Expected

all field tasks System archetecture ,Panel grawing, Loop diagram. Interlock diagram , Graphics modifica
Phase 4
Associate with repairs and testing shop test of control and Shhut off valves, leak rate, lapping, calibration

associate with repairs and testing shop test of control and Shhut off valves, leak rate, lapping,
Phase 5 calibration of instruments hands on under maint engr alongwith field workmen Hands on under Maint en
daily/monthly report, planning sheets/ Job closure

Major Learnings
Phase Sr No Tasks Sr No. Sub Tasks

Preventive Maintenance of
1.1
Field Instruments

1 Field Tasks
Calibration of
1.2
Field Instruments

2.1 Schneider DCS

2.2 Triconex ESD

System Architecture,
Panel Drawing, 2.3 Triconex FGS
2
Loop Diagram,
Interlock Diagram

2.4 ABB TAS

2.5 N2 PSA Plant

 DM Plant,
2.6 ETP,
ADU
DCS Logic Understanding,
3 3.1 Schneider DCS
Graphic Modification

Associate with repairs and testing shop test

4 4.1 Hi-Tech Services, Bharuch
of control and shut off Valves

1.1 TOC Analyzer

1.2 ABB Loading Skid

1.3 Weigh Bridge

1 AMC Visit

1.4 Oxygen Analyzer

 1.5 Gas Chromatography

1.6 Gas Detector

5

1.7 Silica Analyzer

3 Engg Daily/ Monthly Report 2.1 Daily Report

4 Planning Sheets/ Job Closure 3.1 Job Planning

Calibration Management
4.1
Software

01-P-2730A Pump Actuator not

4.2
functioning

5 Other
5 Other

4.3 5S Activity

4.4 Loading Area

d
iagram , Graphics modification & DCS logic understanding.
eak rate, lapping, calibration of instruments

ak rate, lapping,
en Hands on under Maint engr Visit Engg

nings
Activities Completed

1. I am involved in PM activities of Instruments with executives.

2. Participated in revision of PM SOP's.

1. I am involved in Calibration of Instruments,

Done as per Standard Operating Procedures,
with proper Risk Analysis,
Taken Permit To Work,
precaution taken with wearing Safety PPE's,
Taken Tool Box Talk under guidance of Maintenance Engineer along
with technician with plant safety.
2. Participated in revision of CAL SOP's.

1. System Architecture studied for DCS & ESD and changes

understood after IPA Plant comissioned.
2. Daily DCS, ESD, FGS System checking performed and Report to
System Engg for any Abnormality or Major System Alarm.
So that learned Panel wiring, parts of marshalling cabinet, system
cabinet & server cabinet.

1. System Archtitecture studied for ESD.

2. Involved in work on Communication Module of ESD,
So learned about Panel Wiring, Redundancy of Modules.

1. Work on Analog to Binary Bit Migration of FGS Signal from

Triconex to Tyco Fire Alarm Panel for each Tag of Plant.
2. Hot Loop Checked for IPA Plant FGS Signal.
So that learned signal flow, loop diagram & interlocks.

1. Involved in System Comissioning of Redundant Server instead of

Single Server.
2. Both server Redundancy checked.
3. Cumene Skid trial taken with tanker loading.
So that learned TAS installation & configuration.

Prepared N2 PSA Panel Termination Details sheet for ease of

troubleshooting.
So that learned control sequence of plant.
Updated Instrument list by verifying all instruments make, model,
range, accuracy, process connection using p&id.
So that familiar with all instruments in plants.

Understand DCS IO Configuration & Graphic Modification.

Visit Valve Inspection of H2SO4 CV to understood cause of damage

and repair procedure of valve.

1. TOC 4200 Shimadzu PM done & Baseline position checked.

2. Observed Low carrier gas Alarm & Dehumidifier Fatal error so
Alarm issue solved and for error action taken.
3. Conusmables & Standard Accessories part replaced,
CO2 Absorber, Pinch Valve.
4. Calibration Done with 200 ppm. Found 201ppm. & new curve
updated.
5. 8 parts cleaned, 17 parts visual checking OK.
So that learned sample flow, all parts & operation.

1. Checked functionality of RIT lamps & Pushbutton.

2. Checked SOV & DCV working.
3. Checked Earthing relay interlocks.
4. PM done of TAS client PC.
5. Backup taken and removed unwanted data from server.
6. SOP prepared for Server Cleanup & Backup.
So that learned to diagnos Input/Output, changing max flow in BCU,
Loading stopped issue handling.

1. Preventive Maintenance done & precaution taken by maintain gap

of Stopper Bolt, Checking Supply & Neutral Voltage for all
components of RLWS.
2. Calibration done with Corner test, with std weight zero & span
calibration.
3. Verification done with Coal truck weight measure for all WB and
rectify issues.
So that learned work flow, software & 920i indicator operation,
system parts.

1. All panels and its SHS components were checked for its
functionality.
2. PM done by all filters & rotameter cleaned of all analyzer panels.
3. Precaution taken by replacing broken parts with new one.
4. Calibration done with zero by O2: 0% & span by O2: 9.25% std.
gas cylinder.
So that learned sample flow, all parts & operation.
1. 02-AT-37001 & 02-AT-45001 make: Siemens Alarm summary
checked for active fault alarm.
2. AFR checked and PM done.
3. All parameter checked of Analyzer.
4. GC response checked with calibration blend.
5. GC Calibration done with std. calibratin blend.
So that learned sample flow, all parts & operation.

1. Preventive Maintenance done of all components of Gas Detector.

2.Calibration done of Hydrocarbon, Hydrogen and Benzene Gas
Detector with std. sample gas cylinder.
So that learned operation, calibration & maintenance.

1. Analyzer healthiness checked.

2. Reagent checked.
3. Calibration done with 50 ppb std. solution.
4. Found warning so action taken and removed.
5. Silica 5500 software version updated.
So that learned operation, calibration & maintenance.

Daily Report maintain and communicate to seniors.

1.Daily Job Planning Sheet Format prepared for department use. Also
daily allocated work done as per procedure with Job permit, Risk
Assessment and Tool Box Talk.
2. ERP Work request approving & closing as per procedure in given
time.

Learned how to use all Master Calibrator and do offline calibration

using CMX software & below calibrators:
1. POC8
2. MC6
3. Calsys Temp Bath
4. Add new Tag, Area & Plant, Device Manufacture, Calibrator,
Calibration Certificate, History Trend, Area wise report, Date wise
report, Data Transfer from Calibrators to CMX PC.

1. Checked & found gear assembly teeth were broken so replaced

with new one.
2. Checked & found wire harness card not functioning so replaced
with new one.
3. After Calibrated as per DCS Signal & stroke observed found OK.
So that learned operation & working of all components.
1. Sorted instruments & componets, keeping only the essential &
faulty scrapped.
2. Allocated designated place for each type of instruments in
cupboard & rack in workshop so that any worker easily find.
3. Daily ensuring cleaning & maintaining areas in workshop.
4. Made a Excel sheet contains all instruments. So that anybody can
find its availibilty & maintain record.
5. Monthly audit by workshop owner & improving.

1. Due to DCV passing issue it need to be change frequently so

tracking of new & removal DCV critical for troubleshooting.
So New Tag No attached with each DCV that number contain all
information about history of that DCV & record keep in Excel sheet.
 Department/
Sr. No. Identify Area for Project Work Project Objective
Function

Project Terminal Automation System Instrumentation Study of Operation of

1 Functions Reliability Improvements TAS System & System
Improvements
 Project
Project Assigned
Project Name Duration Project Assigned By
To
(in weeks)
Terminal Automation System 6 Mr. Karan Rana Mr. Jignesh Patel
Functions

Terminal Automation System

Functions
Terminal Automation System
Functions

Maintenance & Operations

Maintenance & Operations

Maintenance & Operations

System Reliability Improvements

System Reliability Improvements

System Reliability Improvements

 Key Learning
Major milestones: Start Date End Date Status
Outcome

System Architecture TAS System Architecture 5-Jan-20 21-Jan-20 Completed

System Architecture Weigh Bridge System 22-Jan-20 9-Feb-00 Completed

Architecture
System Architecture Loading Skid Architecture 10-Feb-00 21-Mar-20 Completed

Maintenance & Operation of TAS Server System 5-Jan-20 21-Jan-20 Completed

Operations
Maintenance & Operation of Weigh Bridge 22-Jan-20 9-Feb-00 Completed
Operations System
Maintenance & Operation of Loading Skid 15-Jun-20 30-Jul-20 Completed
Operations
SQL Coding Issue solution, TAS Server Commissioning & 5-Jan-20 21-Jan-20 Completed
Backup of Database, Redundancy
Disk Cleaning for Server

Troubleshooting, Weigh Bridge Corner Test, 21-Jan-20 9-Feb-00 Completed

Calibration & Verification Calibration & Verification

Liters to Kgs Weight Loading Flowmeter vs Weigh 15-Jun-20 30-Jul-20 Completed

Measurement in Bridge Liters to Kgs Weight
Flowmeter Measurement
Target Achieved
(in percentage)

100

100

100

100

100

100

100

100

100