CARGO PUMP CONTROL & MONITORING SYSTEM - tr · PDF fileRauf Orbay Cad. No:37 34944 Tuzla – STANBUL Tel: (0216) 446 2328(pbx) Fax: ... The CARGO WATCH II control system is capable

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Rauf Orbay Cad. No:37 34944 Tuzla – �STANBUL Tel: (0216) 446 2328(pbx) Fax: (0216) 446 23 27

www.tr-marine.com [email protected]

TR-MARINE / CARGO WATCH II v.02

OPERATION AND MAINTENANCE MANUAL

PROJECT REF NO : TRM-CWII/G48 SHIYARD : GISAN HULL NO : NB48

CARGO PUMP CONTROL & MONITORING SYSTEM

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TABLE�OF�CONTENTS�

1.� GENERAL�DESCRIPTION�........................................................................................................................�6�

2.� INSTALLATION�INSTRUCTIONS�..............................................................................................................�6�

3.� ADJUSTMENT�.......................................................................................................................................�6�

4.� COMMISSIONING�.................................................................................................................................�6�

5.� OPERATION�BASICS�..............................................................................................................................�7�

5.1.� GENERAL�..............................................................................................................................................�7�

5.2.� CONTROL�PANELS�.................................................................................................................................�8�

5.2.1.�REMOTE�PANEL�....................................................................................................................................�8�

5.2.1.1.� MAIN�WINDOW�...........................................................................................................................�8�

5.2.1.2.� HYDRAULIC�OPERATION�WINDOW.............................................................................................�10�

5.2.1.3.� CARGO�PUMPS�WINDOW�..........................................................................................................�20�

5.2.1.4.� ALARM�WINDOW�......................................................................................................................�21�

5.2.1.5.� SETTINGS�WINDOW�...................................................................................................................�22�

5.2.1.6.� TREND�WINDOW�.......................................................................................................................�23�

5.2.1.7.� AUXILIARY�PUMPS�WINDOW�.....................................................................................................�24�

5.2.2.�LOCAL�PANEL�......................................................................................................................................�26�

5.2.2.1.� MAIN�WINDOW�.........................................................................................................................�26�

5.2.2.2.� OPERATION�WINDOW�...............................................................................................................�28�

5.2.2.2.1.� OPERATION�WINDOW�1�........................................................................................................�30�




5.2.2.3.� CARGO�PUMPS�WINDOW�..........................................................................................................�38�

5.2.2.3.1.� CARGO�PUMP�1�WINDOW�.....................................................................................................�39�

5.2.2.3.2.� CARGO�PUMP�2�WINDOW�.....................................................................................................�40�

5.2.2.3.3.� STRIPPING�PUMP�WINDOW�..................................................................................................�40�

5.2.2.4.� ALARM�WINDOW�......................................................................................................................�41�

5.2.2.5.� SETTINGS�WINDOW�...................................................................................................................�42�

5.2.2.5.1.� CARGO�PUMP�1�SETTINGS�WINDOW�.....................................................................................�44�



5.2.2.5.4.� SYSTEM�SETTINGS�WINDOW�.................................................................................................�45�

5.2.2.6.� TREND�WINDOW�.......................................................................................................................�46�

6.� OPERATION�MODES�...........................................................................................................................�46�

6.1.� LOCAL�(MANUAL)�CONTROL�OPERATION�............................................................................................�46�

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6.2.� LOCAL�CONTROL�PANEL�OPERATION�...................................................................................................�46�

6.3.� REMOTE�CONTROL�PANEL�OPERATION�...............................................................................................�47�

7.� ALARM�LIST�........................................................................................................................................�47�

8.� MAINTANENCE�...................................................................................................................................�51�

9.� TROUBLE�SHOOTING�..........................................................................................................................�51�

10.� PLC�MANUAL�......................................................................................................................................�52�

��

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TABLE OF FIGURES FIGURE�1�REMOTE�PANEL�MAIN�WINDOW�............................................................................................................�8�FIGURE�2�SYSTEM�INFO�POPUP�WINDOW�..............................................................................................................�9�FIGURE�3�REMOTE�PANEL�HYDRAULIC�OPERATION�WINDOW�.............................................................................�10�FIGURE�4�CARGO�PUMPS�TOUCH�PLACES�ON�WINDOW�......................................................................................�10�FIGURE�5�CARGO�PUMP�1�POPUP�WINDOW�........................................................................................................�11�FIGURE�6�CARGO�PUMP�2�POPUP�WINDOW�........................................................................................................�12�FIGURE�7�STRIPPING�PUMP�POPUP�WINDOW�......................................................................................................�12�FIGURE�8�PROPORTIONAL�VALVES�POSITIONS�.....................................................................................................�13�FIGURE�9�CARGO�PUMPS�SPEED�FEEDBACK�.........................................................................................................�13�FIGURE�10�FILTER�SITUATIONS�..............................................................................................................................�13�FIGURE�11�HYDRAULIC�SYSTEM�PRESSURE�...........................................................................................................�13�FIGURE�12�SOLENOIDS�VALVES�TOUCH�PLACES�ON�WINDOW�.............................................................................�14�FIGURE�13�DRAIN�VALVES�POPUP�WINDOW�........................................................................................................�14�FIGURE�14�HYDRAULIC�MAIN�PUMPS�TOUCH�PLACES�ON�WINDOW�...................................................................�15�FIGURE�15�HYDRAULIC�MAIN�PUMPS�READY�CONDITIONS�POPUP�WINDOW�.....................................................�15�FIGURE�16�HYDRAULIC�MAIN�PUMPS�POPUP�WINDOW�......................................................................................�15�FIGURE�17�SUCTION�VALVES�ON�WINDOW�..........................................................................................................�16�FIGURE�18�HYDRAULIC�OIL�HEATER�TOUCH�PLACE�ON�WINDOW�........................................................................�16�FIGURE�19�HYDRAULIC�OIL�HEATER�POPUP�WINDOW�.........................................................................................�16�FIGURE�20�HYDRAULIC�OIL�TANK�TEMPERATURE�INDICATOR�..............................................................................�16�FIGURE�21�VALVES�FEEDBACK�...............................................................................................................................�17�FIGURE�22�AUXILIARY�PUMPS�POPUP�TOUCH�PLACES�.........................................................................................�17�FIGURE�23�HFC�PUMP�POPUP�WINDOW�..............................................................................................................�18�FIGURE�24�HCC�PUMP�POPUP�WINDOW�..............................................................................................................�18�FIGURE�25�MENU�AND�BACK�BUTTONS�................................................................................................................�19�FIGURE�26�SETTINGS�PASSWORD�POPUP�WINDOW�.............................................................................................�19�FIGURE�27�REMOTE�PANEL�MENU�WINDOW�.......................................................................................................�19�FIGURE�28�REMOTE�PANEL�CARGO�PUMPS�WINDOW�.........................................................................................�20�FIGURE�29�ALARM�STATE�ANIMATED�VALUE�........................................................................................................�20�FIGURE�30�SPEED�ADJUST�BUTTONS�.....................................................................................................................�20�FIGURE�31�REMOTE�PANEL�ALARM�WINDOW�......................................................................................................�21�FIGURE�32�REMOTE�PANEL�SETTINGS�WINDOW�..................................................................................................�22�FIGURE�33�POPUP�KEYBOARD�FOR�VALUE�INPUT�.................................................................................................�22�FIGURE�34�REMOTE�PANEL�TREND�WINDOW�.......................................................................................................�23�FIGURE�35�REMOTE�PANEL�AUXILIARY�PUMP�WINDOW�......................................................................................�24�FIGURE�36�SEA�WATER�COOLING�PUMP�1�POPUP�WINDOW�...............................................................................�25�FIGURE�37��SEA�WATER�COOLING�PUMP�2�POPUP�WINDOW�..............................................................................�25�FIGURE�38��FRESH�WATER�COOLING�PUMP�1�POPUP�WINDOW�..........................................................................�25�FIGURE�39�FRESH�WATER�COOLING�PUMP�2�POPUP�WINDOW�...........................................................................�25�FIGURE�40��BUFFER�LIQUID�CIRCULATION�PUMP�1�POPUP�WINDOW�.................................................................�25�FIGURE�41�BUFFER�LIQUID�CIRCULATION�PUMP�2�POPUP�WINDOW�..................................................................�25�FIGURE�42�LOCAL�PANEL�MAIN�WINDOW�............................................................................................................�26�FIGURE�43�LOCAL�PANEL�SYSTEM�INFO�POPUP�WINDOW�...................................................................................�27�FIGURE�44�PASSWORD�POPUP�WINDOW�FOR�CONTROL�ACCESS�........................................................................�27�FIGURE�45�POPUP�KEYBOARD�...............................................................................................................................�28�FIGURE�46�LOCAL�PANEL�OPERATION�WINDOW�..................................................................................................�28�FIGURE�47�LOCAL�PANEL�MENU�AND�BACK�BUTTONS�.........................................................................................�29�FIGURE�48�LOCAL�PANEL�MENU�WINDOW�...........................................................................................................�29�FIGURE�49�LOCAL�PANEL�OPERATION�1�WINDOW�...............................................................................................�30�FIGURE�50�LOCAL�PANEL�HYDRAULIC�MAIN�PUMPS�POPUP�WINDOW�................................................................�31�FIGURE�51�HYDRAULIC�MAIN�PUMPS�READY�CONDITIONS�POPUP�WINDOW�.....................................................�31�

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FIGURE�52�LOCAL�PANEL�HCC�PUMP�POPUP�WINDOW�.......................................................................................�32�FIGURE�53�LOCAL�PANEL�HFC�PUMP�POPUP�WINDOW�........................................................................................�32�FIGURE�54�LOCAL�PANEL�OPERATION�2�WINDOW�...............................................................................................�33�FIGURE�55��LOCAL�PANEL�SEA�WATER�COOLING�PUMP�1�POPUP�WINDOW�........................................................�34�FIGURE�56��LOCAL�PANEL�SEA�WATER�COOLING�PUMP�2�POPUP�WINDOW�........................................................�34�FIGURE�57�LOCAL�PANEL�FRESH�WATER�COOLING�PUMP�1�POPUP�WINDOW�....................................................�34�FIGURE�58�LOCAL�PANEL��FRESH�WATER�COOLING�PUMP�2�POPUP�WINDOW�...................................................�34�FIGURE�59�LOCAL�PANEL�BUFFER�LIQUID�CIRCULATION�PUMP�1�POPUP�WINDOW�............................................�34�FIGURE�60�LOCAL�PANEL��BUFFER�LIQUID�CIRCULATION�PUMP�2�POPUP�WINDOW�...........................................�34�FIGURE�61�LOCAL�PANEL�OPERATION�3�WINDOW�...............................................................................................�35�FIGURE�62�LOCAL�PANEL�DRAIN�VALVE�POPUP�WINDOW�...................................................................................�36�FIGURE�63�LOCAL�PANEL�HYDRAULIC�OIL�HEATER�POPUP�WINDOW�...................................................................�36�FIGURE�64�LOCAL�PANEL�OPERATION�WINDOW�4�...............................................................................................�37�FIGURE�65�LOCAL�PANEL�CARGO�PUMPS�WINDOW�.............................................................................................�38�FIGURE�66�LOCAL�PANEL�CARGO�PUMP�1�WINDOW�............................................................................................�39�FIGURE�67�LOCAL�PANEL�CARGO�PUMP�2�WINDOW�............................................................................................�40�FIGURE�68�LOCAL�PANEL�STRIPPING�PUMP�WINDOW�.........................................................................................�40�FIGURE�69�LOCAL�PANEL�ALARM�WINDOW�..........................................................................................................�41�FIGURE�71�LOCAL�PANEL�SETTINGS�WINDOW�......................................................................................................�42�FIGURE�70�LOCAL�PANEL�SETTINGS�PASSWORD�POPUP�WINDOW�......................................................................�42�FIGURE�72�POPUP�KEYBOARD�FOR�VALUE�INPUT�.................................................................................................�43�FIGURE�73�CARGO�PUMP�1�SETTINGS�WINDOW�..................................................................................................�44�FIGURE�74�CARGO�PUMP�2�SETTINGS�WINDOW�..................................................................................................�44�FIGURE�75�STRIPPING�PUMP�SETTINGS�WINDOW�................................................................................................�45�FIGURE�76�SYSTEM�SETTINGS�WINDOW�...............................................................................................................�45�FIGURE�77�LOCAL�PANEL�TREND�WINDOW�..........................................................................................................�46� �

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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 GUI1 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

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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

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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

5.2.1. 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.

5.2.1.1. Main Window

Figure 1 Remote Panel Main Window

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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

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HYDRAULIC OPERATION

CARGOPUMP 2

STRIPPINGPUMP

FLOWVALVE 1

CARGOPUMP 1

0-315 bar

P. FILTER 1 P. FILTER 2 P. FILTER 3

P. FILTER 4PRESSUREVALVE

R. FILTER 1 R. FILTER 2 R. FILTER 3

R. FILTER 4

HYD. OILTANK TEMP.

HYD. OIL TANKHEATER 1 & 2

SUCTIONVALVE 1

SUCTIONVALVE 2

SUCTIONVALVE 3

DRAINVALVE 1

DRAINVALVE 4

HYD.PUMP 1 HYD.PUMP 2 HYD.PUMP 3

FLOW VALVE 4

HYD. COOL &CIRCULATION

PUMP

HYD. FILTER &CIRCULATION

PUMP

Hyd.Pump 2Running Hours

Hrs


Hrs


Hrs

FLOWVALVE 2

FLOWVALVE 3

DRAINVALVE 2

DRAINVALVE 3

MMM

RUNNING RUNNING RUNNING RUNNING RUNNINGHEATING

RETURN BALLVALVE 1

RETURN BALLVALVE 2

HYD. PUMPSDRAIN VALVE

CARGO PUMP 1RPM

CARGO PUMP 2RPM

STRIPPING PUMPRPM SP

AP

SP

AP

SP

AP

HYDRAULICSYSTEM PRESSURE

HP3HP1 HP2

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.

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.

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

Figure 3 Remote Panel Hydraulic Operation Window

Figure 4 Cargo Pumps Touch places on window

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CARGO PUMP 1

BEARING TEMP.1

BEARING TEMP.2

BEARING TEMP.3

SPEED

CARGO MEDIA PRESSURE & TEMP.

SUCTION PRESSURE & TEMP.

RUNNING HOURS

FLOW VALVE 1

SPEEDADJUSTMENT

SP

AP

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.

Figure 5 Cargo Pump 1 Popup Window

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STRIPPING PUMP

SPEEDADJUSTMENT

BEARING TEMP.1

BEARING TEMP.2

BEARING TEMP.3

SPEED



RUNNING HOURS

FLOW VALVE 3

SP

AP

CARGO PUMP 2

SPEEDADJUSTMENT

BEARING TEMP.1

BEARING TEMP.2

BEARING TEMP.3

SPEED



RUNNING HOURS

FLOW VALVE 2

SP

AP

Figure 6 Cargo Pump 2 Popup Window

Figure 7 Stripping Pump Popup Window

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Operator can see the proportional valves set positions and actual (feedback) positions

from the hydraulic operation window during operations.

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.

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.

Figure 8 Proportional Valves Positions

Figure 9 Cargo Pumps Speed Feedback

Figure 10 Filter situations

Figure 11 Hydraulic System Pressure

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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.

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

Figure 12 Solenoids Valves Touch Places on Window

Figure 13 Drain Valves Popup Window

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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. The running text and arrows will be visible when pumps are running.

Figure 14 Hydraulic Main Pumps Touch Places on Window

Figure 16 Hydraulic Main Pumps Popup Window

Figure 15 Hydraulic Main Pumps Ready Conditions Popup Window

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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.

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 17 Suction Valves on Window

Figure 18 Hydraulic Oil Heater Touch place on Window

Figure 19 Hydraulic Oil Heater Popup Window

Figure 20 Hydraulic Oil Tank Temperature Indicator

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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.

On the operation window feedbacks of the valves are simulated for the opened or closed

situation.

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

Figure 21 Valves Feedback

Figure 22 Auxiliary Pumps Popup Touch Places

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hydraulic operation window. Other auxiliary pumps are controlled from the Auxiliary Pumps

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.

Figure 24 HCC Pump Popup Window Figure 23 HFC Pump Popup Window

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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 25 Menu and Back Buttons

Figure 27 Remote Panel Menu 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 26 Settings Password Popup Window

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5.2.1.3. 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 28 Remote Panel Cargo Pumps Window

Figure 30 Speed Adjust ButtonsFigure 29 Alarm State Animated Value

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5.2.1.4. Alarm Window

Alarms are monitored when active ACK2 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

Figure 31 Remote Panel Alarm Window

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5.2.1.5. 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 32 Remote Panel Settings Window

Figure 33 Popup Keyboard for Value Input

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5.2.1.6. 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.

Figure 34 Remote Panel Trend Window

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5.2.1.7. Auxiliary Pumps Window

From auxiliary pump window operator can control and see conditions for;

� Sea water cooling pump 1


� Fresh water cooling pump 1


� Buffer liquid circulation pump 1


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.

Figure 35 Remote Panel Auxiliary Pump Window

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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

Figure 41 Buffer Liquid Circulation Pump 2 Popup Window

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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. 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

Figure 42 Local Panel Main Window

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PROJECT No TRM-PCM V.01

PUMP CONTROL AND MONITORING v.01APPLICATION

SHIPYARD GISAN

HULL No NB48

From the question mark symbol system info popup window can be seen as below figure

43.

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.

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.

Figure 44 Password Popup Window for Control Access

Figure 43 Local Panel System Info Popup Window

PRPRPRPRROJOJOJOO ECECECECECT TT NoNoNoNoNo

APAPAPAPAPPLPLPPLP ICICICICCATATATATA IOIOIOIOONNNNN

SHSHSSHS IPIPIPIPPYAYAYAYAARDRDRRDR

HUHUHULLLL NNNNNooooo

Page 28 / 73



When operator enters the right password for control access change, animated buttons will

turn into green for indicating active operator panel.

5.2.2.2. 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 45 Popup Keyboard

Figure 46 Local Panel Operation Window

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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)

� Operation (toggles to hydraulic operation window)

� Cargo Pumps(toggles to cargo pumps window)

� Back to Main Menu(toggles to main menu window)

Figure 47 Local Panel Menu and Back Buttons

Figure 48 Local Panel Menu Window

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5.2.2.2.1. Operation Window 1

From operation 1 window operator can control and see conditions for;

� Main hydraulic pump 1



� 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.

Figure 49 Local Panel Operation 1 Window

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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 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.

Figure 50 Local Panel Hydraulic Main Pumps Popup Window

Figure 51 Hydraulic Main Pumps Ready Conditions Popup Window

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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.

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.

Figure 52 Local Panel HCC Pump Popup Window

Figure 53 Local Panel HFC Pump Popup Window

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From operation 2 window operator can control and see conditions for;







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.


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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

Figure 55 Local Panel Sea Water Cooling Pump 1 Popup Window

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5.2.2.2.3. Operation Window 3 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


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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

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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.

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5.2.2.3. 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.

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5.2.2.3.1. 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.

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5.2.2.3.2. Cargo Pump 2 Window

Figure 67 Local Panel Cargo Pump 2 Window

5.2.2.3.3. Stripping Pump Window

Figure 68 Local Panel Stripping Pump Window

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5.2.2.4. Alarm Window

Figure 69 Local Panel Alarm Window

Alarms are monitored when active ACK3 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

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5.2.2.5. 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 71 Local Panel Settings Window

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.

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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

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5.2.2.5.1. Cargo Pump 1 Settings Window

Figure 73 Cargo Pump 1 Settings Window

5.2.2.5.2. Cargo Pump 2 Settings Window

Figure 74 Cargo Pump 2 Settings Window

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5.2.2.5.3. Stripping Pump Settings Window

Figure 75 Stripping Pump Settings Window

5.2.2.5.4. System Settings Window

Figure 76 System Settings Window

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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. 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.

6.2. 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.

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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.

6.3. 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�/�MESSAGE�DESCRIPTION� EXPLANATION� REQUIRED�ACTION�

� Main�hydraulic�pumps�alarms�

1� Hydraulic�main�pump�1�overload� Main�pump�1�electric�motor�is�overloaded� Stop�motor�and�check�electric�motor

2� Hydraulic�main�pump�1�fault� Main�pump�1�electric�motor�is�faulty� Stop�motor�and�check�electric�motor

3� Hydraulic�main�pump�1�on�fail� Main�pump�1��electric�motor�is�not�started Check�the�cabling�and�electric�motor

4� Hydraulic�main�pump�1�off�fail� Main�pump�1�electric�motor�is�not�stopped�

Check�the�cabling�and�electric�motor



7� Hydraulic�main�pump�2�on�fail� Main�pump�2�electric�motor�is�not�started� Check�the�cabling�and�electric�motor





11� Hydraulic�main�pump�3�on�fail� Main�pump�3�electric�motor�is�not�started� Check�the�cabling�and�electric�motor



13� ��

� Hydraulic�oil�heater�alarms�

14� Hydraulic�oil�heater�1�on�fail� Hydraulic�oil�tank�heater�1�is�not�started� Check�the�cabling�and�heater�

15� Hydraulic�oil�heater�1�off�fail� Hydraulic�oil�tank�heater�1�is�not�stopped� Check�the�cabling�and�heater�

16� Hydraulic�oil�heater�2�on�fail� Hydraulic�oil�tank�heater�2�is�not�started� Check�the�cabling�and�heater�

17� Hydraulic�oil�heater�2�off�fail� Hydraulic�oil�tank�heater�1�is�not�stopped� Check�the�cabling�and�heater�

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18� ��

� Filters�alarms�

19� Pressure�filter�1�clugged� Pressure�filter�1�is�blocked� Check�and�clean�the�filter�




23� Return�filter�1�clugged� Return�filter�1�is�blocked� Check�and�clean�the�filter�




27� ��

� Hydraulic�oil�tank�alarms�

28� Hydraulic�oil�tank�low�level�alarm� Hydraulic�oil�level�is�low� Check�hydraulic�oil�tank�and�fill�with�oil�

29� Hydraulic�oil�tank�low�low�level�alarm�

Hydraulic�oil�level�is�too�low� Check�hydraulic�oil�tank�and�fill�with�oil�

30� Hydraulic�oil�tank�low�temperature�alarm�

Hydraulic�oil�temperature�is�low� Check�hydraulic�oil�tank�temp�and�heaters�

31� Hydraulic�oil�tank�high�temperature�alarm�

Hydraulic�oil�temperature�is�high� Check�hydraulic�oil�tank�temp�and�heaters�

32� ��

� Hydraulic�cooling�and�circulation�pump�alarms�

33� Hydraulic�cooling�and�circulation�pump�overload�

Hydraulic�cooling�and�circulation�pump�electric�motor�is�overloaded�

Stop�motor�and�check�electric�motor

34� Hydraulic�cooling�and�circulation�pump�on�fail�

Hydraulic�cooling�and�circulation�pump�electric�motor�is�not�started�


35� Hydraulic�cooling�and�circulation�pump�off�fail�

Hydraulic�cooling�and�circulation�pump�electric�motor�is�not�stopped�


36� ��

� Hydraulic�filter�and�circulation�pump�

37� Hydraulic�filter�and�circulation�pump�overload�

Hydraulic�filter�and�circulation�pump�electric�motor�is�overloaded�


38� Hydraulic�filter�and�circulation�pump�on�fail�

Hydraulic�filter�and�circulation�pump�electric�motor�is�not�started�


39� Hydraulic�filter�and�circulation�pump�off�fail�

Hydraulic�filter�and�circulation�pump�electric�motor�is�not�stopped�


40� ��

� Sea�water�cooling�pumps�alarms�

41� Sea�water�cooling�pump�1�overload� Sea�water�cooling�pump�1�electric�motor�is�overloaded�


42� Sea�water�cooling�pump�1�on�fail� ��water�cooling�pump�1�electric�motor�is�not�started�


Page 49 / 73



43� Sea�water�cooling�pump�1�off�fail� Sea�water�cooling�pump�1�electric�motor�is�not�stopped�


44� Sea�water�cooling�pump�2�overload� Sea�water�cooling�pump�2�electric�motor�is�overloaded�


45� Sea�water�cooling�pump�1�on�fail� Sea�water�cooling�pump�2�electric�motor�is�not�started�


46� Sea�water�cooling�pump�1�off�fail� Sea�water�cooling�pump�2�electric�motor�is�not�stopped�


47� ��

� Fresh�water�cooling�pumps�alarms�

48� Fresh�water�cooling�pump�1�overload�

Fresh�water�cooling�pump�1�electric�motor�is�overloaded�


49� Fresh�water�cooling�pump�1�on�fail� Fresh�water�cooling�pump�1�electric�motor�is�not�started�


50� Fresh�water�cooling�pump�1�off�fail� Fresh�water�cooling�pump�1�electric�motor�is�not�stopped�


51� Fresh�water�cooling�pump�2�overload�

Fresh�water�cooling�pump�2�electric�motor�is�overloaded�


52� Fresh�water�cooling�pump�2�on�fail� Fresh�water�cooling�pump�2�electric�motor�is�not�started�


53� Fresh�water�cooling�pump�1�off�fail� Fresh�water�cooling�pump�2�electric�motor�is�not�stopped�


54� ��

� Buffer�liquid�circulation�pumps�alarms�

55� Buffer�liquid�circulation�pump�1�overload�

Buffer�liquid�circulation�pump�1�electric�motor�is�overloaded�


56� Buffer�liquid�circulation�pump�1�on�fail�

Buffer�liquid�circulation�pump�1�electric�motor�is�not�startes�


57� Buffer�liquid�circulation�pump�1�off�fail�

Buffer�liquid�circulation�pump�1�electric�motor�is�not�stopped�


58� Buffer�liquid�circulation�pump�2�overload�

Buffer�liquid�circulation�pump�2�electric�motor�is�overloaded�


59� Buffer�liquid�circulation�pump�2�on�fail�

Buffer�liquid�circulation�pump�2�electric�motor�is�not�started�


60� Buffer�liquid�circulation�pump�2�off�fail�

Buffer�liquid�circulation�pump�2�electric�motor�is�not�stopped�


61� ��

� Cargo�pump�1�alarms�

62� Cargo�pump�1�bearing�temperature�1�fail�

Cargo�pump�1�bearing�temperature�1�exceeded�the�alarm�set�point�

Check�the�sensor��




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65� Cargo�pump�1�cargo�media�pressure�fail�

Cargo�pump�1�cargo�media�pressure�exceeded�the�alarm�set�point�


66� Cargo�pump�1�cargo�media�temperature�fail�

Cargo�pump�1�cargo�media�temperature�exceeded�the�alarm�set�point�


67� Cargo�pump�1�suction�pressure�fail�� Cargo�pump�1�suction�pressure�exceeded�the�alarm�set�point�


68� Cargo�pump�1�suction�temperature�fail�

Cargo�pump�1�suction�temperature�exceeded�the�alarm�set�point�


69� Cargo�pump�1�speed�response�fail� Cargo�pump�1�speed�exceeded�the�alarm�set�point�


70� Cargo�pump�1�high�cargo�media�pressure�increase�rpm�;�blocked�

Cargo�pump�1�high�cargo�media�pressure�exceeded�the�set�point�for�rpm�block�


71� Cargo�pump�1�low�suction�pressure�increase�rpm�;�blocked�

Cargo�pump�1�low�suction�pressure�decreased�under�the�set�point�for�rpm�block�


72� ��

� Cargo�pump�2�alarms�










76� Cargo�pump�2�cargo�media�pressure�fail�

Cargo�pump�2�cargo�media�pressure�exceeded�the�alarm�set�point�


77� Cargo�pump�2�cargo�media�temperature�fail�

Cargo�pump�2�cargo�media�temperature�exceeded�the�alarm�set�point�


78� Cargo�pump�2�suction�pressure�fail�� Cargo�pump�2�suction�pressure�exceeded�the�alarm�set�point�


79� Cargo�pump�2�suction�temperature�fail�

Cargo�pump�2�suction�temperature�exceeded�the�alarm�set�point�


80� Cargo�pump�2�speed�response�fail� Cargo�pump�2�speed�exceeded�the�alarm�set�point�


81� Cargo�pump�2�high�cargo�media�pressure�increase�rpm�;�blocked�

Cargo�pump�2�high�cargo�media�pressure�exceeded�the�set�point�for�rpm�block�


82� Cargo�pump�2�low�suction�pressure�increase�rpm�;�blocked�

Cargo�pump�1�low�suction�pressure�decreased�under�the�set�point�for�rpm�block�


83� ��

� Stripping�pump�alarms�

84� Stripping�pump�bearing�temperature�1�fail�

Stripping�pump�bearing�temperature�1�exceeded�the�alarm�set�point�


Page 51 / 73









87� Stripping�pump�cargo�media�pressure�fail�

Stripping�pump�cargo�media�pressure�exceeded�the�alarm�set�point�


88� Stripping�pump�cargo�media�temperature�fail�

Stripping�pump�cargo�media�temperature�exceeded�the�alarm�set�point�


89� Stripping�pump�suction�pressure�fail�� Stripping�pump�suction�pressure�exceeded�the�alarm�set�point�


90� Stripping�pump�suction�temperature�fail�

Stripping�pump�suction�temperature�exceeded�the�alarm�set�point�


91� Stripping�pump�speed�response�fail� Stripping�pump�speed�exceeded�the�alarm�set�point�


92� Stripping�pump�high�cargo�media�pressure�increase�rpm�;�blocked�

Stripping�pump�high�cargo�media�pressure�exceeded�the�set�point�for�rpm�block�


93� Stripping�pump�low�suction�pressure�increase�rpm�;�blocked�

Stripping�pump�low�suction�pressure�decreased�under�the�set�point�for�rpm�block�


94� ��

� Hydraulic�system�pressure�alarms�

95� Hydraulic�system�pressure�h�gh�alarm�

Hydraulic�system�pressure�exceeded�the�alarm�set�point�


96� Hydraulic�system�pressure�low�alarm� Hydraulic�system�pressure�decreased�under�the�alarm�set�point�


97� ��

� Common�alarms�

98� Emergency�stop� One�of�the�emergency�stop�button�is�pressed�

Check�emergency�stop�buttons�

99� Replace�ram�battery� Plc�battery�is�ended� Replacement�needed(refer�to�plc�manual)�

100� ��

8. 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

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10. PLC MANUAL

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Documents

CARGO PUMP CONTROL & MONITORING SYSTEM - tr · PDF fileRauf Orbay Cad. No:37 34944 Tuzla – STANBUL Tel: (0216) 446 2328(pbx) Fax: ... The CARGO WATCH II control system is capable