.
MAINTENANCE SCHEDULEDescription Comment
Maintenance Frequency
Daily Weekly MonthlySemi
AnnuallyAnnually
Overall
visual
inspection
Complete overall visual
inspection to be sure all
equipment is operating and that
safety systems are in place
X
Verify
control
schedules
Verify in control software that
schedules are accurate for
season and occupancy
X
Verify
setpoints
Verify in control software that
setpoints are accurate for
season and occupancy
X
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Check all
gauges
Check all gauges to make sure
readings are as expectedX
Check
outside air
volumes
Check for proper function X
Check
setpoints
Temperature should not exceed
or drop below design limitsX
Check
schedules
Verify the bottom, surface and
water column blow downs are
occurring and are effective
X
Check
deadbands
Assure that all deadbands are
accurate and that the only
simultaneous heating and
cooling is by design
X
Check
sensors
Conduct through check of allsensors for temperature,
pressure, humidity and flow for
expected values
X
Calibrate
sensors
Calibrate all sensors for
temperature, pressure, humidity
and flow
X
MAINTENANCE PROCEDURE
MAINTENANCE OF
MAIN CENTRAL UNIT
( MCU )
Maintenance Of Software
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Work Sequence Detail Detail Work Tools
The equipmentconcerned should beassigned as controlpoints under maintenance
The data of the latest48 hours is shown ina historical trendgraph (totalizer pointis shown in bar chart)
Check the controlpoint on the Graphicscreen
Check point function
Check equipmentschedule
Modify setpoint value
Check the value
Check the sight of theequipment andfacilities
Maintenance Of Harddisk
Work Sequence Detail Work Detail Work Tools
The condition of MCUmust be on
Move to the graphicscreen several times andmake sure that thescreen is displayednormally.
Check Whether the harddisk drive generatesabnormal noisecompared with its initial
state.
Historical Trend
Check
Historical Trend
Check
Assign for
maintenance
Check The Sight
Control Point
Check
Checking screen display
Checking for abnormal
noise
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MAINTENANCE OF DDC CONTROLLER
Intelligent Digital Controller ( IDC )
Work Sequence Detail Detail Work Tools
Check Power input from UPS
Power signal check.
Check indication on/off line.
Check the Installation of theIDC and its I/O slots
The sequence of I/O slotshould follow the design ofpoint assignment
Connect the data setter to theIDC data plug
Error check.
Function check
Operation check
Counter check of the I/O pointand 1 by 2 sheet
Check the reading data setterof I/O point
Data Setter, Digitaltester, Srew driver
Maintenance Of Intelligent Data
Gathering Panel ( IDGP )
Work Sequence Detail Work Detail Work Tools
Test Function
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Check Power input from
UPS
Power signal check.
Check indication on/off
line.
Check the Installation of
the IDGP and its I/O slots The sequence of I/O slot
should follow the design
of point assignment
Connect the data setter to
the IDGP data plug
Error check.
Function check
Operation check Counter check of the I/O
point and 1 by 2 sheet
Check the reading data
setter of I/O point
Data Setter, Digital
tester, Srew driver
Maintenance Of Digital Output
Module
Work Sequence Detail Work Detail Work Tools
Test Function
IDGP
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Check
connection terminal cable
control
Counter check of the I/O
point and 1 by 2 sheet
Connect the data setter to
the IDGP data plug
Error check.
Function check
Operation check
Check the reading datasetter of DO point
Data Setter, Digital
tester, Srew driver
Maintenance Of Digital Input Module
Work Sequence Detail Work Detail Work Tools
Check
connection terminal cable
control
Counter check of the I/O
point and 1 by 2 sheet
Connect the data setter to
the IDGP data plug
Error check.
Function check Operation check
Check the reading data
Data Setter, Digital
tester, Srew driver
Contact output checkContact output check
Contact input checkContact input check
Digital input moduleDigital input module
Digital output module
Test Function DO module
Test Function DI module
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setter of DI point
Maintenance Of Analog Output
Module
Work Sequence Detail Work Detail Work Tools
Check
connection terminal cablecontrol
Check signal output of
AO module
Connect the data setter to
the IDGP data plug Error check.
Function check
Operation check
Check the reading data
setter of AO point
Data Setter, Digital
tester, Srew driver
Signal checkSignal check
Analog output module
Analog output module
Test Function AO
module
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Maintenance Of Analog Input Module
Work Sequence Detail Work Detail Work Tools
Check
connection terminal cable
control
Check signal input of AI
module
Connect the data setter to
the IDGP data plug
Error check.
Function check
Operation check
Check the reading data
setter of AI point
Data Setter, Digital
tester, Srew driver
MAINTENANCE OF THE ACTUATOR
Maintenance Of Control Valve
Work Sequence Detail Work Detail Work Tools
Cleaning body.Cleaning terminal cable.
Check connection terminalCable control.
Check signal input 2 to 10vdc fromcontroller.Check position valve from0% until 100% forproportional type.
Brush, WD-40.
Screw driver
Data setter, Digitaltester
Signal checkSignal check
Analog input moduleAnalog input module
Test Function AI moduleTest Function AI module
Cleaning body
Motorized Valve
Cleaning body
Motorized Valve
Check
connection terminal
cable control
Check
connection terminal
cable control
Test function Motorized
valve
Test function Motorized
valve
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Maintenance Of Variable Air
Volume ( VAV )
Work Sequence Detail Work Detail Work Tools
Check connection terminalCable control
Check function VAV open or close.Check Interlock VAV with the AHUSystem.
Screw driver
Data setter,Digital tester
MAINTENANCE OF THE FIELD SENSOR
Maintenance Of Static
Pressure
Work Sequence Detail Work Detail Work Tools
Check the installation ofstatic pressure
Check signal input fromcontroller
Check the power supply
of static pressure
Connect the data setter
Check the reading datasetter of static pressure
Data setter, Digitaltester
Maintenance Of Temperature
Sensor
Work Sequence Detail Work Detail Work Tools
Test function VAVTest function VAV
Static PressureStatic Pressure
Check connection
Test Function Pressure
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Do measuring more than 5minutes until displaythermometer and display datasetter constant.
Temperature setting.
Digital thermometer,Data setter
Maintenance Of Ampere Tranducer
Work Sequence Detail Work Detail Work Tools
Check the installation ofAmpere Tranducer
Check signal input fromcontroller
Check the power supplyof ampere tranducer
Connect the data setter
Check the reading data
setter of amperetranducer
Data setter, Digitaltester
Maintenance Of Voltage
Tranducer
Work Sequence Detail Work Detail Work Tools
Compare the actual PV
at data setter with digital
thermometer
Compare the actual PV
at data setter with digital
thermometer
Calibration sensor with
Test Function Ampere
Ampere Tranducer
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Check the installation ofVoltage Tranducer
Check signal input fromcontroller
Check the power supplyof voltage tranducer
Connect the data setter
Check the reading data
setter of voltage
tranducer
Data setter, Digitaltester
Maintenance Of Frequency Tranducer
Work Sequence Detail Work Detail Work Tools
Check the installation ofFrequency Tranducer
Check signal input fromcontroller
Check the power supplyof frequency tranducer
Connect the data setter
Check the reading datasetter of frequencytranducer
Data setter, Digitaltester
Test Function Voltage
Voltage Tranducer
Test Function
Frequency Tranducer
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Maintenance Of KWh Tranducer
Work Sequence Detail Work Detail Work Tools Check the installation of
KWh Tranducer
Check signal input fromcontroller
Check the power supplyof KWh tranducer
Connect the data setter
Check the reading datasetter of KWh tranducer
Data setter, Digitaltester
Maintenance Of Power Factor Tranducer
Work Sequence Detail Work Detail Work Tools
Check the installation ofPower Factor Tranducer
Check signal input fromcontroller
Check the power supplyof power factor tranducer
Connect the data setter
Check the reading datasetter of power factortranducer
Data setter, Digital
tester
Test Function
KWh Tranducer
Test Function Power
Power Factor
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MAINTENANCEOFFERING
1. Fully 24 Hours Operating + 2 Times a year
maintenance
The Operator as YAMATAKE Engineer stand by 24
hours a day and 7 days a week
The Operator set The Daily Report, Trending,
Maintenance Schedule, etc.
The Operator will backup data On Line every 1 week
The Operator overcome the existing daily problems
exclude supply the new parts replacement
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The Operator maintain all of BAS equipments 2 times
a year :
a. The Operator calibrate all of sensors and instruments
every 6 months
b. The Operator make maintenance report every 6
months
c. The Operator check the DDC Controller, Control Panel
and the Installation every 6 months
2. 12 Hours Operating + 2 Times a year
maintenance
The Operator as YAMATAKE Engineer stand by 12
hours a day and 7 days a week
The Operator set Daily Report, Trending,
Maintenance Schedule, etc.
The Operator will backup data On Line every 1 week The Operator overcome the existing daily problems
exclude supply the new parts replacement
The Operator maintain all of BAS equipments 2 times
a year :
a. The Operator calibrate all of sensors and instrumentsevery 6 months
b. The Operator make maintenance report every 6
months
c. The Operator check the DDC Controller, Control Panel
and the Installation every 6 months
3. Periodic Maintenance ( 2 Times a Year )
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The Operator maintain all of BAS equipments 2
times a year :
a. The Operator calibrate all of sensors and
instruments every 6 months
b. The Operator make maintenance report every 6
months
c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation every 6 months
4.Contract Maintenance ( 1 Time a Year )
The Operator maintain all of BAS equipments 1
time a year :
a. The Operator calibrate all of sensors andinstruments once a year
b. The Operator make maintenance report in 6 months
c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation every 6 months
5. Spot Service Maintenance
The Operator maintain all of BAS equipments once
in visit until finish :
a. The Operator calibrate all of sensors and
instrumentsb. The Operator make maintenance report
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c. The Operator will backup data On Line
d. The Operator set Daily Report, Trending,
Maintenance Schedule, etc
e. The Operator check the DDC Controller, Control
Panel and the Installation
6.Emergency Call
A. Emergency Call Stand by 12 hours
The Operator handle the existing problems only at
08.00 AM 08.00 PM
The Operator will make the report
B. Emergency Call Stand by 24 hours ( available only
in town )
The Operator handle the existing problems in 24
hours
The Operator will make the report
Maintenance Of Compact Data Gathering Panel (
C -DGP)
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Work Sequence Detail Work Detail Work Tools
Check Power input from
UPS
Power signal check.
Check indication on/off
line.
Check the Installation of
the C-DGP and Terminalcable.
Function check
Operation check
Counter check of the I/O
point and 1 by 2 sheet
Check the reading data
setter of I/O point
Data Setter, Digital
tester, Srew driver
Maintenance Of Intelligent Fan Coil
Unit ( IFC ).
Test Function
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Work Sequence Detail Work Detail Work Tools
Check Power input from
UPS
Power signal check.
Check indication on/off
line.
Check the Installation ofthe IFC and Terminal
cable.
Function check
Operation check
Counter check of the I/O
point and 1 by 2 sheet
Check the reading data
setter of I/O point
Data Setter, Digital
tester, Srew driver
Test Function