CARGO PUMP CONTROL & MONITORING SYSTEM

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1 TR-MARINE / CARGO WATCH II v.02 OPERATION AND MAINTENANCE MANUAL CARGO PUMP CONTROL & MONITORING SYSTEM PROJECT REF NO : TRM-CWII/G48 SHIYARD : GISAN HULL NO : NB48 Page 1 / 73

2 TABLEOFCONTENTS GENERALDESCRIPTION...6 INSTALLATIONINSTRUCTIONS...6 ADJUSTMENT...6 COMMISSIONING...6 OPERATIONBASICS GENERAL CONTROLPANELS REMOTEPANEL MAINWINDOW...8 HYDRAULICOPERATIONWINDOW...10 CARGOPUMPSWINDOW...20 ALARMWINDOW...21 SETTINGSWINDOW...22 TRENDWINDOW...23 AUXILIARYPUMPSWINDOW LOCALPANEL MAINWINDOW...26 OPERATIONWINDOW...28 OPERATIONWINDOW OPERATIONWINDOW OPERATIONWINDOW OPERATIONWINDOW CARGOPUMPSWINDOW...38 CARGOPUMP1WINDOW...39 CARGOPUMP2WINDOW...40 STRIPPINGPUMPWINDOW...40 ALARMWINDOW...41 SETTINGSWINDOW...42 CARGOPUMP1SETTINGSWINDOW...44 CARGOPUMP2SETTINGSWINDOW...44 CARGOPUMP3SETTINGSWINDOW...45 SYSTEMSETTINGSWINDOW...45 TRENDWINDOW...46 OPERATIONMODES LOCAL(MANUAL)CONTROLOPERATION...46 Page 2 / 73

3 6.2. LOCALCONTROLPANELOPERATION REMOTECONTROLPANELOPERATION ALARMLIST...47 MAINTANENCE...51 TROUBLESHOOTING...51 PLCMANUAL...52 Page 3 / 73

4 TABLE OF FIGURES FIGURE1REMOTEPANELMAINWINDOW...8 FIGURE2SYSTEMINFOPOPUPWINDOW...9 FIGURE3REMOTEPANELHYDRAULICOPERATIONWINDOW...10 FIGURE4CARGOPUMPSTOUCHPLACESONWINDOW...10 FIGURE5CARGOPUMP1POPUPWINDOW...11 FIGURE6CARGOPUMP2POPUPWINDOW...12 FIGURE7STRIPPINGPUMPPOPUPWINDOW...12 FIGURE8PROPORTIONALVALVESPOSITIONS...13 FIGURE9CARGOPUMPSSPEEDFEEDBACK...13 FIGURE10FILTERSITUATIONS...13 FIGURE11HYDRAULICSYSTEMPRESSURE...13 FIGURE12SOLENOIDSVALVESTOUCHPLACESONWINDOW...14 FIGURE13DRAINVALVESPOPUPWINDOW...14 FIGURE14HYDRAULICMAINPUMPSTOUCHPLACESONWINDOW...15 FIGURE15HYDRAULICMAINPUMPSREADYCONDITIONSPOPUPWINDOW...15 FIGURE16HYDRAULICMAINPUMPSPOPUPWINDOW...15 FIGURE17SUCTIONVALVESONWINDOW...16 FIGURE18HYDRAULICOILHEATERTOUCHPLACEONWINDOW...16 FIGURE19HYDRAULICOILHEATERPOPUPWINDOW...16 FIGURE20HYDRAULICOILTANKTEMPERATUREINDICATOR...16 FIGURE21VALVESFEEDBACK...17 FIGURE22AUXILIARYPUMPSPOPUPTOUCHPLACES...17 FIGURE23HFCPUMPPOPUPWINDOW...18 FIGURE24HCCPUMPPOPUPWINDOW...18 FIGURE25MENUANDBACKBUTTONS...19 FIGURE26SETTINGSPASSWORDPOPUPWINDOW...19 FIGURE27REMOTEPANELMENUWINDOW...19 FIGURE28REMOTEPANELCARGOPUMPSWINDOW...20 FIGURE29ALARMSTATEANIMATEDVALUE...20 FIGURE30SPEEDADJUSTBUTTONS...20 FIGURE31REMOTEPANELALARMWINDOW...21 FIGURE32REMOTEPANELSETTINGSWINDOW...22 FIGURE33POPUPKEYBOARDFORVALUEINPUT...22 FIGURE34REMOTEPANELTRENDWINDOW...23 FIGURE35REMOTEPANELAUXILIARYPUMPWINDOW...24 FIGURE36SEAWATERCOOLINGPUMP1POPUPWINDOW...25 FIGURE37SEAWATERCOOLINGPUMP2POPUPWINDOW...25 FIGURE38FRESHWATERCOOLINGPUMP1POPUPWINDOW...25 FIGURE39FRESHWATERCOOLINGPUMP2POPUPWINDOW...25 FIGURE40BUFFERLIQUIDCIRCULATIONPUMP1POPUPWINDOW...25 FIGURE41BUFFERLIQUIDCIRCULATIONPUMP2POPUPWINDOW...25 FIGURE42LOCALPANELMAINWINDOW...26 FIGURE43LOCALPANELSYSTEMINFOPOPUPWINDOW...27 FIGURE44PASSWORDPOPUPWINDOWFORCONTROLACCESS...27 FIGURE45POPUPKEYBOARD...28 FIGURE46LOCALPANELOPERATIONWINDOW...28 FIGURE47LOCALPANELMENUANDBACKBUTTONS...29 FIGURE48LOCALPANELMENUWINDOW...29 FIGURE49LOCALPANELOPERATION1WINDOW...30 FIGURE50LOCALPANELHYDRAULICMAINPUMPSPOPUPWINDOW...31 FIGURE51HYDRAULICMAINPUMPSREADYCONDITIONSPOPUPWINDOW...31 Page 4 / 73

5 FIGURE52LOCALPANELHCCPUMPPOPUPWINDOW...32 FIGURE53LOCALPANELHFCPUMPPOPUPWINDOW...32 FIGURE54LOCALPANELOPERATION2WINDOW...33 FIGURE55LOCALPANELSEAWATERCOOLINGPUMP1POPUPWINDOW...34 FIGURE56LOCALPANELSEAWATERCOOLINGPUMP2POPUPWINDOW...34 FIGURE57LOCALPANELFRESHWATERCOOLINGPUMP1POPUPWINDOW...34 FIGURE58LOCALPANELFRESHWATERCOOLINGPUMP2POPUPWINDOW...34 FIGURE59LOCALPANELBUFFERLIQUIDCIRCULATIONPUMP1POPUPWINDOW...34 FIGURE60LOCALPANELBUFFERLIQUIDCIRCULATIONPUMP2POPUPWINDOW...34 FIGURE61LOCALPANELOPERATION3WINDOW...35 FIGURE62LOCALPANELDRAINVALVEPOPUPWINDOW...36 FIGURE63LOCALPANELHYDRAULICOILHEATERPOPUPWINDOW...36 FIGURE64LOCALPANELOPERATIONWINDOW FIGURE65LOCALPANELCARGOPUMPSWINDOW...38 FIGURE66LOCALPANELCARGOPUMP1WINDOW...39 FIGURE67LOCALPANELCARGOPUMP2WINDOW...40 FIGURE68LOCALPANELSTRIPPINGPUMPWINDOW...40 FIGURE69LOCALPANELALARMWINDOW...41 FIGURE71LOCALPANELSETTINGSWINDOW...42 FIGURE70LOCALPANELSETTINGSPASSWORDPOPUPWINDOW...42 FIGURE72POPUPKEYBOARDFORVALUEINPUT...43 FIGURE73CARGOPUMP1SETTINGSWINDOW...44 FIGURE74CARGOPUMP2SETTINGSWINDOW...44 FIGURE75STRIPPINGPUMPSETTINGSWINDOW...45 FIGURE76SYSTEMSETTINGSWINDOW...45 FIGURE77LOCALPANELTRENDWINDOW...46 Page 5 / 73

6 1. GENERAL DESCRIPTION The CARGO WATCH II system is designed for Cargo Pump Controlling and Cargo Pumps Conditions Monitoring. The system comprises 3 pieces of motor starter cabinet, 1 piece of controller cabinet and 1 piece of 15 touch screen located in Cargo Control Room. Each of motor starter cabinets includes a soft starter for hydraulic pump motor starting. Controller cabinet includes controlling and monitoring unit (5.7 touch screen). The system can be controlled by locally manual from controller cabinet and also locally from 5.7 touch screen on the controller cabinet. 15 touch screen is used with customized GUI 1 to have a user friendly and compact design for controlling and monitoring of all the system components. With an option of access to all major system parameters such as alarm set points through the graphical display unit, system can be easily adjusted according to system components characteristics. All system components are approved and tested for marine use. 2. INSTALLATION INSTRUCTIONS Installation of the control system must be executed by the yard in accordance with valid drawings. It is important that all the wires are connected according to electrical drawings. 3. ADJUSTMENT Adjustment points are the alarm set points, analog and digital ranges for pressure, temperature, level sensors, valves feedbacks and throttle valves controller and feedback signals. Final adjustment will be done during commissioning by Yard. 4. COMMISSIONING Check that all connections are done in accordance with the drawings. Dry-test the system without running the electrical motor connected to pump/pumps. Full function test of the system with the electrical motor running. Enter set points according to the desired timing settings for alarms, alarms set points and function delays. 1 Graphical User Interface Page 6 / 73

7 5. OPERATION BASICS 5.1. General The CARGO WATCH II control system is capable of controlling and monitoring all the components involved in the external cargo pumps system depending on the components that are used in. The system is designed for safe and easy operation in order to ensure proper monitoring and operation of the related equipment. If remote operated equipment is used it is possible to have semi automatic start and stop of the pumps, valves and heaters. All major functions are operated and monitored from the control panels with feedbacks. System can be controlled from 3 independent station which are local cabinet, local operator panel (5.7 touch screen) and Remote operator panel (15 touch screen). While the control is under a station other stations will be only the monitoring element for the system. The controlled components consist of; o 3 pieces of 230kW HPP Unit Drive Motors o 1 piece of 11kW Hydraulic Cool and Circulation Pump o 1 piece of 3,5kW Hydraulic Filter and Circulation Pump o 2 pieces of 8,6 kw Sea Water Cooling Pumps o 2 pieces of 3,5 kw Fresh Water Cooling Pumps o 2 pieces of 8,6 kw Buffer Liquid Circulation Pump o 2 pieces of 6 kw Hydraulic Oil Haters o 4 pieces of proportional valves o 4 pieces of solenoid valves The monitored components consist of; o 3 pieces of HPP Unit Drive Motors Conditions o 8 pieces of Auxiliary Pumps Conditions o 2 pieces of Hyd. Oil Heater Conditions o 3 pieces of proportional valves feedback positions o 6 pieces of valves feedbacks o 8 pieces of filters feedbacks o 4 pieces of Hydraulic Oil tank level and temperature feedbacks o 1 piece of Hyd. System Pressure alarm feedback Page 7 / 73

8 o 15 pieces of Cargo Pumps Temperature Feedbacks o 6 pieces of Cargo Pumps Pressure Feedbacks o 3 pieces of Cargo Pumps Speed Feedbacks 5.2. Control panels The operator panels are available for the system as a suite of HMI solutions. The controller system comprises 2 pieces of control panel, 1 of 5.7 touch screen located on controller panel, 1 of 15 touch screen located in cargo control room. Controlling and monitoring of the system is made via operator panels Remote controllable valves, motors, pumps, and heaters Alarms are monitored from the operators panels alarm page Remote Panel Remote operator panel is 15 touch screen controlling and monitoring equipment for the system. Remote panel control access is permitted from the local operator panel Main Window Figure 1 Remote Panel Main Window Page 8 / 73

Main window includes shortcuts to Operation window, Cargo Pumps window, Alarm Page (animated with red color on alarm states) and Settings window which has the allowance for only the service engineer.

9 Main window includes shortcuts to Operation window, Cargo Pumps window, Alarm Page (animated with red color on alarm states) and Settings window which has the allowance for only the service engineer. If the local cabinet or the local operator panel is in operation warnings on the main window for the controller will be seen easily. From the question mark symbol system info popup window can be seen as below figure 2. Figure 2 System Info Popup Window Page 9 / 73

5.2.1.2. Hydraulic Operation Window All of the system controllable and monitor able devices can be controlled and monitored from the Hydraulic Operation window.

Pump 2 Running Hours Hrs FLOW VALVE 1 STRIPPING PUMP RPM FLOW VALVE 2 SP SP SP AP AP AP P. FILTER 1 DRAIN VALVE 1 H YDRAU LIC SYST EM PR ESSURE P. FILTER 2 RETURN BALL VALVE 1 P.

FILTER 3 M HP3 PRESSURE VALVE 0-315 bar HYD.PUMP 1 HYD. PUMP 2 RUN NING RUNNI NG SUCTION VALVE 1 SUCTION VALVE 2 H YD.PUM P 3 RU NNING HYD. OIL TANK HEATER 1 & 2 HEATING HYD.

Figure 3 Remote Panel Hydraulic Operation Window On window, cargo pumps instantaneous speed, hydraulic pumps running hours, proportional valves set positions and actual positions

10 Hydraulic Operation Window All of the system controllable and monitor able devices can be controlled and monitored from the Hydraulic Operation window. HYDRAULIC OPERATION CARGO PUMP 1 RPM HYD. PUMPS DRAIN VALVE CARGO PUMP 2 RPM CA RGO PUMP 2 CARG O PU MP 1 Hyd.Pump 1 Running Hours S TRIPPI NG P UMP Hrs Hyd.Pump 2 Running Hours Hrs FLOW VALVE 1 STRIPPING PUMP RPM FLOW VALVE 2 SP SP SP AP AP AP P. FILTER 1 DRAIN VALVE 1 H YDRAU LIC SYST EM PR ESSURE P. FILTER 2 RETURN BALL VALVE 1 P. FILTER 3 R. FILTER 1 HP2 RETURN BALL VALVE 2 DRAIN VALVE 3 M HP1 Hrs R. FILTER 4 DRAIN VALVE 4 DRAIN VALVE 2 M P. FILTER 4 Hyd.Pump 3 Running Hours FLOW VALVE 3 R. FILTER 2 R. FILTER 3 M HP3 PRESSURE VALVE bar HYD.PUMP 1 HYD. PUMP 2 RUN NING RUNNI NG SUCTION VALVE 1 SUCTION VALVE 2 H YD.PUM P 3 RU NNING HYD. OIL TANK HEATER 1 & 2 HEATING HYD. FILTER & CIRCULATION PUMP HYD. COOL & CIRCULATION PUMP RUNNING RUNNING SUCTION VALVE 3 FLOW VALVE 4 HYD. OIL TANK TEMP. Figure 3 Remote Panel Hydraulic Operation Window On window, cargo pumps instantaneous speed, hydraulic pumps running hours, proportional valves set positions and actual positions (feedback positions), hydraulic system pressure, hydraulic oil tank temperature, filters situations, manual controllable valves situations, and auxiliary pumps conditions can be seen. By touching the cyan back grounded icons operator can reach the popup windows for controllable devices. Figure 4 Cargo Pumps Touch places on window From Cargo Pumps icons operator can reach Cargo Pump1, Cargo Pump 2, and Stripping Pump temperature and pressure values. Operator can also adjust the speed of the Cargo pumps by using proportional valves position increment or decrement. Each of the cargo pumps Page 10 / 73 Rauf Orbay Cad. No: Tuzla STANBUL

11 popup window have the alarm banner for itself. If the alarms for the temperature and pressure values are active indicating values will get red color. When cargo pumps are running animated arrows will be visible. Running hours of the Cargo Pumps can be seen on the popup windows. CARGO PUMP 1 CARGO MEDIA PRESSURE & TEMP. BEARING TEMP.1 SUCTION PRESSURE & TEMP. RUNNING HOURS BEARING TEMP.2 FLOW VALVE 1 SP AP BEARING TEMP.3 SPEED SPEED ADJUSTMENT Figure 5 Cargo Pump 1 Popup Window Page 11 / 73

12 CARGO PUMP 2 CARGO MEDIA PRESSURE & TEMP. BEARING TEMP.1 SUCTION PRESSURE & TEMP. RUNNING HOURS BEARING TEMP.2 SPEED FLOW VALVE 2 SP AP SPEED ADJUSTMENT BEARING TEMP.3 Figure 6 Cargo Pump 2 Popup Window STRIPPING PUMP CARGO MEDIA PRESSURE & TEMP. BEARING TEMP.1 SUCTION PRESSURE & TEMP. RUNNING HOURS BEARING TEMP.2 SPEED FLOW VALVE 3 SP AP SPEED ADJUSTMENT BEARING TEMP.3 Figure 7 Stripping Pump Popup Window Page 12 / 73 Rauf Orbay Cad. No: Tuzla STANBUL

Figure 8 Proportional Valves Positions Operator can see the proportional valves set positions and actual (feedback) positions from the hydraulic

Figure 9 Cargo Pumps Speed Feedback Operator can see the speed of the cargo pumps from hydraulic operation window and alarm point for the speed set on

When a filter clogged the filter color will get red. Hydraulic system pressure can be seen and controlled from hydraulic operation window.

13 Figure 8 Proportional Valves Positions Operator can see the proportional valves set positions and actual (feedback) positions from the hydraulic operation window during operations. Figure 9 Cargo Pumps Speed Feedback Operator can see the speed of the cargo pumps from hydraulic operation window and alarm point for the speed set on the indicators and colored with red. Figure 10 Filter situations Filter Situations can be seen from the hydraulic operation window. When a filter clogged the filter color will get red. Hydraulic system pressure can be seen and controlled from hydraulic operation window. Proportional pressure valve position is monitored on the window and pressure of the system is controlled by increment and decrement of the valve position. If the alarm for the system pressure is active value for the hydraulic system pressure will get red color. Page 13 / 73 Figure 11 Hydraulic System Pressure

But the operator can see the open or close order from the open, close text colored with green.

14 Figure 12 Solenoids Valves Touch Places on Window Solenoids valves popup window will be visible when the operator touches the cyan back grounded places on the window. Operator can control the solenoids valves from the popup window of drain valves. These valves have no feedback for situations opened/closed. But the operator can see the open or close order from the open, close text colored with green. Figure 13 Drain Valves Popup Window By touching the cyan back grounded place on the window the hydraulic main pumps popup windows will be visible for the hydraulic main pumps control. By pressing the green square specified with HP1 text will show the ready conditions for the main pumps. Ready conditions are; o Power available o Suction valve of the pump is opened o Hydraulic oil tank level not low o Hydraulic oil tank temperature not low o Emergency stop not active Page 14 / 73

15 Figure 14 Hydraulic Main Pumps Touch Places on Window Operator will give the order for power request from the popup window for each main pump. Operator can see the start or stop order from the start, stop text colored with green. And the power request order from the power request on, power request off circle colored with green Figure 16 Hydraulic Main Pumps Popup Window Figure 15 Hydraulic Main Pumps Ready Conditions Popup Window If ready conditions will be satisfied, controller will let for start operation of the main pumps. The running text and arrows will be visible when pumps are running. Page 15 / 73

Figure 17 Suction Valves on Window Suction valves feedbacks can be seen from the window if a suction valve is opened, red

16 Figure 17 Suction Valves on Window Suction valves feedbacks can be seen from the window if a suction valve is opened, red colored shapes will get green color on valve icons. Figure 18 Hydraulic Oil Heater Touch place on Window Figure 19 Hydraulic Oil Heater Popup Window From cyan back grounded place for heaters operator can reach the popup window for controlling of heaters. For both two heaters there is one popup control window. Operator can see the start or stop order from the start, stop text colored with green. Heating text will be visible while feedback received from heaters. Heaters start and stop functions are controlled automatically for undesired temperature values for the hydraulic oil. Figure 20 Hydraulic Oil Tank Temperature Indicator Page 16 / 73

Figure 21 Valves Feedback On the operation window feedbacks of the valves are simulated for the opened or closed situation.

17 From the indicator for hydraulic oil tank temperature operator can see temperature for the Hydraulic oil. If the alarm for the hydraulic oil temperature is active, value for the hydraulic system pressure will get red color. Figure 21 Valves Feedback On the operation window feedbacks of the valves are simulated for the opened or closed situation. Figure 22 Auxiliary Pumps Popup Touch Places From cyan back grounded place for auxiliary pumps operator can reach the popup window for controlling of auxiliary pumps. There are only two auxiliary pump controls on the Page 17 / 73

18 hydraulic operation window. Other auxiliary pumps are controlled from the Auxiliary Pumps window. Figure 24 HCC Pump Popup Window Figure 23 HFC Pump Popup Window Hydraulic cool & circulation pump and hydraulic filter &circulation pumps are protected for dry run when the oil level of the hydraulic oil tank is low pumps will be stopped automatically. Ready condition for these two pumps is the hydraulic oil tank low level. On the operation window running hours for the main hydraulic pumps can be seen for unexpected running hours of the main pumps. Page 18 / 73

19 Figure 25 Menu and Back Buttons From all window operator can reach Menu and Back button for fast responses. From Menu button operator can reach all separate monitoring and controlling windows easily By pressing the menu button operator can reach the menu, then operator can choose window that is wanted. Operator can choose; Trend window Alarm Page (toggles to alarm page,back color of the icon is animated with red color when any alarm is active) Settings (display password for settings popup window) Auxiliary Pumps(toggles to auxiliary pumps window) Operation (toggles to hydraulic operation window) Cargo Pumps(toggles to cargo pumps window) Back to Main Menu(toggles to main menu window) When settings button on main window or on menu window is pressed password popup window will be visible. By pressing white back grounded place on password popup window, popup keyboard will be visible Figure 26 Settings Password Popup Window The password can be entered by the help of the keypad. This password is only for service engineers who are authorized for the commissioning of the system. Figure 27 Remote Panel Menu Window Page 19 / 73

20 Cargo Pumps Window Figure 28 Remote Panel Cargo Pumps Window From cargo pumps window operator can reach all the values for cargo pumps like temperature, pressure, speed, proportional valve positions and running hours. Operator has ability to make speed adjustment by increasing or decreasing valve position. All of the system pumps and heaters on/off states are seen from the window. For each pump values are getting red when it is in alarm state which is set from the settings window. Alarm banners are indicating the related pumps alarms only. Figure 30 Speed Adjust Buttons Figure 29 Alarm State Animated Value Page 20 / 73

5.2.1.4. Alarm Window Figure 31 Remote Panel Alarm Window Alarms are monitored when active ACK 2 button will stop the buzzer.

21 Alarm Window Figure 31 Remote Panel Alarm Window Alarms are monitored when active ACK 2 button will stop the buzzer. Reset button will delete the alarm message from the alarm list if the alarm state is not active. By up and down arrow buttons operator can reach the alarms that are not fit on the list. Any of the alarms can t be reset automatically operator must see the alarm and reset from the alarm window. Alarm list s Columns are; Date of the alarm Time of the alarm ACK time of the alarm Alarm message State 2 Acknowledge Page 21 / 73

5.2.1.5. Settings Window Figure 32 Remote Panel Settings Window Alarm points for all analog variables can be set from the settings window.

22 Settings Window Figure 32 Remote Panel Settings Window Alarm points for all analog variables can be set from the settings window. By pressing on the value popup keyboard will be visible and input of the new value will be available. Running hours of the hydraulic main pumps and cargo pumps can be reset from the window. Temperature points for automatic start of the heaters can be set from the window. If the input value for the points are not in the range of the sensor, warning about the range will be visible. Figure 33 Popup Keyboard for Value Input Page 22 / 73

23 Trend Window Figure 34 Remote Panel Trend Window In the trend window operator can see Cargo Pumps speed in RPM and Throttle valve feedback positions. Operator can reach past log for the variables that trend graph records. Page 23 / 73

24 Auxiliary Pumps Window Figure 35 Remote Panel Auxiliary Pump Window From auxiliary pump window operator can control and see conditions for; Sea water cooling pump 1 Sea water cooling pump 2 Fresh water cooling pump 1 Fresh water cooling pump 2 Buffer liquid circulation pump 1 Buffer liquid circulation pump 2 By pressing cyan back grounded places on the window popup windows will be visible for the pressed pump. Operator can see the start or stop order from animated text color of the start/stop button will get green (order) or red (no order) from the popup window. Animated arrows on the pumps will be visible when related pump is running. Page 24 / 73

25 Figure 36 Sea Water Cooling Pump 1 Popup Window Figure 37 Sea Water Cooling Pump 2 Popup Window Figure 38 Fresh Water Cooling Pump 1 Popup Window Figure 39 Fresh Water Cooling Pump 2 Popup Window Figure 40 Buffer Liquid Circulation Pump 1 Popup Window Page 25 / 73 Figure 41 Buffer Liquid Circulation Pump 2 Popup Window

5.2.2. Local Panel Remote operator panel is 5.7 touch screen controlling and monitoring equipment for the system. Local panel control access is permitted from the local operator panel. 5.2.2.1.

26 Local Panel Remote operator panel is 5.7 touch screen controlling and monitoring equipment for the system. Local panel control access is permitted from the local operator panel Main Window Figure 42 Local Panel Main Window Main window includes shortcuts to Operation window, Cargo Pumps window, Alarm Page (animated with red color on alarm states) and Settings window which has the allowance for only the service engineer. If the local cabinet, the remote operator panel or the local panel is in operation warnings on the main window for the controller will be seen easily. From operation modes buttons operator can change the control place with password protect like local operator panel or remote operator panel. When pressed on local panel activate or remote panel activate password popup will be visible for give or take over command. Local cabinet control will be available from the switch that is positioned on control cabinet. While the Local Cabinet is active, other control panels will be only the monitoring station for the system Page 26 / 73

43. From the question mark symbol system

and remote will be the controller panel.

change the controlling device like local

By pressing white back grounded place on

27 43. From the question mark symbol system info popup window can be seen as below figure PROJECT No TRM-PCM V.01 APPLICATION PL AT ION SHIPYARD HULL No PUMP CONTROL AND MONITORING v.01 GISAN NB48 Figure 43 Local Panel System Info Popup Window When local panel is active, remote panel is only used for monitoring device and local panel will be the controller panel. Likely the remote panel is active local panel is only used for monitoring device and remote will be the controller panel. Figure 44 Password Popup Window for Control Access From Password popup window for control access operator can change the controlling device like local operator panel or remote operator panel. By pressing white back grounded place on the popup window, popup keyboard for the password input will be visible. Page 27 / 73

28 Figure 45 Popup Keyboard When operator enters the right password for control access change, animated buttons will turn into green for indicating active operator panel Operation Window Operation window includes the shortcuts for four pages of operation windows. By pressing on shortcuts operator can reach four operation pages separately. Figure 46 Local Panel Operation Window Page 28 / 73

29 From all window operator can reach Menu and Back button for fast responses. From Menu button operator can reach all separate monitoring and controlling windows easily Figure 47 Local Panel Menu and Back Buttons By pressing the menu button operator can reach the menu, then operator can choose window that is wanted. Operator can choose; Trend window Alarm Page (toggles to alarm page,back color of the icon is animated with red color when any alarm is active) Operation (toggles to hydraulic operation window) Cargo Pumps(toggles to cargo pumps window) Back to Main Menu(toggles to main menu window) Figure 48 Local Panel Menu Window Page 29 / 73

30 Operation Window 1 Figure 49 Local Panel Operation 1 Window From operation 1 window operator can control and see conditions for; Main hydraulic pump 1 Main hydraulic pump 2 Main hydraulic pump 3 Hydraulic Cool & Circulation Pump Hydraulic Filter & Circulation Pump Hydraulic system pressure By pressing buttons for the controlled equipments on the window popup windows will be visible for the pumps control. Operator can see the start or stop order from animated text color of the start/stop button will get green (order) or red (no order) from the popup window. Animated ON text will be visible on the button of the controlled pumps when pumps are running. Page 30 / 73

31 On the window operator has ability to see the situation of the controlled equipments. By pressing the green square positioned on the popup window of the hydraulic pumps, texts will show the ready conditions for the main pumps. Ready conditions are; o Power available o Suction valve of the pump is opened o Hydraulic oil tank level not low o Hydraulic oil tank temperature not low o Emergency stop not active Figure 50 Local Panel Hydraulic Main Pumps Popup Window Figure 51 Hydraulic Main Pumps Ready Conditions Popup Window Operator will give the order for power request from the popup window for each main pump. Operator can see the start or stop order from the start, stop text colored with green. And the power request order from the power request on, power request off circle colored with green. If ready conditions will be satisfied, controller will let for start operation of the main pumps. Animated ON text will be visible on the button of the controlled pumps when pumps are running. Page 31 / 73

32 Hydraulic system pressure can be seen and controlled from operation window 1. Proportional pressure valve position is monitored on the window and pressure of the system is controlled by increment and decrement of the valve position. If the alarm for the system pressure is active value for the hydraulic system pressure will get red color. Figure 52 Local Panel HCC Pump Popup Window Figure 53 Local Panel HFC Pump Popup Window Hydraulic cool & circulation pump and hydraulic filter &circulation pumps are protected for dry run when the oil level of the hydraulic oil tank is low pumps will be stopped automatically. Ready condition for these two pumps is the hydraulic oil tank low level. Page 32 / 73

33 Operation Window 2 Figure 54 Local Panel Operation 2 Window From operation 2 window operator can control and see conditions for; Sea water cooling pump 1 Sea water cooling pump 2 Fresh water cooling pump 1 Fresh water cooling pump 2 Buffer liquid circulation pump 1 Buffer liquid circulation pump 2 By pressing buttons for the controlled pumps on the window pumps popup windows will be visible for the pumps control. Operator can see the start or stop order from animated text color of the start/stop button will get green (order) or red (no order) from the popup window. Animated ON text will be visible on the button of the controlled pumps when pumps are running. Page 33 / 73

34 Figure 55 Local Panel Sea Water Cooling Pump 1 Popup Window Figure 56 Local Panel Sea Water Cooling Pump 2 Popup Window Figure 57 Local Panel Fresh Water Cooling Pump 1 Popup Window Figure 58 Local Panel Fresh Water Cooling Pump 2 Popup Window Figure 59 Local Panel Buffer Liquid Circulation Pump 1 Popup Window Figure 60 Local Panel Buffer Liquid Circulation Pump 2 Popup Window Page 34 / 73

35 Operation Window 3 Figure 61 Local Panel Operation 3 Window From operation 3 window operator can control Hydraulic Oil heater 1 & 2 Drain Valve 1 Drain Valve 2 Drain Valve 3 Drain Valve 4 By pressing buttons for the controlled equipment on the window, popup windows will be visible for the heaters and valves control. Operator can see the open or close order from animated text color of the open/close button will get green (order) or red (no order) from the popup window of drain valves. These valves have no feedback for situations opened/closed. For the heaters control, operator can see the start or stop order from animated text color of the start/stop button will get green (order) or red (no order) from the popup window. Animated ON text will be visible on the button of the controlled heaters when running. For Page 35 / 73

36 both two heaters there is one popup control window. Heaters start and stop functions are controlled automatically for undesired temperature values for the hydraulic oil. From the indicator for hydraulic oil tank temperature operator can see temperature for the Hydraulic oil. If the alarm for the hydraulic oil temperature is active, value for the hydraulic system pressure will get red color. Figure 62 Local Panel Drain Valve Popup Window Figure 63 Local Panel Hydraulic Oil Heater Popup Window Page 36 / 73

37 Operation Window 4 Figure 64 Local Panel Operation Window 4 From operation 4 window operators can control and see conditions for; Suction valve 1 Suction valve 2 Suction valve 3 Return ball valve 1 Return ball valve 2 Hydraulic pumps drain valve On the operation 4 window feedbacks of the valves are simulated for the opened or closed situation. Page 37 / 73

38 Cargo Pumps Window Figure 65 Local Panel Cargo Pumps Window Operator can see the speed of the cargo pumps from cargo pumps window and alarm point for the speed set on the indicators and colored with red. By touching the cyan back grounded icons operator can reach the windows for Cargo Pump1, Cargo Pump 2, and Stripping Pump temperature and pressure values. Page 38 / 73

39 Cargo Pump 1 Window Figure 66 Local Panel Cargo Pump 1 Window From cargo pumps windows operator can reach all the values for cargo pumps like temperature, pressure, speed, proportional valve positions and running hours. Operator has ability to make speed adjustment by increasing or decreasing valve position. Operator can see the proportional valves set positions and actual (feedback) positions from the Cargo Pumps window during operations. On the cargo pumps windows running hours for the main hydraulic pumps can be seen for unexpected running hours of the main pumps. Each of the cargo pumps window have the alarm banner for itself. If the alarms for the temperature and pressure values are active indicating values will get red color. Page 39 / 73

40 Cargo Pump 2 Window Figure 67 Local Panel Cargo Pump 2 Window Stripping Pump Window Figure 68 Local Panel Stripping Pump Window Page 40 / 73

5.2.2.4. Alarm Window Figure 69 Local Panel Alarm Window Alarms are monitored when active ACK 3 button will stop the buzzer.

41 Alarm Window Figure 69 Local Panel Alarm Window Alarms are monitored when active ACK 3 button will stop the buzzer. Reset button will delete the alarm message from the alarm list if the alarm state is not active. By up and down arrow buttons operator can reach the alarms that are not fit on the list. Any of the alarms can t be reset automatically operator must see the alarm and reset from the alarm window. Alarm list s Columns are; Time of the alarm Alarm message 3 Acknowledge Page 41 / 73

42 Settings Window When settings button on main window, password popup window will be visible. By pressing white back grounded place on password popup window, popup keyboard will be visible Figure 70 Local Panel Settings Password Popup Window The password can be entered by the help of the keypad. This password is only for service engineers who are authorized for the commissioning of the system. Figure 71 Local Panel Settings Window Page 42 / 73

43 By touching the cyan back grounded icons operator can reach the windows for Cargo Pump1, Cargo Pump 2, and Stripping Pump settings window. By touching the button for System settings running hours, Hydraulic oil tank alarms and Hydraulic oil pressure alarms can be adjusted. Alarm points for all analog variables can be set from the settings window. By pressing on the value popup keyboard will be visible and input of the new value will be available. Running hours of the hydraulic main pumps and cargo pumps can be reset from the window. Temperature points for automatic start of the heaters can be set from the window. If the input value for the points are not in the range of the sensor, warning about the range will be visible. Figure 72 Popup Keyboard for Value Input Page 43 / 73

44 Cargo Pump 1 Settings Window Figure 73 Cargo Pump 1 Settings Window Cargo Pump 2 Settings Window Figure 74 Cargo Pump 2 Settings Window Page 44 / 73

Stripping Pump Settings Window 5.2.2.5.4.

45 Stripping Pump Settings Window Figure 75 Stripping Pump Settings Window System Settings Window Figure 76 System Settings Window Page 45 / 73

5.2.2.6. Trend Window Figure 77 Local Panel Trend Window In the trend window operator can see Cargo Pumps speed in RPM and Throttle valve feedback positions. 6. OPERATION MODES 6.1.

46 Trend Window Figure 77 Local Panel Trend Window In the trend window operator can see Cargo Pumps speed in RPM and Throttle valve feedback positions. 6. OPERATION MODES 6.1. Local (manual) Control Operation Local Control operation can be done from the main control cabinet. By using pushbuttons, switches and potentiometers, operators can control the equipments on the system When Local Control operation is active, local control panel and remote control panel are only the monitoring device controlling of the equipments will not be available from the touch screen control panels Local Control Panel Operation When operation command from the main cabinet is given to the PLC controller local control panel will be in command for control. If it is not in command, operator can take command by using activation buttons from the main window of the Local Control Panel. Page 46 / 73

47 When Local Control Panel is active for control of the system, Local (manual) Operation from main cabinet and remote control operation will not be available. Remote control panel will be only the monitoring device for the system while local control panel is active Remote Control Panel Operation When operation command from the main cabinet is given to the PLC controller remote control panel will be in command for control. If it is not in command, operator can give command by using activation buttons from the main window of the Local Control Panel. When Remote Control Panel is active for control of the system, Local (manual) Operation from main cabinet and local control operation will not be available. Local control panel will be only the monitoring device for the system while remote control panel is active. 7. ALARM LIST ALARM/MESSAGEDESCRIPTION EXPLANATION REQUIREDACTION Mainhydraulicpumpsalarms 1 Hydraulicmainpump1overload Mainpump1electricmotorisoverloaded Stopmotorandcheckelectricmotor 2 Hydraulicmainpump1fault Mainpump1electricmotorisfaulty Stopmotorandcheckelectricmotor 3 Hydraulicmainpump1onfail Mainpump1electricmotorisnotstarted Checkthecablingandelectricmotor 4 Hydraulicmainpump1offfail Mainpump1electricmotorisnot Checkthecablingandelectricmotor stopped 5 Hydraulicmainpump2overload Mainpump2electricmotorisoverloaded Stopmotorandcheckelectricmotor 6 Hydraulicmainpump2fault Mainpump2electricmotorisfaulty Stopmotorandcheckelectricmotor 7 Hydraulicmainpump2onfail Mainpump2electricmotorisnotstarted Checkthecablingandelectricmotor 8 Hydraulicmainpump2offfail Mainpump2electricmotorisnot Checkthecablingandelectricmotor stopped 9 Hydraulicmainpump3overload Mainpump3electricmotorisoverloaded Stopmotorandcheckelectricmotor 10 Hydraulicmainpump3fault Mainpump3electricmotorisfaulty Stopmotorandcheckelectricmotor 11 Hydraulicmainpump3onfail Mainpump3electricmotorisnotstarted Checkthecablingandelectricmotor 12 Hydraulicmainpump3offfail Mainpump3electricmotorisnot Checkthecablingandelectricmotor stopped 13 Hydraulicoilheateralarms 14 Hydraulicoilheater1onfail Hydraulicoiltankheater1isnotstarted Checkthecablingandheater 15 Hydraulicoilheater1offfail Hydraulicoiltankheater1isnotstopped Checkthecablingandheater 16 Hydraulicoilheater2onfail Hydraulicoiltankheater2isnotstarted Checkthecablingandheater 17 Hydraulicoilheater2offfail Hydraulicoiltankheater1isnotstopped Checkthecablingandheater Page 47 / 73

48 18 Filtersalarms 19 Pressurefilter1clugged Pressurefilter1isblocked Checkandcleanthefilter 20 Pressurefilter2clugged Pressurefilter2isblocked Checkandcleanthefilter 21 Pressurefilter3clugged Pressurefilter3isblocked Checkandcleanthefilter 22 Pressurefilter4clugged Pressurefilter4isblocked Checkandcleanthefilter 23 Returnfilter1clugged Returnfilter1isblocked Checkandcleanthefilter 24 Returnfilter2clugged Returnfilter2isblocked Checkandcleanthefilter 25 Returnfilter3clugged Returnfilter3isblocked Checkandcleanthefilter 26 Returnfilter4clugged Returnfilter4isblocked Checkandcleanthefilter 27 Hydraulicoiltankalarms 28 Hydraulicoiltanklowlevelalarm Hydraulicoillevelislow Checkhydraulicoiltankandfillwith oil 29 Hydraulicoiltanklowlowlevel alarm Hydraulicoillevelistoolow Checkhydraulicoiltankandfillwith oil 30 Hydraulicoiltanklowtemperature alarm Hydraulicoiltemperatureislow Checkhydraulicoiltanktempand heaters 31 Hydraulicoiltankhightemperature alarm Hydraulicoiltemperatureishigh Checkhydraulicoiltanktempand heaters Hydrauliccoolingandcirculationpumpalarms Hydrauliccoolingandcirculation pumpoverload Hydrauliccoolingandcirculationpump electricmotorisoverloaded Stopmotorandcheckelectricmotor 34 Hydrauliccoolingandcirculation pumponfail Hydrauliccoolingandcirculationpump electricmotorisnotstarted Checkthecablingandelectricmotor 35 Hydrauliccoolingandcirculation pumpofffail Hydrauliccoolingandcirculationpump electricmotorisnotstopped Checkthecablingandelectricmotor Hydraulicfilterandcirculationpump Hydraulicfilterandcirculationpump overload Hydraulicfilterandcirculationpump onfail Hydraulicfilterandcirculationpump offfail Hydraulicfilterandcirculationpump electricmotorisoverloaded Hydraulicfilterandcirculationpump electricmotorisnotstarted Hydraulicfilterandcirculationpump electricmotorisnotstopped Stopmotorandcheckelectricmotor Checkthecablingandelectricmotor Checkthecablingandelectricmotor 40 Seawatercoolingpumpsalarms 41 Seawatercoolingpump1overload Seawatercoolingpump1electricmotor isoverloaded 42 Seawatercoolingpump1onfail watercoolingpump1electricmotor isnotstarted Stopmotorandcheckelectricmotor Checkthecablingandelectricmotor Page 48 / 73

49 43 Seawatercoolingpump1offfail Seawatercoolingpump1electricmotor isnotstopped 44 Seawatercoolingpump2overload Seawatercoolingpump2electricmotor isoverloaded 45 Seawatercoolingpump1onfail Seawatercoolingpump2electricmotor isnotstarted 46 Seawatercoolingpump1offfail Seawatercoolingpump2electricmotor isnotstopped Checkthecablingandelectricmotor Stopmotorandcheckelectricmotor Checkthecablingandelectricmotor Checkthecablingandelectricmotor 47 Freshwatercoolingpumpsalarms 48 Freshwatercoolingpump1 overload Freshwatercoolingpump1electricmotor isoverloaded Stopmotorandcheckelectricmotor 49 Freshwatercoolingpump1onfail Freshwatercoolingpump1electricmotor isnotstarted 50 Freshwatercoolingpump1offfail Freshwatercoolingpump1electricmotor isnotstopped Checkthecablingandelectricmotor Checkthecablingandelectricmotor 51 Freshwatercoolingpump2 overload Freshwatercoolingpump2electricmotor isoverloaded Stopmotorandcheckelectricmotor 52 Freshwatercoolingpump2onfail Freshwatercoolingpump2electricmotor isnotstarted 53 Freshwatercoolingpump1offfail Freshwatercoolingpump2electricmotor isnotstopped Checkthecablingandelectricmotor Checkthecablingandelectricmotor Bufferliquidcirculationpumpsalarms Bufferliquidcirculationpump1 overload Bufferliquidcirculationpump1electric motorisoverloaded Stopmotorandcheckelectricmotor 56 Bufferliquidcirculationpump1on fail Bufferliquidcirculationpump1electric motorisnotstartes Checkthecablingandelectricmotor 57 Bufferliquidcirculationpump1off fail Bufferliquidcirculationpump1electric motorisnotstopped Checkthecablingandelectricmotor 58 Bufferliquidcirculationpump2 overload Bufferliquidcirculationpump2electric motorisoverloaded Stopmotorandcheckelectricmotor 59 Bufferliquidcirculationpump2on fail Bufferliquidcirculationpump2electric motorisnotstarted Checkthecablingandelectricmotor 60 Bufferliquidcirculationpump2off fail Bufferliquidcirculationpump2electric motorisnotstopped Checkthecablingandelectricmotor 61 Cargopump1alarms 62 Cargopump1bearingtemperature 1fail Cargopump1bearingtemperature1 exceededthealarmsetpoint Checkthesensor 63 Cargopump1bearingtemperature 2fail Cargopump1bearingtemperature2 exceededthealarmsetpoint Checkthesensor Page 49 / 73

50 64 Cargopump1bearingtemperature 3fail Cargopump1bearingtemperature3 exceededthealarmsetpoint Checkthesensor 65 Cargopump1cargomediapressure fail Cargopump1cargomediapressure exceededthealarmsetpoint Checkthesensor 66 Cargopump1cargomedia temperaturefail Cargopump1cargomediatemperature exceededthealarmsetpoint Checkthesensor 67 Cargopump1suctionpressurefail Cargopump1suctionpressureexceeded thealarmsetpoint Checkthesensor 68 Cargopump1suctiontemperature fail Cargopump1suctiontemperature exceededthealarmsetpoint Checkthesensor 69 Cargopump1speedresponsefail Cargopump1speedexceededthealarm setpoint Checkthesensor 70 Cargopump1highcargomedia pressureincreaserpm;blocked Cargopump1highcargomediapressure exceededthesetpointforrpmblock Checkthesensor 71 Cargopump1lowsuctionpressure increaserpm;blocked Cargopump1lowsuctionpressure decreasedunderthesetpointforrpm block Cargopump2alarms Cargopump2bearingtemperature 1fail Cargopump2bearingtemperature1 exceededthealarmsetpoint Checkthesensor Checkthesensor 74 Cargopump2bearingtemperature 2fail Cargopump2bearingtemperature2 exceededthealarmsetpoint Checkthesensor 75 Cargopump2bearingtemperature 3fail Cargopump2bearingtemperature3 exceededthealarmsetpoint Checkthesensor 76 Cargopump2cargomediapressure fail Cargopump2cargomediapressure exceededthealarmsetpoint Checkthesensor 77 Cargopump2cargomedia temperaturefail Cargopump2cargomediatemperature exceededthealarmsetpoint Checkthesensor 78 Cargopump2suctionpressurefail Cargopump2suctionpressureexceeded thealarmsetpoint Checkthesensor 79 Cargopump2suctiontemperature fail Cargopump2suctiontemperature exceededthealarmsetpoint Checkthesensor 80 Cargopump2speedresponsefail Cargopump2speedexceededthealarm setpoint Checkthesensor 81 Cargopump2highcargomedia pressureincreaserpm;blocked Cargopump2highcargomediapressure exceededthesetpointforrpmblock Checkthesensor 82 Cargopump2lowsuctionpressure increaserpm;blocked Cargopump1lowsuctionpressure decreasedunderthesetpointforrpm block Strippingpumpalarms Strippingpumpbearingtemperature 1fail Strippingpumpbearingtemperature1 exceededthealarmsetpoint Page 50 / 73 Checkthesensor Checkthesensor

51 85 86 Strippingpumpbearingtemperature 2fail Strippingpumpbearingtemperature 3fail Strippingpumpbearingtemperature2 exceededthealarmsetpoint Strippingpumpbearingtemperature3 exceededthealarmsetpoint Checkthesensor Checkthesensor 87 Strippingpumpcargomedia pressurefail Strippingpumpcargomediapressure exceededthealarmsetpoint Checkthesensor 88 Strippingpumpcargomedia temperaturefail Strippingpumpcargomediatemperature exceededthealarmsetpoint Checkthesensor 89 Strippingpumpsuctionpressurefail Strippingpumpsuctionpressureexceeded thealarmsetpoint Checkthesensor 90 Strippingpumpsuctiontemperature fail Strippingpumpsuctiontemperature exceededthealarmsetpoint Checkthesensor 91 Strippingpumpspeedresponsefail Strippingpumpspeedexceededthealarm setpoint Checkthesensor 92 Strippingpumphighcargomedia pressureincreaserpm;blocked Strippingpumphighcargomediapressure exceededthesetpointforrpmblock Checkthesensor 93 Strippingpumplowsuctionpressure increaserpm;blocked Strippingpumplowsuctionpressure decreasedunderthesetpointforrpm block Hydraulicsystempressurealarms Hydraulicsystempressurehgh alarm Hydraulicsystempressureexceededthe alarmsetpoint Checkthesensor Checkthesensor 96 Hydraulicsystempressurelowalarm Hydraulicsystempressuredecreased underthealarmsetpoint Checkthesensor 97 Commonalarms 98 Emergencystop Oneoftheemergencystopbuttonis Checkemergencystopbuttons pressed 99 Replacerambattery Plcbatteryisended Replacementneeded(refertoplc manual) MAINTANENCE Change the battery in the PLC every 2 years. Refer to PLC manual. 9. TROUBLE SHOOTING Replace battery every 2 years or immediately when the BAT led on the power supply is in red color. Refer to PLC manual Page 51 / 73

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Electro-Sentry. Users Manual

Electro-Sentry. Users Manual Electro-Sentry Users Manual 2. To view an individual point, e.g. Speed just touch that point and it will display a graph showing the 45 min. of activity. Viewing a Leg: 1. Touch the desired leg, e.g. East