procedure maintenance

8/7/2019 Procedure Maintenance

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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 )


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


Test Function

IDGP


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Check

connection terminal cable

control

Counter check of the I/O



the IDGP data plug

Error check.

Function check

Operation check

Check the reading datasetter of DO point


tester, Srew driver

Maintenance Of Digital Input Module


Check


control




the IDGP data plug

Error check.

Function check Operation check



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


Check

connection terminal cablecontrol

Check signal output of

AO module


the IDGP data plug Error check.

Function check

Operation check


setter of AO point


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


Check


control

Check signal input of AI

module


the IDGP data plug

Error check.

Function check

Operation check


setter of AI point


tester, Srew driver

MAINTENANCE OF THE ACTUATOR

Maintenance Of Control Valve


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 )


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


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


Maintenance Of Temperature

Sensor


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


Check the installation ofAmpere Tranducer


Check the power supplyof ampere tranducer



setter of amperetranducer


Maintenance Of Voltage

Tranducer


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 the power supplyof voltage tranducer



setter of voltage

tranducer


Maintenance Of Frequency Tranducer


Check the installation ofFrequency Tranducer


Check the power supplyof frequency tranducer


Check the reading datasetter of frequencytranducer


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 the power supplyof KWh tranducer


Check the reading datasetter of KWh tranducer


Maintenance Of Power Factor Tranducer


Check the installation ofPower Factor Tranducer


Check the power supplyof power factor tranducer


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


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


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





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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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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UPS

Power signal check.


line.

Check the Installation of

the C-DGP and Terminalcable.

Function check

Operation check




setter of I/O point


tester, Srew driver

Maintenance Of Intelligent Fan Coil

Unit ( IFC ).

Test Function

-


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UPS

Power signal check.


line.

Check the Installation ofthe IFC and Terminal

cable.

Function check

Operation check




setter of I/O point


tester, Srew driver

Test Function

procedure maintenance

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