Solar Turbine Turbotronic-4 Control System Operation Training

Bulan Agustus kemarin, tepatnya 1 minggu sebelum Idul Fitri 1433H/2012 M (di bulan Ramadhan), saya berkesempatan untuk ke Senawang, Negeri Sembilan, Malaysia. Untuk mengikuti Training selama 5 hari dengan tema seperti yang tertulis di judul tulisan ini yaitu Solar Turbine Turbotronic-4 Control System Operation Training.

 

Ide untuk mengikuti training ini awalnya terkait problem2 yang ada pada Compressor Turbine di Site, dimana masalah yang terkait Control System, belum mendapatkan penyelesaian/ jawaban yg cukup clear dari pihak Indoturbine, masalah terkait Control system yg saat itu kami hadapi adalah Backup Seal Oil Periodic Check System, Anti Surge System,dll. Kami memutuskan sebaiknya ada yang dikirim untuk mendalami Logic Control System dari Solar Turbine ini.

 

Setelah mendarat di Kuala Lumpur Int. Airport (KLIA), saya naik Taxi ke Seremban, biayanya sekitar 65 Ringgit Malaysia (RM) dengan jarak sekitar 70 km. Sesampainya di Seremban saya langsung check in di Hotel.
Saya menginap di Klana Resort Hotel & Spa, Seremban selama 6 hari. Seremban ini berjarak sekitar 20 km dari tempat diadakannya Training, yaitu di Solar Turbine Centre Senawang, Kawasan industri Tuanku Ja'far.

 

Training urusan belakangan, yg penting jalan2 dulu... :), Waktu masih menunjukkan pkl 15.00 waktu KL. Maghrib nanti asyik nih kayaknya buka puasa di Mall Suria KLCC @ Petronas Tower. Saya naik KTM (Kereta Listrik) dari Seremban ke KL Sentral, kemudian sambung Light Rapid Transit (LRT/MRT) dari KL Sentral ke KLCC..
Ini suasana ngabuburit di KLCC

 

 

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Air Mancur menari @ KLCC

 

 

...Kembali ke Laptop, Training dilaksanakan selama 5 hari, pengajar adalah Cliff Hofman (Solar Turbine), FYI, untuk Turbotronic 4 Control System adalah menggunakan PLC type Controllogix dengan program RSLogix5000. Sedangkan kalo anda ambil Training Turbotronic 3 Control System, ini menggunakan PLC 5 dengan program RSLogix5.

Berikut ini adalah antara lain Silabus dari Materi training Turbotronic 4 Control System Operation (Solar Turbine):

1. Control System Overview: Control System Purpose/Function, Control Loop, Control System Configuration, On / Off Skid Control System, Field Instrumentation, Control System Hardware, Control Logix (1756 Chassis), Control Logix Controller, Communication Modules (Control Net, Ethernet/IP Communication, Other Comm. Modules, ControlNet Network, Flex I/O Node Function, Operator interface & HMI, TT4000 Remote, Backup relay System, Programming Terminal.
2. Boolean Logic: Binary logic, Noolean Logic Symbol, Turbine Logic Examples.
3. Ladder Logic and the Basic Instruction Set, TT4 Logic Structure, Ladder logic Structure, Bit Level and Word Level Instruction, Data Tags, Indicator and Manipulators, Bit Instructions, Compare Instructions, Arithmetic Instructions, Timer & Counter Instructions, Other Common Instructions
4. Logic Exercises : Simple Turbine logic, Lube Oil Cooler Logic, Lube Oil Heater logic, Fire Detection Logic, Start Sequence, Ignition Sequence
5. Introduction to Software Applications: RSLogix5000, RSNetwork for ControlNet, RSLinx
6. TT4 Offline Program Monitoring: Project File Structure, Project Distribution, Offline Program Monitoring
7. RSLogix5000 Project Familiarization
8. TT4 Program Architecture: Project Organization, Student Exercices, Alarm & Shutdown Logic, Analog Scalling Logic
9. Exercises: Modifying the I/O Configurations, Configuring Communications Drivers, Going Online, Configuring the ControlNet using RSNetworx, Introduction to Online Editing, Forcing, Toggling

 Disediakan juga Laptop dan PLC Controllogix sbg sarana peserta untuk melakukan simulasi.

 

Ini foto di kawasan Industri Tuanku Ja'far Senawang (saya dan 2 rekan dari negara Oman: Ayman dan Musa), utk didalam fasilitas Solar Turbinenya sendiri tdk boleh ambil gambar.

 

 

 

Menurut saya sendiri Training ini baik sekali dan recommended untuk diikuti, walaupun anda sudah sering melakukan operasi dan Troubleshooting dengan Controllogix sekalipun. Bagi saya sendiri Training ini adalah kombinasi antara refreshment dan mempelajari hal2 baru. Kira2 porsinya 50:50.
Saya sendiri mendapatkan nilai Pre Test  64/100 dan Nilai Post Test 100/100.

Partial Stroke Test for Emergency Shutdown Valve

During normal plant operation most SDVs/BDVs remain in static full open/close for long period time.
There is concern about operation failure caused by Valve failure.

Current ESD Test weakest points in my Company: 

• Not covered valve testing such as actuator, stem/shaft, body valve, and etc
• Sources of error may occur: broken shaft or stem, broken actuator springs, leaking piston seals, damaged mechanical feedback, and etc.

Partial stroke test is a function test to check periodically that the SDV is operated securely without any non-conformities such as sticking of valve and actuator in the event of emergency, by closing the valve slightly and slowly to such range as not to interfere with the process during plant operation. With partial stroke test, we will actuate the shutdown valve (ball valve) up to a certain travel percentage (generally it is 15% travel or 15 degree closing) of its full travel.

Advantage of Partial Stroke Test:

• Detectable damage of actuator, stick valve and valve stem
• Reduce the Probability of Failure on Demand (PFD), Improved Safety Integruty Level (SIL)
• Extended interval of full stroke test.

Weak point of Partial Stroke Test:

• Not covered all valve test, e.g. fully valve travel

Pictures below is example of ESDV hydraulic Panel with Partial Stroke Key Switch Facility:

Relation of Probability of Failure on Demand and partial Stroke Test

Probability of Failure on Demand (PFD) is statistical probability or chance that a system will not perform its intended function when required to do so.

Failure Rate (λd) :  The average rate at which a component could be expected to fail.
Test Interval (Ti): Time Interval between test to test
Simplified PFD equation for 1oo1 configuration (ISA TR 84.0.02): PFD= 1/2 λd.Ti
Diagnostic Coverage (DC): The diagnostic coverage of a component or subsystem is the ratio

of the detected failure rates to the total failure rates of the component or subsystem.

PFD with Partial Stroke :

PFD  = PFDp + PFDf

        = [DC. ½ λd .Ti]p + [(1-DC). ½ λd .Ti]f

Full Stroke Compare to Partial Stroke

Full Stroke Test:

• 100% Covered valve component testing, so it will give better reliability performance
• Difficult to implemented in some units that live continuously and have no bypass or switching line.

Partial stroke test:

•  Not covered all valve component testing
• Easier to implemented since it is not interrupted the production.