Instrumentation

Objectives of Instrumentation Department

(1) Measurement : Ensure correct measurement of process parameters
through maintenance of Instruments and Control Systems of different
Plant sections

(2) Control : Effective control of process variables to

yield quality products through improvement initiatives
for better plant operation as well as energy
optimization

(3) Reliable Availability : Ensure reliable

availability of Field Instruments, Valves &
Control Systems
(4) Safety :
Ensure safety of process,
man, machines, materials
and environment

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 Instrumentation Discipline at a glance
Engineers and above : 40

Management Trainees : 02

Members (Technicians) : 25

Apprentice Trainees : 00

Contract Manpower : 62+

TOTAL 129+

Ratio
Graduate Engineers : Non-Graduate Persons = 1 : 3
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Organization Chart of Instrumentation Department
Ranjan Bhattacharya
H.O.D. & Sr. GM

Amitava Chattopadhyay Anirban Bagchi Shantanu Konar

Team Leader & GM Team Leader & DGM Team Leader & GM
NCU & NCAU CES, IOP & CPP Polymers & Bagging

Managers Managers Managers

Engineers Engineers Engineers

Management Trainees Management Trainees Management Trainees

Technicians + Apprentice Technicians + Apprentice Technicians + Apprentice

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 Field Instruments, Control Systems & Valves
Systems Field Instruments
➢ Safety Systems : 30 ➢ Transmitters : 17000
➢ Emergency Shutdown Systems : 15 ➢ Mass flowmeters : 130
➢ Machine Monitoring Systems : 19 ➢ Process Switches : 1610
➢ Turbine Control Systems : 04 ➢ Precision Level Gauges : 97
➢ Distributed Control System : 09 ➢ Bagging Instruments : 12
➢ General Purpose PLC : 85
etc.
Analytical Instruments Valves : The Final Control Elements
➢ Gas Chromatographs : 47 ➢ Control Valves : 2120
➢ Analyzers : 135 ➢ On-Off Valves : 1919
➢ Gas Detector : 718 ➢ Motor Operated Valves : 352

For upkeep of
Instrumentation,
optimum spares
inventory is
maintained.
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Photographs of a few Field Instruments

Pressure Gauge Pressure Switch DP Transmitter Temperature Gauge Temperature Transmitter

Level Switch Servo Level Gauge Ultrasonic Level Transmitter Orifice Flowmeter

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Control Systems
1. Distributed Control System (DCS)
2. Emergency Shut Down (ESD) System
3. Fire & Gas (F&G) System
4. Machine Monitoring System (MMS)

5. Integrated Turbine & Compressor Control (ITCC) System

6. Tank Farm Management System (TFMS)
7. Termination Automation System (TAS)

8. Online Plant Information System (OLPIS)

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and many more… 7
Control Room : Front & Rear Ends

The Front End : The Rear End :

Operator Consoles Marshalling Cabinets

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Control Valve: The Final Control Element

By Joydeep Bhattacharyya
What is a Control Valve ?

Control
Valve

This is a device used to modulate flow of process fluid in line by creating a variable pressure drop in the line. Normally
the pressure drop is made with respect to the control signal received towards flow condition correction required.

By Joydeep Bhattacharyya
Control Valve in Flow Control

By Joydeep Bhattacharyya
Control Valve in Level Control

By Joydeep Bhattacharyya
Control Valve in Pressure Control

By Joydeep Bhattacharyya
Control Valve in Temperature Control

By Joydeep Bhattacharyya
Procedures & Maintenance Techniques followed
❖ Preventive Maintenance (PM)

PM schedule is SAP based with specific tasks. Instruments have been categorized into “A”, “B”, “C”

depending upon criticality. Schedule depends on the criticality & the vendor recommendation for
the type of instrument. It is applicable for online instruments only, which can be done without

hampering the process operation.

❖ Predictive Maintenance (PdM) / Look Listen Feel (LLF)

PdM / LLF is a non-contact type maintenance that covers 100% instruments. It is also schedule

based with specific tasks. This type of maintenance gives insight to prevent surprise failure.

❖ Corrective & Breakdown Maintenance

This type of maintenance is a reactive maintenance driven by failure of instruments or their parts

and is done on case to case basis.

❖ Turn Around (TA) Maintenance

TA maintenance is done for those cases which cannot be done in normal plant running condition.

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Inventory & Maintenance Cost
Inventory : Rs 30.09 Crores

Annualized Maintenance Cost

Supply : Rs 8.27 Crores
Service : Rs 3.80 Crores
Total Cost : Rs 12.07 Crores

N.B. : The above are typical figures only.

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People development initiatives and future plan

1. Safety Trainings

2. DCS / ESD Trainings

3. Functional Trainings

4. On-the-job Trainings

5. RSO Training by BARC

6. Cross-functional Trainings

7. Tool Box Talks

8. Quiz Programmes
It is a continuous learning process … 17
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Challenges & Future Plans
1. Reduction in Plant Downtime
due to malfunction of Instrumentation.
2. Reduction in Energy Consumption
through continuous development
of Instrumentation Systems.

3. Improve in Reliability of Instrumentation Systems by

adoption of better Technology & Maintenance techniques.
4. Asset renewal for overcoming obsolescence & ensuring
reliable availability
5. Alarm Management : To limit operational alarm upto 150
per day per console 18
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 Happy learning…
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