Krishnend .sINSTALLATION&COMMISSIONING

COMMISSIONING has the function to move the installation into a function-enabled operation mode. Set up , installation, programming errors are thus corrected.

During commissioning, errors leads to error functions

OPERATIONS WHILE COMMISSIONINGVISUAL INSPECTIONTEST THE ELECTRICAL INSTALLATIONMECHANICAL & ELECTRICAL CALIBRATION TESTING & ADJUSTMENTSFUNCTION TEST OF THE INSTALLATIONCOMMISSIONING & COMPLETIONTESTING & LOADING

VISUAL INSPECTION

Each commissioning starts with visual inspectionCompleteness with the help of a part listCorrect arrangement & damage

Operational safety: during commissioning utmost care & precaution must be taken to ensure that damages to the plant and injuries to the people are avoided.

TESTING THE ELECTRICAL SAFETY

Before the installation is supplied with electrical power, it must be ensured that there are no electrical hazards.

The testing of electrical safety is the therefore the first commissioning procedure after the visual inspection.

CALIBRATION

Pneumatic & Hydraulic actuators must be aligned mechanically before the commissioning.The sensors are adjusted for commissioning of the individual subsystem. Thus for this, the installation must be supplied with power.

TESTING & ADJUSTMENTS

The operating pressure of pneumatic and hydraulic installations must be tested and adjusted.

Subsequently the outward and inward speeds of working parts eg: of hydraulic cylinders are adjusted.

The control program created and tested by the programmer is transferred to the system.

FUNCTIONAL TEST OF THE INSTALLATION

It must be ensured that all actuators are arranged in their initial position, before the overall function of the installation can be tested.

The first run should be performed in the single step mode and should be controlled, a final test is performed in automatic mode.

DOCUMENTATION

All important test results are documented in writing to be able to prove the safety and faultless function of the installation.

Check lists simulates the test run and serve as documentation of the results.

ELECTRICAL SUBSYSTEMELECTRICAL POWER

400V /230V ACHYRAULIC POWER UNITGENERATION OF COMPRESSED AIR

SPEED CONTROLLERASSEMBLY SECTIONCONVEYOR BELTMAGNETIC STOPPERCONVEYOR ENGINEENGINEENGINEPRESSURE REGULATION

All electrical components in the electrical installation are centralized to an electrical subsystem.Electrical subsystem is tested for electrical safety of equipment of electrical machine & ordinance on industrial safety and health. Visual inspectionVerification against technical documentationInsulationVoltage testFunction test

Function test: Example..on the engine of hydraulics power unit is tested, checked. If the engine works and the direction of rotation is correct. The engine of the installation to generate pressure is tested for its function & the pressure regulator is adjusted to the required value.

The electrical installations are tested using special measuring devices by persons who can assess the dangers of electrical power due to their training, experience, standard knowledge onlythey are ELECTRICIANS

PNEUMATIC INSTALLATION

GENERATION OF COMPRESSED AIRCOMPESSORPRESSURE REGULATORENGINEPneumatic control

Actuators-cylinder-suction

Regulator control

The commissioning starts with visual inspection of pneumatic subsystems.

The pneumatic lines are checked for correct installation & proper connection, it is especially taken into consideration that the lines for movable installation parts may not clamp.

The lubricator must be filled with the correct oil in the right amount for oiled compressed air.The amount of oil that must be supplied to the air is set as per manufacturers instructions(approximately 1 to 2 drops of oil per m3 air)

Procedure recommended:

Actuators & regulator control elements (direction valves) are reset to default on the pressure free installations.All flow control valves are off to keep the piston speeds low during first mode.The pressure is increased slowly on the pressure regulator till it reaches operating pressure.During the movement of actuators, sensors can be checked for end positions & calibrate if required.

Finally, all actuators and valves must be reset to default.The complete control run as per function plan or the displacement step diagram is tested first during commissioning of the control.

Operational safety:There is no individual in the range of motion of then actuators.

ELECTRO MAGNETIC COMPATIBILITY

The use of electrical power is always linked to the conversion into other energy forms.Eg: radiation (light), mechanical(engine)

Thus electromagnetic fields do not necessarily remain same with in the electric field...but can also spread beyond.

Fields that spread can influence the function of other equipments.

Frequency convertor generate high electrical disturbance signals on the engine supply line.This may disturb other electrical equipment or lead to error function

Suggested solutions.

ShieldsFiltersGroundingsKeeping distance(coupling path)

Electromagnetic fields can generate electric tension, this may leads to unforeseen disturbances & break down

HYDRAULIC INSTALLATION

ENGINEHYDRAULIC POWER UNITHYDRAULIC VALVES

HYDRAULIC CYLINDERS

Similar to all subsystems, installation starts with visual inspection.Hydraulic pipesProper connectionsMax. storage, period of life for hosesNo twisting & bendingMax. operating pressure

Before tank is filled with oil, it can be cleaned to completely remove impurities due to manufacturing, transporting, storage or installation.

Filters & suction hoses should be clean

The manufacture stipulates a hydraulic oil to be used.

LeakagesBubblesNoiseOil levelTemperature of pumpsPressure relief valve is set at low pressureNow it is shifted from idle to pressure mode and for this pressure is slowly increased.

This must be controlled by operation the valve manually.

After installation is completed, the movement speeds and operating pressures are set using flow beans and pressure relief valves.

ELECTRICAL CONTROL

CONTROL

-INPUTS-OUTPUTS

CONTROL UNITPOWER SUPPLYSIGNALS

The electrical control consist of SPS(symbolic programming system),control unit.

Electrical power supply to SPS is checkedWhile switching ON it should be in STOP mode

The SPS program is tested in a simulation mode before the commissioningTransfer the program to virtual SPS and monitorErrors detected and are removedThus installation damages are removedAfter successful testing, control program is transferred to the SPSTest results are recorded in the test certificate

OVERALL FUNCTION

After starting up the different subsystem the total installation is put into operation.

SETUP MODEAll different actuators can be controlled individuallyThe respective actuator can be chosen by the selector switch and actuation can be controlled directlySafety interlocking mechanism will not work. for this reason only qualified person is allowed to work in this mode.

SINGLE STEP MODEInstallation will be operated step by step by pressing the start key for each next step.The following operational sequence can be verified in this mode.

AUTOMATIC MODEPressing start, installation will automatically run through its sequence of process

While putting the installation into operation all relevant events are noted and commented in a check list.

TEST CERTIFICATE

The test certificate is produced based on the completed checklists.A general machine descriptionA general layout drawing of machine & illustration of functionalityA list of applied standardsTechnical test resultsOperating manual

Thank you.