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DEPT OF ELECTRONICS and INSTRUMENTATION ENGINEERING

IEEI821 Safety Instrumentation
SAFETY INSTRUMENTATION
Module -5
Operation,Maintenance,Testing,Reporting and
Management of PSMP
Dr V S Krushnasamy
Associate Professor
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Reports/Records
Protection System Maintenance
Program[PSMP]
Self Monitoring Capabilities and Limitations
Notifications of Protection Systems Failures

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DESCRIBE THE WORKING OF VARIOUS TYPES OF

REPORTS REQUIRED FOR MAINTENANCE
MANAGEMENT:

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REPORTS / RECORDS
TEST REPORT :
• Test report is a report which include output data of
function of instrument through which behavior of
instrument can be judge, with known inputs.
• It provides working range of instrument.

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 INSPECTION REPORT
• Inspection report is a report which prepared by
visual verification of physical condition of any
instrument as per their name-plate of data sheet
provide from instrument manufecturer
• As per this type of report we can maintain the
condition of any instrument as it would receive
from factory.
• -As per this report we can have necessary steps
to maintain our instruments and relevant assets
in good condition in different atmosphere like we
can provide protection against different season or
in Hazardous area.
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Following type of Inspection Report can be prepared :
 Inspection reports of Impulse lines & Fittings
 Inspection report of JB, cable glands, cable & cable trays.
 Inspection report of cable route including cable tray / duct
conditions.
 Inspection report of external chamber level instrument.
 Inspection report of cooling system / radiation shields of
Nucleonic detectors.
 Inspection report on visual check of thermowells, flanges and
conduits & Skin T/C.
 Inspection report of sealing element for special design temperature
element.
 Inspection report on visual check of final control elements
[Valves] and accessories.
 Inspection report of instrument air header & air tubing for leakage
and corrosion.
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EQUIPMENT RECORD
Equipment records are grouped under four classifications:
 maintenance work performed,
 maintenance cost,
 inventory, and files.
 Equipment records are useful when procuring new
items/equipment to determine operating performance
trends, troubleshooting breakdowns, making
replacement or modification decisions, investigating
incidents, identifying areas of concern, performing
reliability and maintainability studies, and conducting
life cycle cost and design studies.
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WORK REQUEST
A document that instructs the maintenance
department that work is required.
It identifies the equipment number, a unique
job number, the work requested, any
approvals required, and the priority of the
work.

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 WORK ORDER
 A document that instructs the maintenance person in
what is to be done.
 It identifies crafts, if appropriate, materials, special
tools, critical times, and provides other necessary
information to accomplish the job.
 The format for the work order must be agreed upon
at the beginning of the computerization process.
 It is the key to definition of the job, planning,
scheduling, and control of the work, plus developing
histories for future analysis.
 Although no database is preloaded, one is rapidly
generated.
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WORK PLAN
The asking of why, what, who, where, when,
and how the maintenance group will respond
to a work request. It provides logical answers to
these questions.

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JOB SEQUENCE
 Frequently called scheduling. It recognizes
priorities and resource availability and can
be done at several levels.

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CONTROL REPORTS
An after-the-fact record, or accounting, or what
has been done and some form of measurement.

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 SAFETY INSTRUMENT BIN CARD :
 Bin Card is also called as Cardex, Tag Card etc. The
detailed information about the materials is contained
in the Bin Card.
 Normally Bin Card Consists of the information like
Qty Received, Qty Issued, Minimum Stock Level,
Maximum Stock Level, Recorder Level, Re-Order
Quantity, Closing Stock, Opening Stock etc.
 Bin card is a record of receipt and issue of materials
Quantity of store received is entered with receipt
column and the quantity of store issued is recorded in
the issue column of Bin Card. Balance of quantity of
stores is ensured after every receipt or issue column
of Bin Card.
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 Bin Card also assists to store-keeper for control of
stock. For each item of stores minimum- level, and
ordering level are shown in the part of the Bin-
Card.
 A Bin-Card is also known as BIN TAG or STOCK-

CARD and is usually hung-up or placed in shelf,
rack or bin where the material has been kept. Bin-
cards can also be in the form of loose sheets which
can be maintained in a ledger kept in the stores.
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SAFETY INSTRUMENT LOG BOOK
 Safety Instrument Log Book provide following information in
which daily maintenance related technical data including
solved safety related problems filled by technical person:
 Description of the instrument, critical accessories and software;
 Manufacturer's name, Type identification and Serial number;
 Installation qualification (IQ) and operational qualification
(OQ) records obtained from the installer or manufacturer; and
other related material such as instrument service and repair,
warranty information, service contract conditions and
specifications, and equipment manufacturer representative’s
names and telephone numbers.

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Log book also useful to provide information

to technical Engineer / Technician about an
problem of Instrument/ Safety Instrument,
where in more than one numbers of engineer
worked.
It is easy to carry-out the work / execution of
maintenance task for different
engineer/technician who work in changeable
shift duty.
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 SAFETY INSTRUMENT MAINTENANCE INDENT
BOOK: (PHYSICAL, HUMAN RESOURCE)
 Indent book is bunch of Indent slip which is
Order for GOODS/ ASSETS/
INSTRUMENT-PARTS (placed often
through a local or foreign agent of a foreign
supplier) under specified conditions of sale,
the acceptance of which by the supplier (or
the agent) constitutes a contract of sale.
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 SAFETY INSTRUMENT COMPLAINT
BOOK
 Complaint book is a bunch of slip of complaint
form which shows a reason for dissatisfaction
of any Instrument/ Service of Instrument/
Function of Instrument/ Malfunction of
Instrument.
 Complaint book is necessary to identify about
nature of problem in instrument so that
performance of instrument can be improve by
eliminating such a problems from instruments
and its function. Dept of Instrumentation Technology
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Define the terms context to Protection System Maintenance Progra
VERIFICATION :
 A means of determining that the Protection System or component
is functioning correctly and is fit for service.
MONITORING :
 Observation of the correctness of routine in-service operation of
the Protection System or component.
TESTING :
 Application of signals to a Protection System or component
removed from service, to observe functional performance or
output behavior.
PHYSICAL INSPECTION :
 To detect visible signs of component failure, reduced performance
and degradation.

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CALIBRATION :
 Adjustment of the operating threshold or measurement
accuracy of a Protection System measuring element to
meet manufacturer’s specifications or an application
accuracy requirement.
UPKEEP :
 Routine activities necessary to assure that the component
remains in good working order and implementation of
any manufacturer’s hardware and software service
advisories which are relevant to the application of the
device.
RESTORATION :
 The actions to restore proper operation of
malfunctioning components, too.
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LIST TYPES OF PROTECTION SYSTEM
MAINTENANCE PROGRAM [PSMP - 5.2.1 TO
5.2.7] :
MONITORING BY ANALYSIS OF FAULT RECORDS,
PERFORMANCE-BASEDMAINTENANCE PROCESS,
MAXIMUM ALLOWABLE VERIFICATION INTERVALS,
TIME BASED VERSUS CONDITION BASED
MAINTENANCE,
CONDITION BASED MAINTENANCE [CBM]
PROGRAMS,
TIME BASED MAINTENANCE [TBM] PROGRAMS,
OVERLAPPING THE VERIFICATION OF SEGMENTS
OF THE PROTECTION SYSTEM.
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DESCRIBE THE WORKING OF VARIOUS
TYPES OF PSMP 5.2.1 TO 5.2.7 MAINTENANCE
MANAGEMENT:
 An ongoing program by which Protection
System components are kept in working order and
proper operation of malfunctioning
components is restored.
 The protective relay system maintenance and
testing includes the entire protective relay system
consisting of relay inputs, relay sources, the
protective relays, the relay outputs, associated
communication equipment, and control
circuitry.
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Typical maintenance of a protective relay system include the
following maintenance task :
 Verify all relay inputs — voltages, currents, pilot signals, and
control signals.
 Verify individual relay performance, timing, settings, and
accuracy.
 Verify all relay outputs — trips, close signal, transfer trip or pilot
signals, breaker failure initiate, alarms, etc., for all setting groups
if applicable.
 Perform a functional trip test of the circuit breaker.
 Perform a functional test of all auxiliary relays, including lock-
out relays.
 Perform load or in-service tests.
 Perform end-to-end testing where relay scheme is dependent
upon
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quantities- from the other end, such as a line differential. 29
Dept of Instrumentation Technology
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MONITORING BY ANALYSIS OF FAULT
RECORDS:
 Fault record processing systems gather the data and they
search for evidence of component failures or setting
problems hidden behind an operation whose overall
outcome seems to be correct.
 A typical Fault record will verify particular parts of
certain Protection Systems in the vicinity of the Fault.
 For a given Protection System installation, it may or may
not be possible to gather, within a reasonable amount of
time, a collection of internal and external Fault records
that completely verify the Protection System.
•

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MONITORING BY ANALYSIS OF
FAULT RECORDS:
Machine fault can be defined as any change in a
machinery part or component which makes it
unable to perform its function satisfactorily .
or
It can be defined as the termination of
availability of an item to perform its intended
function.
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 Maintenance can be defined as the total

activities carried out in order to restore or
renew an item to working condition, if fault
is there.
 Maintenance is also defined as combination
of action carried out to return an item to or
restore it to an acceptable condition.
 The classification of maintenance according to
timings of action for maintenance is shown in
Table 1.
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 Fault records may verify that the particular
relays that tripped are able to trip via the
control circuit path that was specifically
used to clear that fault.
 A relay or DFR record may indicate correct
operation of the protection communications
channel.
 Furthermore, other nearby protection systems
may verify that they restrain from tripping
for a fault just outside their respective zones
of protection.
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Performance-Based Maintenance
 A performance-based maintenance process may
justify longer maintenance intervals, or require
shorter intervals.
 In order to use a performance-based maintenance
process, the documented maintenance program
must include records of repairs, adjustments,
and corrections to covered protection systems.
 The system owner must regularly analyze these
records of corrective actions to develop a
ranking of causes.
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• Recurrent problems are to be highlighted,
and remedial action plans are to be
documented to mitigate or eliminate
recurrent problems.
• A performance-based maintenance program
requires auditing processes like those
included in widely used industrial quality
systems (such as ISO 9001-2000, Quality
management systems — Requirements; or
applicable parts of the NIST Baldridge
National Quality Program).
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The audits periodically evaluate:

 The completeness of the documented
maintenance process.
 Organizational knowledge of and adherence
to the process.
 Performance metrics and documentation of
results.
 Remediation of issues.
 Demonstration of continuous improvement.
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 PBM method looks at individual relay system
performance for each fault that it is exposed to
and determines appropriate maintenance
requirements based on actual relay
performance.
 PBM method can be used to extend the intervals
between time-based testing. It is based on a
determination that the relay system performed
satisfactorily for a recent event.
 Performance-based testing is most appropriate
for transmission or distribution lines that
experience periodic
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fault operations.
Dept of Instrumentation Technology 54
MAXIMUM ALLOWABLE
VERIFICATION INTERVALS
 The maximum allowable testing intervals and
maintenance activities show how CBM (Condition
based Maintenance) with newer device types can
reduce the need for many of the tests and site visits
that older Protection System components require.
 Periodic maintenance testing is performed to ensure
that the protection and control system is operating
correctly after a time period of field installation.
 These tests may be used to ensure that individual
components are still operating within acceptable
performance parameters ‐ this type of test is needed
for components susceptible to degraded or changing
characteristics due to aging and wear.
Unmonitored:
Applies to electromechanical and analog solid
state protection systems.
 The telecommunications equipment (Category 5
of Table) used with these legacy systems
frequently includes partial or full monitoring
capabilities, allowing longer testing intervals for
that category of equipment 5 years
Partially Monitored
 Applies to microprocessor relays and associated
protection system components whose self-
monitoring alarms are transmitted to a location
where action can be taken for alarmed failures.(7
Years)

Thoroughly Monitored
protection system components that meet partial
monitoring requirements, plus additional monitoring of
alarms and performance measurement values.
 With these additional monitoring actions, the bulk

of the protection system elements that are likely to
fail are monitored continuously or frequently, so that
maximum allowable verification intervals may be
significantly extended.
 Even these additional monitoring steps do not assure
that every possible failure is detected, so infrequent
periodic verification is still required.(10 Years)

Fully Monitored
protection system components in which every
element or function required for correct operation
of the protection system is monitored continuously or
verified, including verification of the means by which
failure alarms or indicators are transmitted to a
central location for immediate action.
 Full monitoring includes all elements of thorough
monitoring.
 For fully-monitored systems or segments,
documentation is required that shows how every
possible failure, including a failure in the
verification or monitoring system or alarming
channel, is detected. ( Continuous Monitoring and
Verification)
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Condition-Based Maintenance (CbM)

 Condition-based maintenance (CbM) refers
to a collection of activities, inspections, tests
and procedures that are performed in
response to the failure or destabilization of
equipment, a machine or a material.
 It focuses on responding to the root causes of
machine or material failure, and dealing
with those issues after problems occur.
 Condition-based maintenance is performed only when a
need arises, typically in response to a deviation from the
normal operation of a machine or piece of equipment.
 CbM is based on using real-time data trends to optimize
maintenance resources. Via continuous monitoring, a
computerized system observes the equipment's health, and
action is taken only when necessary.
 It is dependent on the collection of historical data for the
component in question. Present conditions of the equipment
or material are then continuously compared to a historical
baseline. This baseline is used as a point of reference for
system upsets.
 Challenges of CbM include its high cost, interruptions with
production output when performed in a large processing
facility and the need for specialized personnel to perform
recovery
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 CBM is a maintenance program that

recommends maintenance actions (decisions)
based on the information collected through
condition monitoring process.
• In CBM, the lifetime (age) of the
equipmentis monitored through its
operating condition, which can be measured
based on various monitoring parameters, such
as vibration,temperature, lubricating oil,
contaminants, and noise levels
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 The motivation of CBM is that 99 per cent of
equipment failures are preceded by certain signs,
conditions, or indications that a failure is going to
occur .
 Therefore, CBM is needed for better equipment
health management, lower life cycle cost,
catastrophic failure avoidance etc.

 The heart of CBM is the condition monitoring (CM)
process, where signals are continuously monitored
using certain types of sensor or other appropriate
indicators. Thus, maintenance activities (e.g., repairs
or replacements) are performed only ‘when needed’
or just before failure .
 In general, the main goal of CBM is to perform a
real-time assessment of equipment conditions in
order to make maintenance decisions,
consequently reducing unnecessary maintenance
and related costs. Fig. 5 presents two important
processes of CBM.
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 Time-based maintenance, also known as
periodic-based maintenance is a traditional
maintenance technique.
 In TBM, maintenance decisions (e.g., preventive
repair times/intervals) are determined based on
failure time analyses. In other words, the aging
(expected lifetime), T, of some equipment is
estimated based on failure time data or used-
based data .
 TBM assumes that the failure behavior
(characteristic) of the equipment is predictable.
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• Failure rate trends can be divided into three

phases: burn-in,useful life, and wear-out.
• The TBM technique assumes that equipment
experience decreasing failure rates early in
their life cycle (burn-in), followed by a near
constant failure rate (useful life). At the end
of their life cycles (wear-out), equipment
experience increasing failure rates.

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 The first process of TBM starts with failure

data analysis/modeling.The basic purpose of
this process is to statistically investigate the
failure characteristics of the equipment
based on the set of failure time data
gathered.

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DEPT OF ELECTRONICS and INSTRUMENTATION ENGINEERING

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DESCRIBE THE WORKING OF VARIOUS TYPES OF

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 A Bin-Card is also known as BIN TAG or STOCK-

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Log book also useful to provide information

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 Maintenance can be defined as the total

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The audits periodically evaluate:

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 With these additional monitoring actions, the bulk

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Condition-Based Maintenance (CbM)

 CBM is a maintenance program that

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• Failure rate trends can be divided into three

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 The first process of TBM starts with failure

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