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INSTRUMENT MAINTENANCE
PRACTICES
PRESENTED BY
PREM BABOO
CONTENTS
• INSTRUMENTATION BASICS
• MAINTENANCE PRACTICES
Introduction
• National Fertilizers Limited is a chemical process
industry. Any process industry is a combination of
all Technical and Non-Technical disciplines. All
disciplines/ departments functions are interlinked
to each other.
• Instrumentation in process industry plays a very
important role. In the very beginning we need to
measure all inputs and outputs at a pre-determined
level. For measuring different process parameters,
we need particular type of instrumentation. The
combination of all type of measurements, its
transmission for monitoring, recording and
controlling at desired level comes under process
Instrumentation.
Following are the basic needs to know by every process
engineer/operator to start/run any chemical process, plant or
section-
1. Process parameters like Pressure, Level, Flow,
2. Temperature, Chemical composition, Vibration etc.
3. Transmission of these parameter to Controlling
device in Control Room
4. Control action at pre-determined level
5. Maintaining Safety of Process for the safety of Man,
Machine & Material
6. Operation of the all sections at optimized level to
achieve maximum capacity utilization within minimum
energy investment
Let us start with an outline and overview of basic concept of
Instrumentation in process industry.
Inst maint practices
Control Loops
With the basic concept of process
control overview, we further derive
from it to following control loops-
 Single variable Control Loop
 Multi-variable Control Loop
These control loops are being given here
for your understanding only.
Single Variable Control Loops
- Pressure Control
- Temperature Control
- Level Control
- Flow Control
Pressure Control
Temperature Control
Level Control
Flow Control
Multi-variable Control Loops
- Boiler Drum Level Control
(3-Element)
- Compressor Anti-surge Control
Boiler Drum Level Control
BOILER DRUM
LT
FT
FT


FIC
A/M
setpoint
ECONOMIZER
RA
LIC
Condensate Pot
Air S
Water
Supper
Heater
De Supper
Heater

D/AFO
Compressor Anti-surge Control
TURBINE 1 2 3 4
FIC62
LS
PIC 75
PIC
HV-62
MAINTENANCE PRACTICES
• DAY TO DAY MAINTENANCE
• PREVENTIVE MAINTENANCE
• SHUTDOWN MAINTENANCE
• BREAKDOWN MAINTENANCE
• SPARES MANAGEMENT
• UP-GRADATION OF SYSTEMS
• During normal operation of the plant,
there may arise some doubts on the
performance of some instruments. The
same has to be checked, confirmed and
rectified.
• There are some routine checks which are
to be done and consumables are to be
provided.
DAY TO DAY MAINTENANCE
Procedures followed
• The normal practice is that the operation
group will be raising an MWO for any type of
maintenance job which has to be carried out.
• Prepare for the job, refer related documents
to ensure safe operation
• Clearance has to be taken and proper
isolation / bypassing is required
• Job to be carried out
• Clearance to be given
• Ensuring of results
PREVENTIVE MAINTENANCE
• Preventive maintenance is the one done
to prevent the instruments from
reaching a breakdown. Some of them are
– Daily Check Lists
– Weekly Schedules
– Monthly Schedules
– Quarterly Schedules
– Half yearly Schedules
– Yearly Schedules
SHUTDOWN MAINTENANCE
• We normally go for annual maintenance
shutdown of the plant every year. All the
preventive maintenance jobs which
cannot be taken up during running of the
plant is taken up during shutdown.
BREAKDOWN MAINTENANCE
• During running of the plant some times we
face serious troubles with the equipments
which may require a complete stopping of
the system. This is normally termed as
break down maintenance
SPARES MANAGEMENT
• Normally in new projects we keep provision for
sufficient spares for maintaining all equipments
and Control system for minimum 2-years
operation. After this we review the requirement of
spares and keep provision for procuring the spares
in Revenue budgets. The Revenue budget is being
approved in advance so that spares procurement
action can be taken to meet any emergency and for
repair & maintenance of defective instruments,
minimum spares shall be kept always in spares
inventory. Procurement action is being initiated as
per requirement in due time every year.
UP-GRADATION OF SYSTEMS
• In Instrumentation field, a lot of development is being done.
The old process instrumentation was pneumatic type and
control system was Single loop controller type.
• Interlock systems which is also known as Emergency
Shutdown system were based on Electro-mechanical relay
type system.
• But now a days there is total change in Instrumentation
philosophy. Total instrumentation is based on Electronic
systems i.e. right from Transducer/transmission system to
DCS, PLC based systems. So to make maximum use of latest
instrumentation we always go for Up-gradation.
• To take maximum benefits from these developments, we
always go for latest features and diagnostics in our
Instrumentation systems.
- Keeping in view of latest instrumentation we have
taken total Electronic control system for our Line-II
Expansion plants I.e.the field instrumentation is total
electronic smart transmitters, the control system is
Distributed type Control system (DCS) and Interlock
systems are PLC based failsafe, redundant and available
system.
- Similarly as best maintenance practices we have gone
for up-gradation of Instrumentation system of our Line-
I Plants. We have implemented many up-gradation
schemes of Instrumentation systems in last 2-years and
it is planned to upgrade other obsolete systems.
UPGRADATION SCHEMES
IMPLEMENTED
• ‘Yokogawa’ make Centum CS-3000 Distributed Control
System in Ammonia & Urea Line-I Plants along with
Compressors Instrumentation
• ‘Bently-Naveda’ make 3500-series with System-1
Diagnostic Vibration, Axial Thrust & Speed Monitoring
and protection system for Steam Turbine driven High
Speed Centrifugal Compressors
• ‘GE-Fanuc’ make 90-70 series Programmable Logic
Controllers of D.M.Plant-I, Condensate Polishing Unit &
Old Ammonia Storage Plant
In brief, it is described in next slide that how the
scheme of up-gradation is being implemented.
UPGRADED SYSTEMS
DISTRIBUTED CONTROL SYSTEM (DCS).
‘Foxboro’ make micro processor based
Single Loop Programmable Controllers
of Ammonia & Urea Plants Line-I with
Latest ‘Yokogawa’ make Centum CS-3000
Distributed Control System along with
split and pneumatic control systems of
High Speed Centrifugal Steam Turbine
Compressors to make it centralize.
Air
compressor
controls
Ref
compressor
controls
Syn
compressor
controls
Condensate
polishing
unit
Ammonia
main plant
Separate PLC Based
control
Separate Single loop
Based control
Separate pneumatic
control
600 MR
450 MR
900 MR
Old Control Philosophy of Ammonia Plant
Ammonia
storage
plants
Separate PLC Based
control
Urea 11
Compresso
r
Urea main
plant11
Urea 21
compressor
Urea main
plant21
Urea 11 P1
& P2
Urea 21 P1
& P2
550 MR
450 MR
550 MR
450 MR
Separate Single loop
Based control
Separate pneumatic
control
Separate pneumatic
control
Old Control Philosophy
of Urea Plant
LIMITATIONS OF THE OLD
CONTROL SYSTEM
• The life expectancy is not ensured due to
continuous use for last 18 years.
• Un-predictive failure due to ageing
problem.
• Non-Working Data Acquisition System.
• Non Reliable Recording with high
maintenance cost.
• Optimization through cascaded loops not
possible.
• Plant disturbance in case of single point
failure- non redundant system.
• Non Centralized Controls of pilot plants
& Compressors.
• Compressor pneumatic controllers with
slow response time leads to inefficient
operation of compressors.
SUPERIORITY OF LATEST SYSTEMS
• All the limitations listed previously will be wiped
out
• In addition, the latest control system is
- certified and ensured for reliability
- Availability
- Redundancy
• Minimum Down time on account of Control
System failure
• user friendly
• on line modeling for process graphics
• The System being offered is certified spare and
service support for next 15-Years
• historical data.
• alarm management.
• self diagnosis.
• auto tuning.
• on line maintenance.
• These features are directly resulting to
Energy saving with optimum manpower.
• Latest control system is having open-end
connectivity and platform for other
system like advance control system,
Mass spectrometer, Management
information system etc.
NEW INTEGRATED CONTROL SYSTEM FOR
AMMONIA PLANT
Amm
Comp
Vibr
Amm
Comp
ESD
Amm
main
ESD ASSH
PLC
IAC-III
PLC
Comprssr
DCS
CPU
plant PLC
Ammonia
Storage
PLC
Amm
Main DCS
11
ESD
21
ESD
Urea
Comp
Vibr
21
P1&P2
21
comp
Urea 11
P1&P2
11comp
Urea
DCS
NEW INTEGRATED CONTROL SYSTEM
FOR UREA PLANT
Compressor control room
Six operator stations Historian
Controller1
Remote Stns for S/Ic
& P/Ic
Engr station
Controller2
Controller3
600Mr
AMMONIA-I CONTROL SYSTEM
11- Compressor
control room
Six operator stations Historian
Controller11 sec
Remote Stns for S/Ic
& P/Ic
Engr station
Controller21 sec
600Mr
UREA-I CONTROL SYSTEM
21- Compressor
control room
300Mr
UPGRADATION SCHEMES UNDER
IMPLEMETATION
• Up-gradation of Solid state & Electro-mechanical relay
based Emergency Shutdown Systems of Ammonia & Urea
Line-I Plants to Fail-safe PLC based ESD systems along
with Line-I Compressors ESD systems
• Up-gradation of Gas Turbine Generator-1/2 Control
Systems (GE Mark-IV to GE Mark-VI)
• Up-gradation of Control Systems of Heat Recovery Units
(HRU-1/2/3) in Captive Power Plant
• Up-gradation of Burner Management system of Heat
Recovery Units (HRU-1/2/3) in Captive Power Plant
• Up-gradation of FIRE ALARM SYSTEM of the Complex
PROPOSED UP-GRADATION
SCHEMES
• We are also planning to up-grade the
instrumentation of Material Handling and Urea
Bagging Plant
• Even the latest instrumentation of Line-II plants
i.e.DCS & ESD, Compressors Control system
shall be due for up-gradation between year 2010
to 2015
Major projects of other units
under implementation
• In our sister units at Bhatinda, Panipat &
Nangal we are having Fuel oil based
fertilizer plants which are still having old
instrumentation. These plants are being
switched over to NG/LNG based plant and
the all instrumentation shall be up-graded
to latest electronic, DCS, PLC based
instrumentation. There we shall be having
more advanced instrumentation.
Inst maint practices
Inst maint practices
Conclusion
• In brief I just conclude here that the NFL corporation as a
whole is becoming a Powerful and Giant Fertilizer
industry which is having Latest technology in every field
and Instrumentation in particular.
• We are having the richest culture of the best maintenance
practices.
• Our Management is also considered to be progressive and
liberal to adopt latest energy efficient schemes.
• We all shall be having very good opportunities to work in
latest technological environment & full utilization of your
latest technical skills.
• All of you are having very bright future and full
satisfaction to work with us.
Thanks
Prem Baboo
Fertilizers Consultanats
+2349078758249
+2348055320446
+919425736974
+919691937949

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Inst maint practices

  • 3. Introduction • National Fertilizers Limited is a chemical process industry. Any process industry is a combination of all Technical and Non-Technical disciplines. All disciplines/ departments functions are interlinked to each other. • Instrumentation in process industry plays a very important role. In the very beginning we need to measure all inputs and outputs at a pre-determined level. For measuring different process parameters, we need particular type of instrumentation. The combination of all type of measurements, its transmission for monitoring, recording and controlling at desired level comes under process Instrumentation.
  • 4. Following are the basic needs to know by every process engineer/operator to start/run any chemical process, plant or section- 1. Process parameters like Pressure, Level, Flow, 2. Temperature, Chemical composition, Vibration etc. 3. Transmission of these parameter to Controlling device in Control Room 4. Control action at pre-determined level 5. Maintaining Safety of Process for the safety of Man, Machine & Material 6. Operation of the all sections at optimized level to achieve maximum capacity utilization within minimum energy investment Let us start with an outline and overview of basic concept of Instrumentation in process industry.
  • 6. Control Loops With the basic concept of process control overview, we further derive from it to following control loops-  Single variable Control Loop  Multi-variable Control Loop These control loops are being given here for your understanding only.
  • 7. Single Variable Control Loops - Pressure Control - Temperature Control - Level Control - Flow Control
  • 12. Multi-variable Control Loops - Boiler Drum Level Control (3-Element) - Compressor Anti-surge Control
  • 13. Boiler Drum Level Control
  • 15. Compressor Anti-surge Control TURBINE 1 2 3 4 FIC62 LS PIC 75 PIC HV-62
  • 16. MAINTENANCE PRACTICES • DAY TO DAY MAINTENANCE • PREVENTIVE MAINTENANCE • SHUTDOWN MAINTENANCE • BREAKDOWN MAINTENANCE • SPARES MANAGEMENT • UP-GRADATION OF SYSTEMS
  • 17. • During normal operation of the plant, there may arise some doubts on the performance of some instruments. The same has to be checked, confirmed and rectified. • There are some routine checks which are to be done and consumables are to be provided. DAY TO DAY MAINTENANCE
  • 18. Procedures followed • The normal practice is that the operation group will be raising an MWO for any type of maintenance job which has to be carried out. • Prepare for the job, refer related documents to ensure safe operation • Clearance has to be taken and proper isolation / bypassing is required • Job to be carried out • Clearance to be given • Ensuring of results
  • 19. PREVENTIVE MAINTENANCE • Preventive maintenance is the one done to prevent the instruments from reaching a breakdown. Some of them are – Daily Check Lists – Weekly Schedules – Monthly Schedules – Quarterly Schedules – Half yearly Schedules – Yearly Schedules
  • 20. SHUTDOWN MAINTENANCE • We normally go for annual maintenance shutdown of the plant every year. All the preventive maintenance jobs which cannot be taken up during running of the plant is taken up during shutdown.
  • 21. BREAKDOWN MAINTENANCE • During running of the plant some times we face serious troubles with the equipments which may require a complete stopping of the system. This is normally termed as break down maintenance
  • 22. SPARES MANAGEMENT • Normally in new projects we keep provision for sufficient spares for maintaining all equipments and Control system for minimum 2-years operation. After this we review the requirement of spares and keep provision for procuring the spares in Revenue budgets. The Revenue budget is being approved in advance so that spares procurement action can be taken to meet any emergency and for repair & maintenance of defective instruments, minimum spares shall be kept always in spares inventory. Procurement action is being initiated as per requirement in due time every year.
  • 23. UP-GRADATION OF SYSTEMS • In Instrumentation field, a lot of development is being done. The old process instrumentation was pneumatic type and control system was Single loop controller type. • Interlock systems which is also known as Emergency Shutdown system were based on Electro-mechanical relay type system. • But now a days there is total change in Instrumentation philosophy. Total instrumentation is based on Electronic systems i.e. right from Transducer/transmission system to DCS, PLC based systems. So to make maximum use of latest instrumentation we always go for Up-gradation. • To take maximum benefits from these developments, we always go for latest features and diagnostics in our Instrumentation systems.
  • 24. - Keeping in view of latest instrumentation we have taken total Electronic control system for our Line-II Expansion plants I.e.the field instrumentation is total electronic smart transmitters, the control system is Distributed type Control system (DCS) and Interlock systems are PLC based failsafe, redundant and available system. - Similarly as best maintenance practices we have gone for up-gradation of Instrumentation system of our Line- I Plants. We have implemented many up-gradation schemes of Instrumentation systems in last 2-years and it is planned to upgrade other obsolete systems.
  • 25. UPGRADATION SCHEMES IMPLEMENTED • ‘Yokogawa’ make Centum CS-3000 Distributed Control System in Ammonia & Urea Line-I Plants along with Compressors Instrumentation • ‘Bently-Naveda’ make 3500-series with System-1 Diagnostic Vibration, Axial Thrust & Speed Monitoring and protection system for Steam Turbine driven High Speed Centrifugal Compressors • ‘GE-Fanuc’ make 90-70 series Programmable Logic Controllers of D.M.Plant-I, Condensate Polishing Unit & Old Ammonia Storage Plant In brief, it is described in next slide that how the scheme of up-gradation is being implemented.
  • 26. UPGRADED SYSTEMS DISTRIBUTED CONTROL SYSTEM (DCS). ‘Foxboro’ make micro processor based Single Loop Programmable Controllers of Ammonia & Urea Plants Line-I with Latest ‘Yokogawa’ make Centum CS-3000 Distributed Control System along with split and pneumatic control systems of High Speed Centrifugal Steam Turbine Compressors to make it centralize.
  • 27. Air compressor controls Ref compressor controls Syn compressor controls Condensate polishing unit Ammonia main plant Separate PLC Based control Separate Single loop Based control Separate pneumatic control 600 MR 450 MR 900 MR Old Control Philosophy of Ammonia Plant Ammonia storage plants Separate PLC Based control
  • 28. Urea 11 Compresso r Urea main plant11 Urea 21 compressor Urea main plant21 Urea 11 P1 & P2 Urea 21 P1 & P2 550 MR 450 MR 550 MR 450 MR Separate Single loop Based control Separate pneumatic control Separate pneumatic control Old Control Philosophy of Urea Plant
  • 29. LIMITATIONS OF THE OLD CONTROL SYSTEM • The life expectancy is not ensured due to continuous use for last 18 years. • Un-predictive failure due to ageing problem. • Non-Working Data Acquisition System. • Non Reliable Recording with high maintenance cost. • Optimization through cascaded loops not possible.
  • 30. • Plant disturbance in case of single point failure- non redundant system. • Non Centralized Controls of pilot plants & Compressors. • Compressor pneumatic controllers with slow response time leads to inefficient operation of compressors.
  • 31. SUPERIORITY OF LATEST SYSTEMS • All the limitations listed previously will be wiped out • In addition, the latest control system is - certified and ensured for reliability - Availability - Redundancy • Minimum Down time on account of Control System failure • user friendly • on line modeling for process graphics • The System being offered is certified spare and service support for next 15-Years
  • 32. • historical data. • alarm management. • self diagnosis. • auto tuning. • on line maintenance. • These features are directly resulting to Energy saving with optimum manpower. • Latest control system is having open-end connectivity and platform for other system like advance control system, Mass spectrometer, Management information system etc.
  • 33. NEW INTEGRATED CONTROL SYSTEM FOR AMMONIA PLANT Amm Comp Vibr Amm Comp ESD Amm main ESD ASSH PLC IAC-III PLC Comprssr DCS CPU plant PLC Ammonia Storage PLC Amm Main DCS
  • 35. Compressor control room Six operator stations Historian Controller1 Remote Stns for S/Ic & P/Ic Engr station Controller2 Controller3 600Mr AMMONIA-I CONTROL SYSTEM
  • 36. 11- Compressor control room Six operator stations Historian Controller11 sec Remote Stns for S/Ic & P/Ic Engr station Controller21 sec 600Mr UREA-I CONTROL SYSTEM 21- Compressor control room 300Mr
  • 37. UPGRADATION SCHEMES UNDER IMPLEMETATION • Up-gradation of Solid state & Electro-mechanical relay based Emergency Shutdown Systems of Ammonia & Urea Line-I Plants to Fail-safe PLC based ESD systems along with Line-I Compressors ESD systems • Up-gradation of Gas Turbine Generator-1/2 Control Systems (GE Mark-IV to GE Mark-VI) • Up-gradation of Control Systems of Heat Recovery Units (HRU-1/2/3) in Captive Power Plant • Up-gradation of Burner Management system of Heat Recovery Units (HRU-1/2/3) in Captive Power Plant • Up-gradation of FIRE ALARM SYSTEM of the Complex
  • 38. PROPOSED UP-GRADATION SCHEMES • We are also planning to up-grade the instrumentation of Material Handling and Urea Bagging Plant • Even the latest instrumentation of Line-II plants i.e.DCS & ESD, Compressors Control system shall be due for up-gradation between year 2010 to 2015
  • 39. Major projects of other units under implementation • In our sister units at Bhatinda, Panipat & Nangal we are having Fuel oil based fertilizer plants which are still having old instrumentation. These plants are being switched over to NG/LNG based plant and the all instrumentation shall be up-graded to latest electronic, DCS, PLC based instrumentation. There we shall be having more advanced instrumentation.
  • 42. Conclusion • In brief I just conclude here that the NFL corporation as a whole is becoming a Powerful and Giant Fertilizer industry which is having Latest technology in every field and Instrumentation in particular. • We are having the richest culture of the best maintenance practices. • Our Management is also considered to be progressive and liberal to adopt latest energy efficient schemes. • We all shall be having very good opportunities to work in latest technological environment & full utilization of your latest technical skills. • All of you are having very bright future and full satisfaction to work with us.