Doha South STW

maintenance strategy

METITO (Overseas) Qatar

06/02/2023
Instrumentation & Automation Assets Maintenance
1. Brief Introduction on Instrumentation & control system
2. Number of assets under Instrumentation disciplinary
3. Different types of Electrical equipment’s
Analyzers- pH, DO, Conductivity, ORP, Turbidity/TSS, Chlorine
Flow Meter
Transmitters-Pressure, Level, Temperature, Vibration
Switches- Pressure, Temperature, Proximity, Flow, Limit
Gauges-Pressure, Temperature
PLC
SCADA
4. Maintenance schedules for the above Assets as per FMECA
5. Job task for the different assets
6. TPA Calibration
7. Spares procurement procedure
8. PM plan execution through MAXIMO
9. CM plan execution through MAXIMO
10. PTW-Permit To Work
 • Introduction on Instrumentation & Control System

• Instrumentation & Control System is the science of automated measurement and

control.
• In first part , the measuring INSTRUMENTS which are nothing, but the equipment
/devices used for measure different types of process parameters like PRESSURE,
TEMPERATURE, FLOW, PHYSICAL STATE, POSITION, VOLUME , CHEMICAL
CONCENTRATION VIBRATION , PHYSICAL STATE of different process variables like
FLUID, SOLID MATERIAL, MACHINE PARAMETERS , CHEMICALS etc.
•
•
 Introduction on Instrumentation & Control System

In second part the data which is transmitted by measuring instruments is get recorded and
analyzed by the controlling equipment i.e., PLC/SCADA and the final process condition/
state will be decided based on logical analysis programmed in PLC.

https://www.youtube.com/watch?v=7if7MSqiepg&t=198s

Some instruments which are used as final controlling devices behaves as per the logical
instruction from PLC /SCADA and influences the process parameters as per requirement..
 Instrument Assets details

Types of Instrument & Control Assets:

Instruments related to process control and equipment safety Instruments related to Safety and Surveillance
§ Analyzers • Fire Control & Alarming system
§ Flow Meters • Fire Fighting System (Fire Trace
§ Transmitters (Pressure, Temperature, System)
Level) • CCTV surveillance System
§ Pneumatic Actuators
§ Electric / Motorized Actuators
§ Switches(Pressure, Temperature, Flow,
Limit, Proximity)
§ Solenoid operated Valves (SOV)
§ Vibration Transmitter
§ Gauges (Pressure & Temperature)
§ UPS/Battery Charger
§ PLC/SCADA/SERVER
§
TOTAL NO. OF INSTRUMENTATION & CONTROL ASSETS IN DSSTW - 3338 nos.
 Types of instrument assets / equipment

• PROCESS ANALYZERS:
• pH Analyzer
v This is the instrument used for
measurement of Hydrogen –ion activity
in water-based solutions

v Indicates & Transmits the level of acidity &

alkalinity of solution .

v Unit of measurement is pH

v pH7 is neutral. Value Less that pH7 is acidic

and above pH7 is alkaline.

v Installed in SBR and ULTRAFILTRATION

PLANT.
v

•
•
 Types of instrument assets / equipment

• ORP Analyzer
v This is the instrument used for
measurement of ORP (Oxidation &
Reduction Potential) of water.

v Indicates possible contamination in water,

especially metallic contamination.
v
v ORP is determined by measuring the
potential of a chemically-
inert (platinum) electrode which is
immersed in the solution. The
sensing electrode potential is read
relative to the reference electrode of
the pH probe

v Unit of measurement is mV .

v Installed in INLET DISTRIBUTION

CHAMBER.
v

•
 Types of Instrument Assets / Equipment

• Dissolved Oxygen Analyzer

v This instrument measures the concentration of oxygen
dissolved in water.
v It is expressed as amount of oxygen per unit volume
(mg/L)
v Biological oxygen in water is essential for respiration of
aquatic life and it is also acts as a chemical oxidizer.
v Measurement is affected by temperature gradient,
salinity and barometric pressure.
v Two methods of measurement :- AMPOROMETRIC
METHOD & FLUORESCENCE QUENCHING METHOD
v Calibrated in atmospheric air and Air saturated water
method.
v
v Installed in SBR, ASP, SAS BALANCING TANK and
AEROBIC DIGESTERS.
 Types of Instrument Assets / Equipment
• Conductivity Analyzer
v Conductivity is the ability of process fluid to allow
current to travel through it.
•
v Conductivity indicates the number of impurities,
dissolved material and suspended material in
process water.
•
v Conductivity of water measurement is important in
wastewater and industrial water treatment as it
indicates that the pollutant has entered in process
water.
v The unit of conductivity is uS/cm or mS/cm.
•
v Conductivity also indicates the salinity level of water.
•
v Installed in INLET DISTRIBUTION CHAMBER & TSE
OUTLET.
•
v Two methods of measurement- CONDUCTIVE METHOD
& INDUCTIVE METHOD
 Types of Instrument Assets/ Equipment
• Turbidity Analyzer & TSS Analyzer
v Turbidity is cloudiness /haziness of water caused by
presence of large no. of foreign particles.
•
v The presence of these foreign particles makes the water
contaminated and the treatment process becomes
difficult.
v This also affects the oxygen and food supply to aquatic
life.
•
v The foreign particles are mostly urban runoffs, erosion,
algae, sediment erosions etc.

v Turbidity and TSS are similar things but presented in

different manner.
•
v Turbidity represents the transparency of water .
TSS(TOTAL SUSPENDED SOLID) represents the amount
of contaminates in water that causes the turbidity.
•
v Turbidity is measured by turbidity meter/sensor. This
method is called SCATTER-DETECTION METHOD.
v 3 concepts are mostly used for SCATTER-DETECTION
METHOD.
 Types of Instrument Assets/ Equipment
• Turbidity Analyzer & TSS Analyzer
v The unit of measurement is NTU(Nephelometric
Turbidity Units) or FNU(Formazin Nephelometric
Units).

v Turbidity sensors are installed in SBR outlet, TTP Inlet and

outlet and UF inlet and outlet.

v TSS analyzers are installed in Thickening centrifuge outlet .

v The purpose of TSS analyzer is to detect the dryness of

thickened sludge.
v
v The scatter-detection method is most accurate online method
to measure turbidity.
v
v The calibration of TSS & Turbidity are done with lab sample
comparison method.
•

•
 Types of Instrument Assets/ Equipment
• Chlorine analyzer
v Chlorine is used as a disinfectant in water treatment.
v Dosed as pure chlorine gas or SODIUM
HYPOCHLORITE(NaOCl).
v Less dosing will cause improper disinfection of water.
Excess dosing will make water poisonous for Aquatic
life and domestic use.
v After dosing of SODIUM HYPOCHLORITE(NaOCl), it
dissolves in water as hypochlorous acid called as free
chlorine
v Free chlorine and combined chlorine, together called as
total chlorine.
v Ideal range of free chlorine in water is 0.5 mg/L to 2 mg/L.
v Chlorine concentration measurement is required to check ,
if the disinfection is proper or not and the possible
presence of harmful by products like dichloramine and
trichloramine.
v Chlorine is measured for two parameters- FREE
CHLORINE & TOTAL CHLORINE.
v Measured is two methods- AMPOROMETRIC METHOD &
COLOROMETRIC METHOD

•
 Types of Instrument Assets/ Equipment
• Chlorine analyzer
v In Amperometric method A sensor is put directly in
contact with the process water.

v Mostly mounted in a flow cell of sampling system.

v pH Compensation is used by an additional pH sensor

as pH value affects the reaction of chlorine in water.
v Installed in UF outlet and TSE pump discharge line.
v Measurement unit is mg/L or ppm.

•
 Types of Instrument Assets/ Equipment
FLOW METERS:
•
v Flow meter is a device/ instrument used for measuring the rate of
flow of liquid, gas or slurry in a particular pipe or channel.

v Flow measurement is important from billing and process

controlling point of view.

v It can affect the profit and loss of a company business and create
large scale of disruption in process.

v The flow measurement is of two type- Mass flow & Volumetric

flow.

v The Units of measurement are Kg/Hr. , LPS, CuM/Hr.

v Types of Flow meters- EMFM, DPFM, VORTEX FM, VARIABLE

AREA FM , ULTRASONIC FM.

v In DSSTW, the widely used FM are EMFM , ULTRASONIC FM

and VARIABLE AREA FM.
 Types of Instrument Assets/ Equipment
FLOW METERS:
•
v EMFM-Electromagnetic flow meter
v Suitable for measurement of liquid mass.
v Not suitable for pure / DM/RO water.
v Works on electromagnetic induction concept.
v

v Ultrasonic flow meter is also called clamp on flow

meter.
v Works on ultrasonic wave time travel concept.
v Noncontact type application
v
v
 Types of Instrument Assets/ Equipment
FLOW METERS:

v DPFM-Differential pressure type flow meter.

v Widely used for all types of steam, liquid, slurry.
v Used as a combination of DP transmitter, orifice/venturi
tube
v
v
v
v
v VARIABLE AREA FLOW METER is also called ROTA
METER.
v Mostly used for liquid and gas application.
v Less accurate measurement.
v Used for flow rate detection & not for billing purpose.
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
v Transmitter is a device which coverts the physical process
variables that and
signal format measured
sends itbytosensors to suitable
final controlling electric
device.

v The widely used transmitted signals are 4-20 mA DC current,

3-15 PSIG pneumatic and Field bus digital signals.
v
v Transmitters can be of ANALOG TYPE, DIGITAL TYPE and
PNEUMATIC TYPE.
v
v Most widely used transmitters in DSSTW are digital smart
transmitters.
v
v Pressure Tx , Temperature Tx, Level Tx, Vibration Tx
 Types of Instrument Assets/ Equipment

TRANSMITTERS:-
§ PRESSURE TRANSMITTER

v Used for continuous online measurement of pressure

of process fluid.
v
v Mounted on process lines directly or by impulse lines.
v
v
v Pressure experienced by sensing diaphragm will get
converted by internal electronics to analog signal
of 4-20mA .
v
v Unit of measurement is Kg/Cm2 , BAR, mmH2O, PSIG
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ PRESSURE TRANSMITTER
v
v Connected to PLC/SCADA.
v
v Can be used as DP transmitter, Flow transmitter, level
transmitter.
v
v Used for monitoring, process control and equipment
safety .
v
v Installed in Blower suction & discharge lines, Pump
discharge lines and headers, UF skids and Blower
lubricating oil loops.
v

v
v
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ LEVEL TRANSMITTER
v
v Used for continuous measurement of process material
level at variable ranges.
v
v Important for water treatment process to avoid
flooding, dry run of pumps, process disturbance.
v
v Use both contact type and non-contact type
technologies for measurement.
v
v The output is electric signal(4-20m A) and is directly
corelated with the physical level in tank/basin.
v
v Communicates with PLC/SCADA.
v
v

v
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ LEVEL TRANSMITTER
v
v DP transmitter- Differential pressure transmitter used
as level transmitter in TTP basins for head
measurement.

v Hydrostatic level sensor with transmitters are used for

sludge tanks and high viscous liquid basin.
v
v In DP transmitter both are clubbed up in one unit.
v
v

v
v
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ LEVEL TRANSMITTER
v
v
v Ultrasonic level transmitters are used in most of the
basins for continuous level measurement
v
v Radar type level sensors are used for chemical tanks
and surge vessels for safe and accurate level
measurement
v
v
v Except DP method, All other methods have SENSOR
and transmitter as two subunits of the system.
v

v
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ TEMPERATURE TRANSMITTER
v
v Temperature transmitter is a device used to send the
measured temperature of any process variable or
machine parts to PLC/SCADA.
v
v Temperature transmitters combination of temperature
sensing element and transmitter.
v
v The sensing elements are of two types- Thermocouple
and RTD.
v
v Thermocouple and RTD(Resistance temperature
detectors) are the sensors which converts the
temperature to form of electrical signals like voltage
and Resistance.
v
v Transmitter amplifies the signal and send to PLC/SCADA.
v
v Transmitter O/P is 4-20mA .
v
v Installed in the SBR AND DIGESTER BLOWERS.
 Types of Instrument Assets/ Equipment
TRANSMITTERS:-
§ VIBRATION TRANSMITTER
v
v Vibration transmitter is used for detecting the vibration of
rotating machine parts.
v
v Vibration monitoring is important for avoiding a faster
wear and potential failure of rotating machine parts.
v
v It is very important for machine performance and life
cycle monitoring.
v
v Installed directly on machine parts like bearings,
couplings, foundation pad/plates.
v
v Communicates with PLC/SCADA.
v
v The o/p is 4-20 mA .
v
v Used for monitoring and safety of heavy rotatory
machines.
v
v
 Types of Instrument Assets/ Equipment
SWITCHES:-
v Switches are the devices used for detecting any change in
process state/condition.
v
v Also used for detecting the position of the moving machine
parts.
v
v Changes the state of electrical connectivity upon change in
any process state /condition.
v
v Mostly used for process interlocked and safety interlocks of
machine.
v
v Useful for protection of the machine parts and avoids any
unwanted incidents related to process or safety.
v
v Flow switch, pressure switch, temperature switch, proximity
switch, Limit switches. Are different types of switches
used in DS-STW
v

§
§
 Types of Instrument Assets/ Equipment
Gauges:-

v Gauges are used as indicating instruments for process

variables like pressure and temperature.
v
v Mounted on the process lines and used as local indicators.
v
v Very useful for frequent manual monitoring and alert
instruments.
v
v Sometimes used as testing and comparing instrument.
v
v
v Pressure gauges are Installed in suction and discharge lines
of blowers, pumps
v
v Temperature gauges are installed in oil reservoir tanks of
blowers.

§
§
v
 Types of Instrument Assets/ Equipment
PLC(PROGRAMABLE LOGIC CONTROLLERS):-
v Special purpose industrial computers used for used to control
different electro-mechanical processes for use in
manufacturing, plants, or other automation environments.
v
v Equipped with required input and output peripheral circuit.
Receives signals from field instruments and generates
outputs for actuating/reacting devices in field.
v
v Specially programmed by professionals for controlling of any
process related logic task.
v
v The main brain of plant process and controls the overall process.
v
v Simultaneously monitors, controls and records multiple types of
process automatically

§
§
https://www.youtube.com/watch?v=PbAGl_mv5XI
v
v
 Types of Instrument Assets/ Equipment
PLC(PROGRAMABLE LOGIC CONTROLLERS):-

v PLCs have many components like Power supply module,

CPU, communication module, input module, output
module .
v
v Input module receives signal from field devices, CPU makes
logical decision based on programming and the out
module drives the reacting device in field as per the
logical decision.
v
v Multiple PLCs connected in a network manages a vast plant
process.
v
v Each section is managed by its specific PLC.
v
v PLC panels are installed in Control rooms and some extended
units are installed in field and communicates to main PLC.
v
v For critical applications redundancy of system is applied.

v
v
 Types of Instrument Assets/ Equipment
SCADA (Supervisory control and data acquisition ):-
v A system of software and hardware elements used for

• Control industrial processes locally or at remote locations

• Monitor, gather, and process real-time data
• Directly interact with devices such as sensors, valves, pumps,
motors, and more through human-machine interface (HMI)
software
• Record events into a log files
v Number of PLCs & RTUs are connected in network and finally
communicates with SCADA.
v SCADA monitors, controls and records multiple process
simultaneously .
v Enhances productivity, down grades down time and enhances
efficiency of process.
v Centralized control structure enable a proper and efficient control
and supervision oof critical plant process
v
https://www.youtube.com/watch?v=nlFM1q9QPJw
v
 Types of Instrument Assets/ Equipment
SCADA (Supervisory control and data acquisition ):-
 Types of Instrument Assets/ Equipment
MAINTENANCE SCHEDULE:-
v Preventive Maintenance is required for efficient
performance of equipment's with longer life span.
v
v Proper maintenance with adequate frequency is very
much essential for healthy and efficient
performance of assets.
v
v Each equipment is studied, and its criticality level is
decided. Based on its criticality level and OEM
recommendation PM plan has been decided.
v
v Process criticality, client requirement, OEM
recommendation and experience are the factors
based on which the PM frequency has been
decided.
v
v Proper PM in proper frequency , reduces down time,
productivity loss and operational and maintenance
 Types of Instrument Assets/ Equipment
MAINTENANCE SCHEDULE:-
 Types of Instrument Assets/ Equipment
JOB TASK FOR ASSETS:-
v FMECA(Failure mode effect and criticality
analysis) has been implemented.
v
v Job task for each asset in its each frequency
is decided based on its possible failure
modes, OEM recommendation,
experience and execution feasibility.
v
v The job task for each asset in its each PM
frequency has been recorded and its
criticality level is analyzed.
v
v Final job task is implemented in EAMS and
SOP/MS has been published.
 Types of Instrument Assets/ Equipment
JOB TASK FOR ASSETS:-
 Types of Instrument Assets/ Equipment
TPA CALIBRATION:-
v The method of comparison of measurement delivered by
device under test with a standard device.
v A standard device is a device whose accuracy is known.
v The accuracy of standard device must be higher than that
of device under test.
v The acceptability of device is decided based on the error
percentage, potential effect on process/safety/machine
and its operational life span.
v Authorized third party are engaged for the activity.
v
v Certificates with all details of calibration with validity
period are published.
v Assets are tagged with calibration sticker for ensuring their
usability within that validity period
v
https://www.youtube.com/watch?v=SFOSEFp9yEU&t=7
s
 Types of Instrument Assets/ Equipment
TPA CALIBRATION:-
 Types of Instrument Assets/ Equipment
PM EXECUTION THROUGH MAXIMO:-
 Types of Instrument Assets/ Equipment
PM EXECUTION THROUGH MAXIMO:-
 Types of Instrument Assets/ Equipment
PM EXECUTION THROUGH MAXIMO:-
 Types of Instrument Assets/ Equipment
CM EXECUTION THROUGH MAXIMO:-
 Types of Instrument Assets/ Equipment
CM EXECUTION THROUGH MAXIMO:-
 Types of Instrument Assets/ Equipment
CM EXECUTION THROUGH MAXIMO:-
 Permit to work–PM Maintenance

Check list and Support the Close work

Safety Permit to Toolbox talk
Planned activity recording of report by order in
requirement work Induction
activities photos EAMS
 Arrange Toolbox talk Report
Preliminary material and Permit to Engineer Carry out the
Site feed back supported by
investigation isolation work Supervisor job
attendance photos
THANKS