Transcript Environment Diagnosis Service Detail Part 2

ENVIRONMENT DIAGNOSTIC
( PART.2 )
Yokogawa Indonesia
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Environmental 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.
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Environmental Diagnosis - Application
Environmental Diagnosis is applicable for :
- Environmental assessment before equipment installation
- Investigation of environmental conditions and evaluation of
the effects of countermeasures
- Review / Preparation of Maintenance programs
Change in maintenance philosophy from time based to condition
based maintenance
- Review Of Maintenance Problem
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Environmental Diagnosis
Environmental Diagnosis is used to diagnose the environment
where instrumentation equipment are installed.
By knowing and understanding the installation environment (not by
sensory means) by means of numerical representation to grade
the environment, Yokogawa can propose :
- Optimum measures for improving the installation environment
- Optimum Maintenance procedures such as the most suitable
cycle for Periodic Inspection Service
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FLUCTUATING ENVIRONMENTAL ELEMENTS WHICH AFFECT FACILITIES
CORROSIVE GAS
HUMIDITY
DUST
POWER SUPPLY
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TEMPERATURE
NOISE
GROUNDING
VIBRATION
Environmental Diagnosis
Environmental factors can be classified as :
Human Analogy
- Cumulative stress factors :
Sickness
temperature, humidity, corrosive gas, dust
- Instantaneous stress factors :
Vibration, Noise, Grounding, Power Supply
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Accident
Environmental Diagnosis - Temperature Effect
j 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
j Low Temperature
- Rotating equipment - increased load caused by
reduced lubrication properties
j Large
Temperature
Fluctuations
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- 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
Environmental Diagnosis - Humidity Effect

High
Humidity

Low 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
- Static electricity occur at humidity level of 30%
or lower causing erratic operation or damage to
circuit
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Environmental Diagnosis - Gas Effect
Gases affecting equipment and system :
- Sulphur Dioxide ( S02 )
- Hydrogen Sulfide ( H2S )
SOURCE
- Combustion of oil and coal as fuel, gas discharge
from iron and steel industry,gas discharge from
incinerators, pulp and paper industry
- Oil refinery, ammonia plant, pulp and paper plant,
steel industry, sewerage disposal plant
- Nitrogen Oxide ( N02 )
- Sulphuric acid plant, internal combustion engines
such as automobile
- Chlorine ( CL2 )
- chemical plant, pulp and paper plant
- Ammonia (NH3 )
- Fertilizer plant, Phenol resins
- Ozone ( O3 )
- Photochemical smog and electric dust collector
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Environmental Diagnosis - Gas Effect
Hydrogen
Sulfide (H2S)
Sulfur Dioxide
(SO2)
Chlorine (CL2)
Corrosion on Copper and Silver metals.
Conductive Materials generated by corrosion
(rust) damage insulation between components
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Environmental Diagnosis - Gas Effect
TYPE
Line Break
Corrosion
C
O
R
R
O
S
I
O
N
Corrosive Film
Whiskers
Electrochemical
Migration
Dendrite
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WHAT IS IT
Line break caused by corrosion
The surface of metal is coated by an
insulating corrosive film caused by
sulfide of chlorine gas
A metal deposit creates a hair-like
crystalline growth. Metallic tin
forms on tin plating material or
sulfide gas causes a dendritic
growth of copper and silver sulfide.
A metal, usually silver, is ionized
along the surface of an insulator
by electrolytic fluid generated by
moisture or impurities in the air.
A type of migration. A sulfide
corrosive gas ionizes metal, usually
copper and creates a denditic
crystalline deposit.
EFFECT
Line break.
Examples: lead wires
in printed pattern
Contact failure
Examples : Lead,
switches and other
contacts
Insulation failure and
short-circuiting
Examples : Pattern
area and IC lead
Insulation failure and
short-circuiting
Examples : Pattern
area and IC lead
Insulation failure and
short-circuiting
Examples : Between
adjacent printed
pattern
Environmental Diagnosis - Dust Effect
Accumulated or adhered dust can through capillary action absorb
moisture and cause condensation
Dust entering cracks between mechanical components can cause
operational failure
Insulating dust that adheres to switches and connectors will cause
poor connections
Dust renders optical sensors inoperative by blocking light signals from
reaching receptors
Dust clog filters and reduces the effect of air-conditioning
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ENVIRONMENTAL DIAGNOSIS ITEMS
Analytic Items
Evaluation Items
Temperature
Temperature
And Humidity
Rate of temperature
Change
Description
Spot measurement of temperature and humidity
distribution
Trend graph of continuous measurement of
temperature and humidity
Computation of hourly rate of change of
temperature for all continuous measurement of
temperature and humidity
Relative Humidity
Correlation of temperature and humidity
Dust
Corrosive
Gases
Airborne dust
Spot measurement of multiple points such as
instrument rack, inside a cubicle, etc
Corrosion Rate
Measurement of reactivity and judgement of the
severity level based on ISA standard
Spot quantitative
analysis of gas
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concentration
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Measurement of gas concentration of H2S,
SO2,NH3,CL2,HCL,NO2
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
Concentration
Eco-Checker
Working 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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INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS
CORROSION
CORROSION CLASSIFICATION COUPON
 3 metal test pieces of copper, silver
Rate Of Corrosion
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
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INSTRUMENT USED FOR ENVIRONMENTAL DIAGNOSIS
Suspended Dust
DIGITAL 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
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Classification Of Environment According to JEIDA Standard
JEIDA 29
Japan Electronic
Industry Development
Association
An industrial computer setup
environmental standard whereby
temperature, humidity, dust, gas and
other setup environmental values
have been classified to allow
standardization between products of
different makers.
Class A : An environment that
satisfies the requirements of
computer system
Class B : A general environment
that has not been specially
prepared for computer use
Class Si : An environment that is
especially harsh for computer
system
(i = 1 to 3 a larger figure indicates
a harsher environment)
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Classification Of Environment according to JEIDA Standard
ENVIRONMENT CRITERIA
Class A
Class B
Temperature
15 ~ 30 Deg C
5 ~ 40 Deg C
Humidity
40 ~ 70 %RH
20 ~ 80 %RH 10
20 ~ 90
80 %RH
Rate Of
Temperature
Change
+/- 5 Deg
Per Hour
Dust
0.1 mg/m3
or less
Corrosive
Gases
Temperature
and humidity
are low and
gases are not
detected
+/-10 Deg C
Per Hour
0.3 mg/m3
or less
Temperature
is relatively
low gas
presence is
slight
Class S1
Class S2
Class S3
0 ~ 50 Deg C -10 ~ 60 Deg C -25 ~ 70 Deg C
10~~95
5
90%RH
%RH
5 ~ 100 %RH
+/- 15 Deg C
Per Hour
-
-
10 mg/m3
or less
-
-
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
(P/s refer to
table of
corrosive gas
factor)
Assess Mark <=9 Assess Mark <=25 Assess Mark <=36 Assess Mark <=50 Assess Mark <=51
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Classification Of Environment According to JEIDA Standard
ENVIRONMENT CRITERIA
JEIDA 29 Each Corrosive Gas Factor Assessment Mark
1
2
3
4
Value Mark Value Mark Value Mark Value Mark
Ann Ave Temp( Deg C)
A
<=20
1
Ann Ave humidity (%RH)
B
<=50
1
SO2
C1
<=.04
NO2
C2
H2S
Gas
(ppm)
<=25
2
<=30
4
>30
8
<=60
8
<=75
16
>75
24
1
<=.08
3
<=.2
6
<=5
9
<=.02
1
<=.05
3
<=.1
6
<=5
9
C3
<=.003
1
<=.01
8
<=.1
14
<=10
20
CL2
C4
<=.002
1
<=.01
10
<=.1
20
<=1
30
NH3
C5
<=.1
1
<=1
2
<=10
4
<=100
8
16
>.12
24
Extent Of Fouling
D
<=.03
1
<=.06
8
<=.12
Equivalent salinity
(mg/cm2)
* Total assessment mark = A + B + C1 + C2 + C3 + C4 + C5 + D
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Classification Of Environment According to ISA Standard
ENVIRONMENT CRITERIA
CLASSIFICATION
OF ENVIRONMENT
Thickness of oxide film
(Angstrom/30 days)
Definition
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G1
G2
G3
MILD
MODERATE
HARSH
< 300
An
environment
that does
not
influence
equipment
reliability
< 1000
An
environment
that is
considered
to influence
equipment
reliability,
the effect
being
measurable
corrosion
G4
SEVERE
<2000
>=2000
An
environment
in which
corrosion is
highly
probable
and
considered
to influence
equipment
reliability
An
environment
in which
electric and
electronic
equipment
is estimated
to be
unusuable
because of
corrosion
Process Of Environmental Diagnosis
Site Survey
Measurement
Corrosive Gas
Analysis
Analysis
Installation of
measuring
equipment
Temperature
Humidity And
Rate Change
Analysis
Report
Preparation
Dust / Humidity
/Temperature
Spot Values
Site
Investigation
1 day
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1 month
1 month
I
S
S
U
E
R
E
P
O
R
T
Process Of Environmental Diagnosis
Pre-Investigation
To optimize effectiveness of investigation
procedure by gathering relevant information in
advance of initial environmental investigation of a
facility
• Operation start date of installed system
• Maintenance history (cleaning/part replacement)
• Trouble history,particularly environmental cases
Site Investigation
• System expansion in future, etc
To investigate from various angles aspects such as occurrence , isolation,
and measures for elimination of adverse environmental factors in the site
• Air tightness against outside atmosphere (convection heat, dust and gas)
• Artificial heat generation source
• Air-conditioning system
• Dust elimination method adopted
• Surrounding condition of installation room
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Maintenance Strategies
Time Based Maintenance
Are we supplying maintenance
when it’s needed ?
To minimize risk of breakdown,
frequency of maintenance cycle
is questionable
ENVIRONMENT
DIAGNOSIS
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
good, maintenance cycle can be substantially
increased leading to cost reduction
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Maintenance Proposal Based On Environmental Diagnosis Results
1
Level
2
Value
3
Env Factor
Value
Points
Points
Value
Temperature ° C
<= 20
1
<= 25
2
<= 30
Humidity % RH
<= 50
1
<= 60
4
<= 70
Dust mg/m3
<= 0.02
1
<= 0.04
6
Corrosion Rate ° A <= 200
1
<= 300
8
4
Points
Value
Points
4
<= 40
8
8
<= 80
16
<= 0.06
12
<= 0.1
24
<= 400
16
<= 500
32
Values collected from environmental data are evaluated and match against a point system
Environment grade
Total Points
A
B
C
D
E
4 to 12
13 to 29
30 to 59
60 to 80
Over 80
4
3
2
1
Env to be improved
Maintenance Cycle
The total points obtained for all environmental factors are summed to grade the environment
and to determine the recommended maintenance cycle
Analysis Period
June 30 to July 7,1994
July 29, 1994
Jun 30~Jul 29,94
Env. Factor
Actual
Measured Data
Evaluation Points
Temperature ° C Humidity % RH
Dust mg/m3
Max
29.3
Max
52
Max
0.045
Corrosion Rate
°A
Min
24.7
Min
29
Min
0.032
286
4
4
12
8
Acc. Coefficient
1.0
1.8
1.5
1.43
Total Points
4.0
7.2
18.
11.4
0
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Copyright
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Indonesia
Example
of maintenance
proposal based on evaluated results. The total points obtained is 40.6
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