PT.YOKOGAWA INDONESIA Environment Diagnosis ( ED ) by Service & Business Department.

PT.YOKOGAWA INDONESIA

Environment Diagnosis

( ED )

byService & Business Department

RMS.25.10.04

Available Service

Remote Maintenance Support Environment diagnosis Renewal service Annual Maintenance Contract Shutdown Maintenance 24-Hours Emergency Service On Call Service Customer Training Technical Consultation Lab and Site Calibration Job Start-Up and Commissioning Parts Replacement & Repair Shop Maintenance Engineering Solution

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Environmental DiagnosisEnvironmental Diagnosis

Objective :

To maintain functional and operation reliability of equipment to be the same as new, by controlling environmental factors which are causing stresses and negative effect on them.

How to Maintain Electronic system

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MAINTENANCE TECHNOLOGI

Risk evaluation & Management from time base maintenance to condition base maintenance

Diagnosis technology to evaluates constant loss

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1. 1. Risk evaluation with a prolong of maintenance cycleRisk evaluation with a prolong of maintenance cycle(1) Evaluation of trouble history ( In case of DCS)(1) Evaluation of trouble history ( In case of DCS)(2) Evaluation with bathtub curb and deterioration curb (2) Evaluation with bathtub curb and deterioration curb

relationship relationship(3) Evaluation with Environmental Diagnosis(3) Evaluation with Environmental Diagnosis

2. Risk Management2. Risk Management (with actual sample) (with actual sample)(1) replacement of lifetime parts (Aluminum Condenser)(1) replacement of lifetime parts (Aluminum Condenser)(2) Renewal Service (Washing, Coating)(2) Renewal Service (Washing, Coating)(3) Environmental Optimizing work (with Optimizing unit)(3) Environmental Optimizing work (with Optimizing unit)

Risk Evaluation & Management

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Initial failure Random failure

Time

Correlation of Bathtub Curb and Lifecycle

Failure rate

↑Acceptable failure

rate

↑Renewal (Treatment to extend life)

Life extension

Random failure ＞ Wear-out failure Random failure ≦ Wear-out failure

Wear-out failure

System life = Up to the intersecting point of random failure and deterioration

Deterioration

Temperature ・ Relative humidity Dust ・ Corrosive gas

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FLUCTUATING ENVIRONMENTAL ELEMENTS WHICH AFFECT FACILITIES

CORROSIVE GAS HUMIDITY TEMPERATURE

DUST NOISE

POWER SUPPLY GROUNDING VIBRATION

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Environmental DiagnosisEnvironmental Diagnosis

Environmental factors can be classified as :

- Cumulative stress factors :

temperature, humidity, corrosive gas, dust

- Instantaneous stress factors :

Vibration, Noise, Grounding, Power Supply

Human Analogy

Sickness

Accident

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Environmental Diagnosis - Temperature EffectEnvironmental Diagnosis - Temperature Effect

High Temperature- Increase failure rate of semiconductors as changes in wiring material and contaminants in ICs that are accelerated by heat - Rotating equipment -heat deteriorates and changes grease and reduces lubrication of bearings/parts- acceleration of corrosive reactions

Low Temperature

- Rotating equipment - increased load caused by reduced lubrication properties

Large Temperature

Fluctuations- Error in analog circuit increase. Resistors and capacitors are heat dependent and circuit characteristics will change- Condensation occurs because humidity exceeds 100% easily due to rapid cooling

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Environmental Diagnosis - Humidity EffectEnvironmental Diagnosis - Humidity Effect

High Humidity- Water on surface of components lowering insulation. Even when 100% humidity not reached,condensation may occur on surfaces in contact with the air or isolated areas- Rotating equipment - grease contaminated by water lowering lubrication properties- High humidity accelerate corrosive reactions

Low Humidity

- Static electricity occur at humidity level of 30% or lower causing erratic operation or damage to circuit

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“Always There For You”

Environmental Diagnosis - Gas EffectEnvironmental Diagnosis - Gas Effect

Hydrogen Hydrogen Sulfide (H2S)Sulfide (H2S) Sulfur Dioxide Sulfur Dioxide

(SO2)(SO2)Chlorine (CL2)Chlorine (CL2)

Corrosion on Copper and Silver metals. Conductive Materials generated by corrosion (rust) damage insulation between components

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INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS

TEMPERATURE AND HUMIDITY

Electronic Digital Hygrometer

Memory function allow recording of data for months

Dedicated software to sort and analyze data on computer including plotting of temperature humidity chart

Recording interval can be set

Internal battery for continuous measurement

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INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS

Corrosive Gas Corrosive Gas ConcentrationConcentration Eco-CheckerEco-Checker

Working PrinciplesWorking Principles

Five metal pieces of copper, silver, iron-nickel alloy, aluminium and iron are left in environment for one month

The rough amount of corrosive factor elements (chlorine,salt and sulfur) in the corrosive film on the test pieces is measured using X-ray Spectrometric analysis.

Results are used with experimental data and field test to derive average concentration of H2S,CL2 and SO2 gas

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Suspended DustSuspended Dust

DIGITAL DUST METERDIGITAL DUST METER

Floating dust is exposed to light and total weight of dust per volume is measured as proportional to the amount of light scattered by the dust

INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS

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CORROSION

Rate Of Corrosion

CORROSION CLASSIFICATION COUPON

3 metal test pieces of copper, silver and gold-plated copper are left in the environment for 30 days

Electrochemical analysis is used to analyze the chemical composition of the corrosion film on the test pieces

Result is converted into an equal amount of corrosive compounds (the data values are converted into an equal corrosive film thickness)

Thickness in Angstrom will enable environment to be classified according to ISA standard criteria

INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS

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Classification Of Environment according to Classification Of Environment according to JEIDA StandardJEIDA Standard ENVIRONMENT CRITERIAENVIRONMENT CRITERIA

40 ~ 70 %RH 20 ~ 80 %RH 10 ~ 90 %RH

- -

Assess Mark <=25 Assess Mark <=36 Assess Mark <=50 Assess Mark <=51Assess Mark <=9

Class A Class B Class S1 Class S2 Class S3

15 ~ 30 Deg C 5 ~ 40 Deg C 0 ~ 50 Deg C -10 ~ 60 Deg C -25 ~ 70 Deg C

20 ~ 80 %RH 10 ~ 90 %RH 5 ~ 95 %RH 5 ~ 100 %RH40 ~ 70 %RH

Temperature

Humidity

Rate Of Temperature Change

Dust

Corrosive Gases

(P/s refer to table of corrosive gas factor)

+/- 5 Deg Per Hour

+/-10 Deg C Per Hour

+/- 15 Deg C Per Hour

- -

0.1 mg/m3 or less

0.3 mg/m3 or less

10 mg/m3 or less

Temperature and humidity are low and gases are not detected

Temperature is relatively low gas presence is slight

Humidity is slightly high and gas presence is low

Temperature and humidity are high and gas presence is also slight

Temperature and humidity are high and substantial gas is present

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Classification Of Environment According to JEIDA Classification Of Environment According to JEIDA StandardStandard ENVIRONMENT CRITERIAENVIRONMENT CRITERIA

JEIDA 29 Each Corrosive Gas Factor Assessment Mark

4

Gas (ppm)

2 3 4

Value

1

Extent Of Fouling Equivalent salinity (mg/cm2)

SO2

H2S

NO2

CL2

NH3

Ann Ave Temp( Deg C)

Ann Ave humidity (%RH)

A

C2

C1

B

C3

C4

D

C5

Mark Value Value ValueMarkMark

<=20

<=50

<=.04

<=.02

<=.003

<=.002

<=.1

<=.03

1

1

1

1

1

1

1

1

<=25

<=.05

<=.01

<=.01

<=1

<=.06

<=60

<=.08

2

8

3

8

10

2

8

3

<=30

<=75

<=.2

<=.1

<=.1

<=10

<=.12

<=.1

4

16

6

6

14

20

4

16

>30

<=5

<=5

<=10

<=1

<=100

>.12

>75

8

9

9

20

30

8

24

24

* Total assessment mark = A + B + C1 + C2 + C3 + C4 + C5 + D

Mark

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Process Of Environmental Diagnosis

Site Survey Measurement Analysis

1 day

Installation of measuring equipment

1 month 1 month

Corrosive Gas

Temperature Humidity And Rate Change

Analysis

Analysis

Report Preparation

ISSUE

REPORT

Dust / Humidity /Temperature Spot Values

Site Investigation

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Humidity Cycle TestBefore wash

2.880

2.900

2.920

2.940

2.960

2.980

3.000

3.020

0:00 1:00 2:00 3:00 4:00 5:00Test hour H［］

Out

put

V［］

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

Tem

p./H

umid

ity

After wash

2.880

2.900

2.920

2.940

2.960

2.980

3.000

3.020

0:00 1:00 2:00 3:00 4:00 5:00Test hour [H]

Out

put

V［］

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

Tem

p./H

umid

ity

9 ch outputTemperatureHumidity

Occurrence Recovery

No occurrence of accuracy error

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Example of External factor (1)Example of External factor (1)

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Pattern Break !!

Mist

Pattern Break

（（ Pattern Break & Spots Pattern Break & Spots ））（（ Pattern Break & Spots Pattern Break & Spots ））

Example of External factor (2)Example of External factor (2)

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Maintenance StrategiesMaintenance Strategies

Time Based Maintenance

Are we supplying maintenance when it’s needed ?

To minimize risk of breakdown, frequency of maintenance cycle is questionable

ENVIRONMENT ENVIRONMENT DIAGNOSISDIAGNOSIS

Condition Based Maintenance

Reduces risk whilst minimizing maintenance work

Maintenance cycle is planned based on environmental condition and historical data and scheduled according to need rather than inflexible schedule

If environmental conditions of the equipment are If environmental conditions of the equipment are good, maintenance cycle can be substantially good, maintenance cycle can be substantially increased leading to cost reductionincreased leading to cost reduction

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THANK YOU FOR YOUR ATTENTION