IGG Detailed Troubleshooting

Head office & Changwon factory Pohang factory
76, Yeondeok-ro, Sungsan-gu, Changwon city, Korea 1111, Haean-ro, Heunghae-up Buk-gu, Pohang city, Korea
Tel : +82-55-269-7700(rep), E-mail : service@kangrim.com Tel : +82-54-230-8500, Home : www.kangrim.com
TROUBLE SHOOTING OF I.G.G
1. PLC CPU RESET METHOD

1) Purpose of use
* push the reset button
2. SCHEMETIC DIAGRAM OF INERT GAS GENERATOR

* Local gauge board
F.O INLET PRESS'
IGNITION MAIN
30 BAR FIRING
24~26 BAR
25 BAR 24~25 BAR
F.O CAPACITY OUTLET

SPRIANO
ZERO SPAN
0.2 BAR 1.2 BAR
WATSON
ZERO SPAN
0.2 BAR 1.0 BAR
INSTRUMENT AIR INLET

PRESSURE :
MORE THAN 7 BAR
F.O CONTROL INLET

PRESS' : 2BAR
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3. IGNITION FAILURE CHECK POINT

1) CHECKING FLAME SCANNER AND DETECTOR RELAY OPERATION
Light a lighter on the flame scanner(2EA) and then check that flame LED is
"ON" in main control panel Also, flame detector relay is "ON" in local JB panel.
2) CHECKING POWER BREAKER AND IGNITOR CONDITION

- If the "3F3" breaker("3F3" breaker is ignition glow plug power supply to transformer.
if you find ignition power supply breaker refer drawing) is "OFF" in main control
panel, Turn on the "3F3" breaker and try IGG operation.
- The "3K6" relay ("3K6" relay is ignition power to transformer refer drawing) is "ON"
And going to buner side for voltage measure to ignitor.
(Glow plug cable indicates about D.C 11V by volt meter)
"3F3" breaker D.C 11V
iii). Check Solenoid valve & Glow Plug
① Please remove the two cables of glow

plug and then check that spray F.O from pilot
burner
② Please remove the two solenoid valve and
then check glow plug is burning
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f.o is
glow plug position untill touching spraying
with f.o spray.
4. BEFORE AUTO START CONDITION OF MAIN PANEL
1 4
2 3
1, 2 : BLOWER DISCHARGE VALVE

-> IGG POWER ON CONDITION : one valve full open, other valve full close
3 : IGG CAPACITY VALVE -> ABOUT 50% OPEN
4 : ATMOSPHERE VALVE -> FULL OPEN
5 : SCRUBBER SEA WATER INLET VALVE -> FULL OPEN
6 : S.W AUX. SUPPLY V/V -> FULL CLOSE
7 : S.W EFFLUENT LINE VALVE -> FULL OPEN
S.W EFFLUENT OVERBOARD VALVE -> FULL OPEN
PLEASE CHECK ABOVE VALVES CONDITION.
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5. CHECKING MAIN GUN OPERATION
1) OPERATION CONDITION (FIRING)

- Operated with solenoid valve at F.O inlet valve operation Also, supply
control air to under port and nozzel to be open by operation of rod the main gun.
2) NORMAL CONDITION (FIRING STOP)
- Supply control air past the solenoid valve to be connected to upper port of
main gun and nozzel to be close by operation of rod the main gun.
3) CHECKING MAIN GUN HIGHT
-> Main gun hight sets as "A" of picture And "A" sets value according to IG design capacity to a mark.
"A" gap alingn purpose is to smooth injection.
DESIGN "A" GAP HIGHT

1,500㎥/H 110 mm
3,750㎥/H 50 mm
4,500㎥/H 50 mm
6,750㎥/H 90 mm
7,500㎥/H 90 mm
10,000㎥/H 90 mm
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6. IG F.O PRESSURE SETTING MANUAL

1) F.O PUMP(NO.1 & NO.2) RUNNING BY MANUAL MODE
2) F.O PRESSURE SETTING
- Refer picture and find f.o return valve
- Refer right picture and turn knob of solenoid valve to "1"
F.O INLET
PRESSURE
GAUGE
1 -> CLOSE
0 -> OPEN
3) Refer upper picture and check f.o inlet pressure

4) Adjust pump pressure regulator valve to get into inlet pressure 25bar
5) Recover solenoid valve to normal condition
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7. IG FLAME FAIL CHECK LIST

1) IGNITION PART
IGNITION FIRING YES □ NO □
PILOT AIR SOL V/V (OPEN ) YES □ NO □
PILOT F.O SOL V/V (OPEN) YES □ NO □
GLOWPLUG VOLTAGE (11V) YES □ NO □
FLAME DETECTION(MAIN/IGNITION) YES □ NO □
2) MAIN BURNER PART

INLET RETURN
FIRING F.O PRESS BAR BAR
F.O MAIN INLET V/V (OPEN) YES □ NO □
F.O RETURN V/V (OPEN) YES □ NO □
AIR FLUSHING SOL V/V
(OPERATION TEST ) YES □ NO □
F.O CAPACITY(I/P CONVERTER) INLET BAR OUTLET BAR
3) ADDITIONAL
CAPACITY V/V (OPEN RATING) %
ATMOSPHERE V/V (OPEN) YES □ NO □
OIL TYPE D.O □ G.O □
BLOWER LOAD(AMPHERE) NO.1 A NO.2 A
SHIP'S AFT DRAFT
COMB' PRESS' mmWG I.G PRESS' mmWG
SCRUBBER SEA WATER PRESS' BAR
O2 ANALYSER I.G SAMPLING YES □ NO □
MAIN GUN 'A' GAP

-> mm
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8. CALIBRATION OF I.G CAPACITY VALVE

A. After power 'on' of main panel, please select the "Air capacity valve switch" to 'manual'.
(Ship staff can find this
switch inside the main
control panel)
[Picture 1]
B. decrease the air capacity to 25%.
[Picture 2]
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C. From the IG capacity valve side, open the positioner cover and J/B cover.
Then, please check whether input is 8mA between terminal 7&8(red marking)
8 mA input signal can not be

used for 'zero' calibration.
[Picture 3]
D. Please check whether positioner cam disc position is "0.25" or not.

Also, Please check whether the capacity valve position is 25% open or not.
[Picture 4]
If there is a different from this picture, please reset using this bolt.
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E. Increase the air capacity to 100%.
F. Please check whether input is 20mA between terminal 7&8(red marking). Refer to [Picture 3]
G. Please check whether positioner cam disc position is "1" or not.

And limit contact switch should be opened.
Also, Please check whether capacity valve position is 100% open or not.
H. After finish all of above contents, return the air capacity valve to "auto".
Then, restart the IGG on auto mode.
I. Increased or decreased the air capacity and check the movement of capacity valve.
(capacity set point 25% ~ 100%)
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J. Reference for positioner cam disc position
25% setting position
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9. CALIBRATION OF I.G CAPACITY VALVE
When you use the signal generator

Minmun signal (4mA) - > output pressure gauge : 0.2bar
Maxmum signal (20mA) - > output pressure gauge : 1bar
** SIGNAL CONTROL METHOD (IN MAIN CONTROL PANEL OF IGG) **

1. F.O CAPACITY VALVE SWITCH POSITION : MANUAL
2. F.O CAPACITY SET POINT ADJUST :
0 % - > MINIMUM SIGNAL (4mA) - > 0.2 bar
100% -> MAXIMUM SIGNAL (20mA) - > 1.0 bar
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10. MANUAL OPERATION

1) IG EMERGENCY OPERATION PROCEDURE (CASE: AIR CONTROL BY MANUAL)
- IG AIR CAPACITY VALVE OPERATION BY MANUAL.
AA) IG main control panel door open and can find select switch "air capacity valve"
BB) Selected to manual and decrease the capacity set point until "25%".
CC) Check capacity valve open rating about "25%".
(If capacity valve is not as open and more open as "25%", Try zero & span calibration
valve curve according with calibration manual.)
- IG OPERATION BY MANUAL MODE

AA) Press manual mode button and press scrubber sea water pump start button.
BB) Press blower start button and check combution air pressure ,IG outlet pressure,
blower motor ampere.
(If checked datas is similar comparing with value of "firing data sheet", Try next step.)
CC) Press f.o pump start button and press "glow plug" button.
DD) The "glow plug" button lamp on and press "pilot on" button after 35seconds.
EE) Check "flame on" LED lamp on and press "main on" button.
FF) Check "flame on" LED lamp keep on and press "glow plug" button for ignitor stop.
GG) If oxygen content of generation gas become 6 ~ 7%, press "pilot on" button for
ignition firing stop.
HH) If oxygen content of generation gas not become 1 ~ 5%, adjust f.o capacity
set point according with oxygen content. (recommand oxygen content is 3 ~ 4%)
2) IG EMERGENCY OPERATION PROCEDURE (CASE: F.O CONTROL BY MANUAL)

- IG AIR CAPACITY VALVE OPERATION BY MANUAL.
AA) If not become normally oxygen content (allowable range 1 ~ 5%) in auto mode.
BB) IG main control panel door open and can find select switch "F.O capacity valve"
CC) Selected to manual and decrease the f.o capacity set point until "25 ~ 30%".
DD) Check f.o I/P convert output pressure about "0.4bar".
(If f.o I/P convert output pressure is difference more than "0.1bar, Try zero & span
calibration I/P convert according with calibration manual.)
- IG OPERATION BY AUTO MODE
AA) Press auto mode button and to be waiting satbility flame condition.
BB) If oxygen content is 6~7%, press the f.o capacity increase button accoding to
generation gas oxygen content. ( increase by 2~3%) Also, checking oxygen content
must be wait 1 min, because analyser oxygen content sensing take to time about 1min).
CC) If oxygen content become 3~4% and need more generation inert gas,
press the IG capacity set point increase button.
DD) IG capacity set point to be adjusted by 10%.
caution) The f.o capacity must increase absolutely as 2~3%, and the i.g capacity set
point button must increase absolutely as 10%.
KR7100291701_R00

IGG Detailed Troubleshooting

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Head office & Changwon factory Pohang factory

TROUBLE SHOOTING OF I.G.G

1. PLC CPU RESET METHOD

2. SCHEMETIC DIAGRAM OF INERT GAS GENERATOR

F.O CAPACITY OUTLET

INSTRUMENT AIR INLET

F.O CONTROL INLET

3. IGNITION FAILURE CHECK POINT

2) CHECKING POWER BREAKER AND IGNITOR CONDITION

iii). Check Solenoid valve & Glow Plug

① Please remove the two cables of glow

4. BEFORE AUTO START CONDITION OF MAIN PANEL

1, 2 : BLOWER DISCHARGE VALVE

5. CHECKING MAIN GUN OPERATION

1) OPERATION CONDITION (FIRING)

"A" gap alingn purpose is to smooth injection.

DESIGN "A" GAP HIGHT

6. IG F.O PRESSURE SETTING MANUAL

- Refer right picture and turn knob of solenoid valve to "1"

3) Refer upper picture and check f.o inlet pressure

7. IG FLAME FAIL CHECK LIST

2) MAIN BURNER PART

MAIN GUN 'A' GAP

8. CALIBRATION OF I.G CAPACITY VALVE

B. decrease the air capacity to 25%.

8 mA input signal can not be

D. Please check whether positioner cam disc position is "0.25" or not.

E. Increase the air capacity to 100%.

G. Please check whether positioner cam disc position is "1" or not.

J. Reference for positioner cam disc position

25% setting position

50% setting position

75% setting position

100% setting position

9. CALIBRATION OF I.G CAPACITY VALVE

When you use the signal generator

** SIGNAL CONTROL METHOD (IN MAIN CONTROL PANEL OF IGG) **

10. MANUAL OPERATION

- IG OPERATION BY MANUAL MODE

2) IG EMERGENCY OPERATION PROCEDURE (CASE: F.O CONTROL BY MANUAL)

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SIGNAL CONTROL METHOD (IN MAIN CONTROL PANEL OF IGG)