Technician Training: Startup Basics

1. Technician Training: Startup Basics

2. Startup Basics
o Pre-Power – Instructions & Checklist
o Power Checks
o Pumps & Rotation Checks
o Actuated Valves
o Sensors & Instrumentation
o Control Panel PLC Input-Output
o Alarm Log Accuracy
o Data Communications

3. o Before activating power to the control panel network, it is important to have a
complete pre-check
 Energizing the panels with wiring incomplete or incorrect can be a safety
issue and can damage equipment
o Fuel System controls are a network of panels and devices with multiple
interconnecting wires
 It is important that all of the elements of the network be complete and
correct prior to energizing any panel within the network
 Check every device & every panel for correct wire terminations
 Check for any loose wires in terminal blocks
 Check for damage wire insulation
 Check for frayed wires at terminations
 Check for open panels or junction boxes
 Check that all wire is stranded copper conductors
Pre-Power

4. o Power wiring is usually performed under a separate contract
 After a complete pre-power check - Observer power connections & work
with the electrical contractor to activate and verify circuits
o When the power circuit is activated – Check at the control panel for the correct
voltage and phases where applicable
o With the proper checks, the control panels can be energized by the internal
circuit breakers, fuses, or disconnects
 The PLCs should power up and display a green power-on indicator
Power Check

5. o Single Phase & Three Phase pumps can rotate in either direction
 Rotation can be checked by observing the fan on the motor, while the pump motor
starter is momentarily bumped
 DO NOT run the dry pump for more than a few seconds
 Submersible pumps usually only operate in one direction and a check is not required
o Pumps should be marked with the direction of rotation, or refer to the sketch for the
common Viking Pump orientation
 Moving fluid along the long arc of the pump cavity
Pumps & Rotation Check

6. o The method to change directions is noted on the motor
 Single Phase – Usually interchange wires 5 & 8
 Three Phase – Interchange any two power leads
o When fluid is available to operate the pumps under load, the amp load on the
pump power wire should be checked to assure that it is in normal range
 The overload trip setting should be checked to match the full load amp
(FLA) noted on the motor nameplate
Pumps & Rotation Check (cont.)

7. o When the control panel is energized, all actuated valves should move to the closed
position, unless specifically programmed otherwise
 Confirm the closed valve position for all actuators by the actuator indication dial
 Check the valve stem to confirm that the valve itself is in fact closed & that the
closed position is indicated on the control panel screen
o Use the control panel to move the actuated valves – one by one – to the open position
 Confirm that the correct valve moves to the open position & that the control panel
screen indicates open
o Common errors in wiring actuators
 Open/Closed command signals are switched, Open/Closed limit switch signals are
switched, wiring not secured
Actuated Valves

8. o When the control panel is energized – All sensors should be in their normal
position
 Control Panel screen should be checked to confirm sensor position
o Where possible the sensor state should be changed by manipulating the sensor,
and confirm that the control panel indication changes to the proper condition
o Common Errors
 Loose wire connections at the sensor or the panel termination
Sensors & Instrumentation

9. o Control panel schematic – relates the sensor or valve wire termination # to an
input or output # on the PLC
o PLC has indicators for inputs/outputs for the on/off state
 Review wiring schematic and manipulate the sensor to generate a PLC
input
 Confirm that the correct PLC input is generated
o If problems are identified with valves and sensor indications on the PLC screen,
check that associated input or output on the PLC to see if it is in fact activated
Check Control Panel PLC Input/Output

10. o If the PLC input is not activated, check that the sensor wire is landed on the
correct terminal block & the wire termination is good
 Then check that the power wire going out to the sensor is terminated
correctly in the panel
 Recheck the wiring terminations at the sensor and confirm that there is
power on the sensor COM wire
 For an on/off sensor, disconnect the sensor and use a continuity test
with a Fluke to confirm that the sensor is good and changes state
properly
Check Control Panel PLC Input/Output (cont.)

11. o Alarm Log – Records date, time, and location of the alarms for the operator
o As the sensors are tested, confirm that the alarm log is generated accurately
o If the log is not accurate and the PLC input check correctly, then it is likely a
programming issue
Check Alarm Log Accuracy

12. o The master control panel likely has a BMS interface
 When the fuel system startup is complete the integration of the system should be checked
o BMS interface is dry contacts only
 Conditions such as a leak/general alarm should be generated and confirmed to be received by
the BMS system
o Typically the BMS has a data connection with the fuel system and up to hundreds of points of
monitoring
 The first step is to make sure that the BMS is communicating properly
 Can it see the fuel system panel on its network and can it read some obvious values like
Pump Manual Mode/Tank Volume
o Once communications to the BMS valid – Check individual points
 Operate the fuel system or manipulate sensors to generate the required points
 If the inputs are correct at the PLC, then any BMS discrepancy is a pogromming issue,
either within the PLC or at the BMS
Check Data Communications