Fluid Technology International Pvt. Ltd.

Project : FTI-O&M-Proj.-F01

Operation and Maintenance Team

S.No. Employee Name Designation Shift

Date Head of Department

 Fluid Technology International Pvt. Ltd.
Project :

Operation and Maintenance Organogram

O&M Manager

Plant Supervisor

Admin Executive Plant Operator

Janitorial Staff Painter Assitant Operator 1 Assistant Operator 2 H

Date Head of Department

 Pvt. Ltd.
FTI-O&M-Proj.-F02

anogram

or

sistant Operator 2 Helper

 Fluid Technology International Pvt. Ltd.

Project: FTI-O&M-Proj-F03

Operation & Mainenance Tools and Equipments

S.No. Item Name Description Quantity

Date Department Heaad

 Fluid Technology International Pvt. Ltd.

Project:

Spare parts and Consumables

S.No. Item Name
Date :
id Technology International Pvt. Ltd.

FTI-O&M-Proj-F02

Spare parts and Consumables

Description Quantity
Department Head :
 Fluid Technology In
Project:

PLANT MAINTENA
⃝●

MAINTENANCE TASK

2
3

6
7

8
9

10

11

12

13
14
 Fluid Technology Intern
Project:

PLANT MAINTENANCE M
⃝●

MAINTENANCE TASK

PLANT AREA/FACILITY
Check all plant containers from outside for any damages/rust.
Check all containers from inside (insulation/floor/roof) for any damage/rust
Check all containers outside supports and equipment skids/supports
Check plant area plantation (Grass and Trees)
Check plant pathways for any damages
Check for unusual odor/smell
Check plant area over all housekeeping (Kithen/Washrooms/Office container)
Check plant area/containers lightings.
Check any evidence of bondary wall damages and erosion
Check for water grown weeds
Check for any Fence damages
Check for any evidence of short circuiting
Check for equipment fastening nut bolts

SEA WATER INTAKE STRUCTURE

Check intake suction foot valves and strainers
Check intake suction pipes/flanges bolt tightening.
Check intake suction pipes bolting, flanges and gaskets for leaks/damage/Rust
Check piping system support for any damages/Rust
Check intake piping surface for wears/damage/leaks
Check platform fences for any damage/Rust
Check intake platform trucces for any damages/cracks
Check intake platform lights and indication light
Check electrical wiring to platform for any insulation damages

PLANT PIPING/JOINTS/FITTING/CONNECTION
Check all plant piping and fittings (HDPE/PVC/S-Duplex/SS) any leakages/damages/Rust
Check pipes/fittings bolting, flanges & gaskets for any leaks/damages/Rust
Check piping system support/clamps for any loose/damage/rust
Check piping/fittings surface for wears/damage/leaks
Check pipe joints and fittings for any cracks/leakages
Check all threaded fittings for seal leaks

CENTRIFUGAL PUMPS
Check the overall sound level of the pump.
Check pump inlet/out flanges bolts and piping condition.
Check pump cleanness condition (rusting/damage).
Check for any leaks, damaged gaskets and condtion of all pipe couplings
Check coupling adjustment
Check alignment of pump with motor shaft
Check flexible coupling and tightening tourque of coupling bolts (HP)
Check Balanc disc of pump (HP)
Check mechanical seal for early signs of leak or failure leaks

ELECTRIC MOTORS
Check bearing for abnormal temp. & vibration.
Check oil level of bearing.
Check Motor fan Performance.
Check for abnormal sound/Noise.
Check all electrical connectors for any loose or rust/Carbon
Check Megger for integirity of windiing insulation

CARTIDGE HOUSING
Check last cartidge filter change date
Check ΔP
Check cartidge filters element for any damages/blockage
Check O-ring conditon
Check inlet/outlet flanges for any leaks/damage/Rust
Check any CH any internal damage
Check inlet/out flanges bolt tightening.

VALVES (SAMPLE /BALL /ISOLATION /BUTTERFLY)

Check for any leakages from valves
Check the torque/tightening of the handvalve or lever
Check lubrication of lever bearing or spindle
Check the valve o-rings
Check full handle stroke or turn
Check general condition of valve
Verify consistency of required valve setting
Check indications on valve name plate
ACTUATOR
Check the cover of the emergency manual override is correctly installed
Check the housing cover of the actuator (Tightening of screw)
Check for grating noises from the actuator
Check the position indicator matches the signal of control

CENTIFUGAL SEPARATOR
Check seprator in/out flanges for any leakages/rust/damage
Check seprator bolt tightening and piping condtion.

MULTIMEDIA VESSELS
Check Multimedia condition for each vessel dust scaling
Check inlet/out bolt tightening of each vessel
Check inlet/outlet piping for any leaks/damages/Rust
Check all multimedia vessels for any leakage/Damages/Cracks
Check pressure drop across Vessels common header
Check vessels backwash status
Check

RO/POLISHING RO PRESSURE VESSELS

Check for any leakages/deterioration from pressure vessels head
Check connecting side ports for any leakages/deterioration/Scaling
Check and assure all external head assembly and sideports are dry (No leakages)

w
RO MEMBRANE
Check membrane element performance (Operational logsheet)
Check last membrane change date
Check last CIP date

PRESSURE EXCHANER
Check for any leakages/corrosion on end lock ring segments
Check and assure HP and LP stream flow rate are with in design limit
Check and assure seawater feed to PX are filtered to 10 micron
Check endcaps/segmented lock rings are corrosion free
Check housing heads and weap holes for any salt buildup and corrosion
Check for any unusual/abnormal sound

DOSING SYSTEM
Check pumping of liquid functioning properly
Check suction and discharge pressure are normal as per pump specificaiton
Check chemical tank/Cane for deterioration, crystallization, precipiation
Check for abnormal noise and vibration during operation
Check for air ingness from pump head joints and suction line.
Check retightening of pump head mounting bolts evenly
Check and change dosing pump wear part list

INSTRUMENTS
Check all instruments and transmitters for correct functioning.(Verify with analog
readings)
Check and assure instrument caliberation with date.
Check and clean instruments sensor electrode.

PESSURE GUAGES
Check pressure guage physical condition and display
Check and assure regular cleaning of pressure guages
Check guage functionality in conjuction with downstream component
Check pressurized connection pipe for seal condition
Check and assure gauges caliberation with date

ELECTRICAL COMMPONETS
Tansformer
Check oil levels of MOG and assure upto limit level
Replace the slica gel if color changed
Check air fan/oil pumps and control circuits
Check and assure cleaning of all electrical bushing, marshalling box inside/outside
Analysis of oil condition
Air Conditioner
Check all plant air conditioners functionality (colling)
Check Air conditioner inner/outer for any unusal noise and vibration
Check and assure AC filter cleaning
Electric Wires and Connection
Check all plant electrical wiring for any insulation damages
Check all electrical connections tightening
Electrical Control Pannel
Check electrical timers for correct readings
Observe controllers and settings for malfunction
Check for unprotected electrical connections
Check panel housing for damage or short circuit
VFD
Check the interior/exterior fans for any blockage
Check and clean fan air filter
Check for any corrosion/oxidation or dust
Check line side terminal and Torque
Check load side terminak and Torque
Check plug-in connection
Check relay contracts
Check circuit board and breakers
Check any insulation damage
Check power supply LEDS
Check DC link capacitor
Check heat sink for dust and durbis
Check contractor wire screws tightening
y International Pvt. Ltd.
FTI-O&M-Proj.-F0

TENANCE MASTER PLAN

Frequency

Daily Weekly Monthly 3 Months 6 Months Yearly

FTI-O&M-Proj.-F0

As Necessary
S.No. Maintenance Task Equipment Details
a. Check all containers and its support from outside for any damages/rust
b. Check all containers from inside (insulation/floor/roof) for any damage/rust
c. Check all containers supports equipment skids
d. Check plant area plantation
c. Check plant pathways for any damages
d. Check for unusual odor/smell
e. Check plant area over all housekeeping
Check plant area/containers lighting.
g. Check any evidence of bond wall damages and erosion
i. Check for water grown weeds
k. Check for any Fence damage
m. Check for any evidence of short circuiting
Check for euipment fastening nut bolts
Observations Action required Status
S. No. Items Quantity Remarks
1 CF
ransformer Maintenance Checks on a Monthly Basis

1. Oil level in the oil cap must be checked on a monthly basis so that it doesn’t drop below a fi
2. Keep the breathing holes in the silica gel breather clean to ensure proper breathing action a
3. If your electrical transformer has oil filling bushing, make sure that the oil is filled up to the

Daily Basis Maintenance Testing and Checking

Here are 3 maintenance tests you should run on your transformer on a daily basis:

1. Oil levels of MOG( Magnetic Oil Gauge) of the main tank and conservator tank. Always main
2. Replace the silica gel if its color changes to pink.
3. If any leakage is detected seal it.

Annual Transformer Maintenance Schedule

The air fans, oil pumps along with other items that are used to cool down a transformer and c

1. Make sure that you clean all the bushings of your electrical transformer with only soft cotto
2. Oil condition of OLTC should be carefully examined on an annual basis. For that take an oil
3. Make sure to clean out the inside of all of the marshalling boxes annually. Check proper fun
4. All the control switches, alarms and relays along with their circuits, Remote Tap Changer Co
5. Examine all the pockets for the Winding Temperature Indicator and Oil Temperature Indica
6. The proper function of Buchholz and Press Release Device relay need to be checked on a ye
7. Make sure to measure the resistive value of the earth connection and rizer should be meas

Transformer Maintenance on a Half Yearly Basis

Your electrical transformer needs to be checked every 6 months for IFT, DDA, flash point, slud
Maintenance of Current Transformer
A current transformer is a vital part of any equipment installed in an electrical substation for p

1. Thermo vision scanning of primary terminals and the top dome of a live CT must be conduc
2. All CT secondary connections should be examined, cleaned and tightened each year to ensu
 that it doesn’t drop below a fixed limit and hence avoid damage due to it.
sure proper breathing action at all times.
e that the oil is filled up to the correct level.  

er on a daily basis:

conservator tank. Always maintain to keep oil filled up to the desired level in MOG.

ool down a transformer and control circuit must be inspected annually.

ansformer with only soft cotton cloth annually.

ual basis. For that take an oil sample from drain valve and test it for moisture content (PPM) and dielectric strength (BDV). If the BDV valu
xes annually. Check proper functioning of the space and illumination heaters. All of the terminal connections of control and relay wiring ne
cuits, Remote Tap Changer Control Panel and Relay and Control Panel have to be cleaned with a proper cleaning agent.
or and Oil Temperature Indicator if they have the necessary level of oil and make sure to top it up if required.
ay need to be checked on a yearly basis.
tion and rizer should be measured annually with a clamp on the earth resistance meter.  

s for IFT, DDA, flash point, sludge content, acidity, water content and dielectric strength along with how resistant it is to transformer oil.

n an electrical substation for protection purposes as well as for electrical measurement. Insulation resistance of the CT has to be checked

me of a live CT must be conducted on an annual basis.

nd tightened each year to ensure that the secondary currents have the lowest resistance path.
trength (BDV). If the BDV value is found low and the PPM value high, then the oil needs to be replaced.
of control and relay wiring need to be tightened at least once a year.
ning agent.

tant it is to transformer oil.

e of the CT has to be checked on an annual basis.