site specific safe operating procedure mechanical … · 3) hazard of falling object during lifting...

SITE SPECIFIC SAFE OPERATING PROCEDURE Mechanical Section: LPG Recovery Plant

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Moderated on 13th

May, 2015

INTRODUCTION:

Mechanical Section of LPG Recovery Plant carries out all the scheduled as well as

breakdown maintenance of Pump, Compressor, Cooling Tower Fans etc.

SOP for the Mechanical Section has been prepared such manner that a new person

also can approach and perform a job safe manner. In this SOP we have tried to

cover all the activities of Mechanical Section giving top priority to the safety of

man and machine. However there are always remaining possibility of improvement

and any new recognized practice, procedure/ method are always welcome. This

SOP should be reviewed at least once in a year.


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CONTENTS:

Chapter 1: Activities of Mechanical Section.

Chapter 2: Hazards & General safety precaution for Maintenance

Jobs.

Chapter 3: SOP of Major Overhauling of Inlet Compressor CM-11.01

Chapter 4: SOP for Major Overhauling of Expander Compressor

EC-12.01

Chapter 5: SOP for Break Down Maintenance of any equipments

Chapter 6: SOP for Daily Plant Checking.

Chapter 7: SOP for Inspection and Testing of Overhead Travelling

Crane.

Chapter 8: SOP for Major Overhauling of LPG Dispatch Pump.

Chapter 9: SOP for Testing SRV.

Chapter 10: SOP for Maintenance and Inspection of LPG Storage vessels.

Chapter 11: SOP for Maintenance and Inspection of NG Storage vessels.

Chapter 12: SOP for Hot job in Hazardous area.


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CHAPTER –I

ACTIVITIES OF MECHANICAL SECTION

The Mechanical Section of LPG department is responsible for:

Maintain the plant availability to achieve MOU target Maintenance of all rotary and stationary equipment of the LPG plant to keep

them in proper working conditions.

Execution of various contract jobs under the department related to maintenance of the plant.

Planning of maintenance activities for annual plant maintenance. Spare parts/Inventory management for maintenance of the plant.

Following are the objectives of the section:

To reduce the cost of the maintenance activity compared to previous year. To keep the minimum MTBF (Mean Time Between Failures) of critical

equipments for achieving the MOU target. To keep good relation and cooperation with different sections of LPG

department.

To keep good relation and understanding with other departments of the company.

To keep close watch on various activities so that there is judicious use of assets and consumables.


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CHAPTER –II

GENERAL SAFETY PRECAUTION FOR MECHANICAL

SECTION

2.01 Toolbox Meeting must be done everyday after job allocation /

before starting of job.

2.02 Special PPEs relevant to the specific job must be used while

doing the job. Safety shoes must be used all the times.

2.03 Inspect each tool for damage before use. Get instruction from

your Supervisor, if you are unfamiliar with a tool.

2.04 Periodic (once in two months) tool checking must be done and maintain

tools register. Never use any defective tool. Always use the right tools for

the job.

2.05 Ensure that power tools are grounded or double insulated in case of

electric tools.

2.06 Keep all tools clean. Keep the tools at their proper storage location.

2.07 Electrical Permit to Work (EPW) must be obtained from Electrical

Engineer before starting of any rotating equipment job.

2.08 Do not keep / throw waste materials like oily jute, paper, grease, iron

particles etc. here and there around the work place. Keep them in the

designated storage bin.

2.09 Un-authorized persons should not be allowed in the working area.

2.10 Outsiders / Trainees / Visitors should be always under supervision.


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CHAPTER- III

SOP of Major Overhauling of Inlet Compressor CM-11.01

Note: Major overhauling done once after 5/6 years in presence of experts from

the OEM.

3.1 Pre job servicing of CM-11.01

ACTIVITY 1. Plant should be S/D Condition.

2. Two nos. inlet and out let valves at LPG off take point should be closed.

3. Insert Spade at Plant Inlet (SDV-213) up stream and plant out let (SDV-364) Upstream

4. Drain the lube oil after cooling down till emptied and mark properly.

5. De pressurize the compressor till atmospheric Pressure.

6. Remove all accessories lines from the compressor.

HAZARDS

1) Hazard of entry gas.

2) Pressurized oil, gas may cause of accident.

3) Oil spillage.

PPEs

Safety shoe, Dungaree , Hand gloves, Helmet etc.

PREPARATION

1) Get Ready proper size spade, proper tools, drums &

bucket to collect drained lube oil. 2) Wear PPEs such as hand gloves and helmet before

starting the job

STEP BY STEP

1) Get clearance from operation in charge.

2) Drain the oil at low speed by throttling the isolation valves.

3) Keep the drained oil in drum up to 85% of drum level.

4) Mark the drum as DRAINED OIL with date mentioning grade– SERVO PRIME 46 or Servo FRIDZE 68


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PROCEDURE 5) If drained oil from compressor gear box then it will be

SERVO PRIME 46 6) If drained from compressor sump then mark as

SERVO FRIDZE 46

3.2 Servicing of CM-11.01 to be followed strict instruction

mentioned in York Compressor Manual

ACTIVITY

1. Removing of Suction Line 14’’ piece. 2. Removing of Discharge line 12’’piece.

3. Removing of Coupling Hub from the Drive Shaft with special Wrench provided from Original Equipment

Manufacturer (OEM) 4. Removing the Drive shaft from main compressor.

shaft with special Wrench provided from OEM. 5. Removing of Drive End Main Bearing.

6. Removing of Drive End Oil Seal Assembly. 7. Removing of Oil pump, Thrust Bearing and Reservoir

End main bearing. 8. Removing the oil reservoir, Oil Seal and Balance

Piston Seal. 9. Removing the oil reservoir.

10. Lifting Top of Compressor Casting.

11. Removing the pre rotation vane mechanism. 12. Removing of Diffusers.

13. Removing of inter stage Labyrinth Seals. 14. Removing of Rotor.

15. After removing all parts cleaned and replace the damaged parts if required and fit back carefully as

per advice by OEM experts.

HAZARDS

1) Hazard of sudden injury.

2) Hazard from dust etc. to the eye / ear.

3) Hazard of falling object during lifting items by Over Head Crane.

4) Hazard of falling down from platform which was made for convenient to carry out the job.

PPEs

Safety shoe, Dungaree , Hand gloves , Helmet

PREPARATION

1) Check the platform that its wooden planks are


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fasten properly.

2) Use proper tools supplied by OEM. 3) Wear hand gloves and helmet before starting the

job. 4) Take ready air supply hose with proper isolation

valves.

STEP BY STEP PROCEDURE

1) Listen the instruction /advice by OEM experts. 2) Take out the dismantled parts carefully, place at

properly and cover the same. 3) Clean the parts by rubbing cloth with cleaner and by

blowing air. 4) Hold the air hose terminal.

5) Open the valve as required. 6) Apply air jet to the equipment as required.


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CHAPTER IV

SOP of Major Overhauling of Expander- Compressor EC-12.01

4.0 Pre job Overhauling (Major) of Expander-Compressor EC-12.01

Disassembly Sequence

COMPRESSOR CASE and BEARING HOUSING PIPE (NB: To follow DATA BOOK VOL. II Expander/Compressor Manual)

ACTIVITY

(a) Control AC Power and Lube OIL Pump, OFF

(b) Expander Inlet Block Valve Shut. (c) Disconnect lube piping, Drain Line and Seal Gas Lines.

(d) Remove Tachometer. (e) Disconnect Temperature probe cable.

(f) Remove Thrust Equalizer. (g) Unbolt Compressor – Process Piping.

(h) Removal of Compressor line piece -Inlet and out let. (i) Removal of Compressor Follower

(j) Removal of Bearing Housing Piping.

HAZARDS

Hazards of finger/ hand injury Hazards of falling Pipe piece on body and injury

PPEs

Safety shoe, Dungaree, Hand gloves , Safety Helmet etc.

PREPARATION

All person involved should be with PPEs Choose the location at which item will be placed.

Place the hand cart/ trolley at the designated location.


Place the Overhead Travelling Crane at suitable location so that the hoist does not require pulling action while lifting.

Check the fastening of sealing rope properly. Item with the hoist should move at minimum height and

guided by at least one person.


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4.1 Major Overhauling of Expander-Compressor EC-12.01

Disassembly Sequence BEARING HOUSING ASSEMBLY (NB: Before attending go through DATA BOOK VOL. II Expander/Compressor

Manual)

ACTIVITY

1. Nose Cone Expander removal

2. Nose Cone Compressor removal

3. Center Stretch Rod removal.

4. Shaft Key Expander removal.

5. Expander Wheel with special tools puller.

6. Shaft Key Compressor removal

7. Compressor wheel with special tools puller.

8. Compressor Wheel Seal with jack screw holes

provided.

9. Compressor Shaft Seal Insert with jack screw holes

provided.

10. Compressor Shaft Seal with jack screw holes

provided.

11. Compressor Shaft Seal Ring with Puller.

12. Expander Wheel Seal with jack screw holes

provided.

13. Expander Shaft Seal Insert with jack screw holes

provided.

14. Heat Barrier with jack screw holes.

15. Expander Shaft Seal Ring with Puller.

16. Shaft Removal.

17. Compressor Bearing.

18. Temp. Probe Exp. Bearing.

19. Expander Bearing.

HAZARDS

Hazards of finger/ hand injury. Hazards of falling Pipe piece, tools on body and injury.

PPEs Safety shoe, Dungaree, Hand gloves Helmet etc.


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PREPARATION

1. Use proper tools provided by OEM.

STEP BY STEP

PROCEDURE

1. Remove parts serially as mentioned in above activity

with special tools. 2. Keep all removed parts at clean surface to avoid

contact of dirt particles.

4.2 Major Overhauling of Expander-Compressor EC-12.01

Assembly Sequence BEARING HOUSING ASSEMBLY (NB: Before servicing go through DATA BOOK VOL. II Expander/Compressor Manual)

ACTIVITY 1. Cleaning of parts. 2. Checking of parts.

3. Replace defective parts. 4. To assemble reverse the above mentioned disassembly

sequence- 4.1 Activity.

HAZARDS

1. Hazard of finger injury. 2. Hazard of falling heavy material,tools on the body.

3. Hazard of ignition.

PPEs Safety Helmets, Safety shoe, Dungaree, Hand gloves

PREPARATION

1. Ready with proper gasket

2. Ready with digital caliper scale. 3. Use Non Sparking Tools.

STEP BY STEP

PROCEDURE

1. Clean the disassembled spares and bearing housing pipe assembly with diesel or other recommended cleaning agents

and take out unwanted particles by smooth rubbing. 2. Dry up the spares.

3. Check Axial play of shaft- reliable limit ( 0.0006’’ to 0.0016’’)

Note:

(a) Use lubricant on all “O” rings. Insure compatibility Insure compatibility of lube with process gases.

(b) Secure with loctite (under the head only) of each fastener.

Bearing bolts must be cleaned, prepped with loctite


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compound and torque uniformly.

(c) Use new gasket and “O” ring kits. (d) The Expander wheel and compressor wheel must be

torque in the following manner: I. Torque both nose cones to 90 ft. lbs.

II. Loosen Nose cone both ends, and torque both to 9o ft. lbs.

(prior to torque nose cones, apply a small amount of loctite to stretch bolt thread)

(e) Go through DATA BOOK VOL. II Expander /Compressor Manual for fasteners of different materials.

(f) Carry out Final fastening after measuring the clearance

of Bearing Housing (where Expander and compressor wheel fitted with) in between expander casing and compressor

casing as follows:

Expander Side:

(I) Insert Bearing Housing to expander casing by temporally fixing lead wire (measure diameter= x) at

expander wheel blades. (II) Take out Bearing Housing and take lead wire

measurement (Av. Measurement=Y) (III) Difference (X-Y) = Z this will be the gasket side for

expander side. (IV) Minimum Clearance = Av. Clearance- Axial Play

(V) Total clearance= Z + Minimum clearance.

Compressor Side:

(I) After placing Bearing Housing, fit lead wire (Measure

Diameter=M) at compressor wheel blade. (II) Insert Compressor casing.

(III) Take out compressor casing and take measure lead (Av. Measurement = N)

(IV) (M-N) = O this will be gasket size for compressor side.

(IV) Minimum clearance=Av. Clearance - Axial play (V) Total clearance= O + Minimum clearance.

(g) Fit the removed accessories/pipes again.


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CHAPTER V

SOP for Break Down Maintenance of any equipments

Break Down Maintenance of any equipments

ACTIVITY

1. Power supply isolation.

2. Depressurization if required. 3. Decoupling.

4. Lifting of equipment. 5. Transfer to workshop if overhauling is not possible at site.

6. Rectification of problem. 7. Fitting back of equipment.

8. Power up and trial run.

8. Report generation if found OK and update in history card.

HAZARDS

1. Hazard of finger injury.

2. Hazard of falling heavy material, tools on the body. 3. Hazard of spark.

PPEs

Safety Helmets, Safety shoe, Dungaree, Hand gloves etc.

PREPARATION

Electrical Shut Down of equipment if required. Lifting device or crane service ready if required.

Be ready with spares. Non sparking tools should be ready as per requirement if

work is in hazardous area.


1. Take clearance from Operation and Electrical Section. 2. Take Shut Down of equipment by following electrical

standard procedure to attend the equipment trouble. 3. Isolate Suction and Discharge valve of the equipment if

required. 4. Depressurize the system in presence of Shift Engineer.

5. Check the Equipment and clean it. 6. Decouple the equipment.

7. Replace the defective parts if possible at site otherwise bring those to workshop.

8. Use lifting device or crane service to lift the equipment.

9. Reassemble the equipment. 10. Alignment of the equipment is compulsory.

11. Inform the Electrical section to provide power. 12. Pressurize the system if required

13. Take a trial run. 14. Generate the report if it is OK and update in history card.


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CHAPTER VI

SOP for Daily Plant Checking.

Daily Plant Checking

ACTIVITY 1. Monitor the equipment Daily. 2. Record the findings at LPG (M)2 form.

3. Top up lube oil and grease up where required. 4. Inform concerned Engineer immediately if any

abnormality is found.

HAZARDS 1. Hazard of head injury. 2. Hazard of falling down.

PPEs Safety shoe, Safety Helmets etc.

PREPARATION

1. Keep ready of Daily Plant Check List Form LPG (M) 2.


1. Check each running equipment for smooth running for all working days as per check list, : Form LPG(M) 2

2. Check lube oil level, fill/observe vibration & sound and check other parameters as per check list and record.

In case of any abnormality, inform concerned officer(s) immediately.

3. Top up lube oil and attend any loose fitting of running and

standby equipment as necessary. In case if shut down is required, inform concerned officer(s) before taking up the

job. 4. Attending person puts his signature on the form LPG (M) 2

after duly filled and submits the same to Sectional J.E.-II (M) who puts his signature after going through it and sends to the

5. Sectional Engineer checks, signs and put in respective file. Abnormality, if any, is attended at the earliest on priority

basis.


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CHAPTER VII

SOP for Inspection and Testing of Overhead Travelling Crane.

Inspection and Testing of Overhead Travelling Crane.

ACTIVITY

1. Yearly checking of Over Head Travelling Crane by Govt. approved competent person.

2. Replacement of defective parts. 3. Greasing up.

4. Load check by weight. 5. Get certificate from Govt. approved competent.

6. Mark the Crane - Next testing due date.

HAZARDS

1. Hazard of injury. 2. Hazard of falling objects.

PPEs Safety shoe, Safety Helmets Hand Gloves, Safety Belt and

Dungaree.

PREPARATION

1. Take cold permit as per OISD-105.

2. Make ready weight up to 13 MT and collect from LPG Filling Plant.

3. Wear safety belt during climbing to Overhead Travelling Crane

STEP BY STEP

PROCEDURE

1. The inspection and testing of lifting tools and tackles are to be tested and certified every year by a competent person as per statutory norms. The job is carried out through contract. 2. The lifting tools and tackles are physically checked by the competent person for any deformation /damage etc. and the defective parts are replaced / repaired. 3. The capacity of the lifting tools are checked and confirmed. 4. The tools are then tested at different loads by putting the loads stage-wise and the same is checked by the competent person for any abnormality:

(a) 25% of rated capacity, (b) 50% of rated capacity, (c) 75% of rated capacity, (d) 100% of rated capacity load.

5. In case of any abnormality, it is not tested with further load till it is rectified. 6. The tested weight is then stamped on the tools and necessary certificates are issued by the competent person for record. 7. The persons involved in the above process are provided with safety appliances as required.

8. Mark the Crane - Next testing due date.


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CHAPTER VIII

SOP for Major Overhauling of LPG Dispatch Pump.

Major Overhauling of LPG Dispatch Pump

NB: Overhauling is done in presence of OEM Expert.

ACTIVITY

1. Power supply isolation.

2. Depressurization of the sump. 3. Blind/ spade insertion.

4. Pump cover opening. 5. Pump Lifting and placing.

6. Overhauling.

7. Fit it back. 8. Pressurize the sump.

8. Leak test. 9. Power Up the equipment

10. Trial Run 11. Handed over to operation.

12. Report generation.

HAZARDS

1. Hazard of injury.

2. Hazard of falling objects. 3. Hazard of spark.

PPEs Safety shoe, Safety Helmets, Dungaree & Hand gloves

PREPARATION

1. Make the over head travelling chain pulley block ready. 2. Make the sealing rope to fasten the lifting items ready.

3. Make non sparking tools ready.

4. Make fire fighting extinguisher near to work site ready. 5. Alert the operating personnel.

STEP BY STEP

PROCEDURE

1. Take the equipment shut down from electrical section following standard shut down procedure.

2. After getting clearance from electrical section, contact shift engineer/ operating staff for isolating the suction, discharge and vapour return line of the pump . Shift engineer / operating staff will de-pressurize the system by opening the drain valve of barrel of the pump to flare.

3. After ensuring de-pressurization, insert proper size blind / spade at flanges of Suction, Discharge and Vapour line and tighten the nuts and bolts.

4. Disconnect the vapour line.

5. Remove the discharge bend from the unit with the help of over head


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chain pulley block after loosening the nuts and bolts.

6. Open the nuts and bolts of the top cover of pump. Slowly lift the cover (where pump and motor are mounted) with the help of over head chain pulley block. Use proper non sparking sealing at *J* hook of pulley to resist the load and to avoid safety hazardous.

7. Take the pump to the open space near to the Mercaptan system area with over head travelling rail.

8. Slowly lower down the equipment on the ground, check the unit and rectify it as per requirement to satisfaction of CE(M) or his representative.

9. After rectifying the trouble of the unit , assemble the pump & motor at the barrel by lifting it with chain pulley block and normalize the system.

10. Pressurize the barrel by opening the vapor return line of pump in presence of Shift engineer / Operating Staff.

11. Check the leak at flanges with soap water solution.

12. Take a trial run.

13. If it is found o.k, generate the report and submit the same.


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CHAPTER IX

SOP for Testing SRV Testing of SRV

ACTIVITY

1. SRV of Plant area, Mounded Bullet Area, LPG Dispatch Line and LPG Filling plant area are tested yearly.

2. Generally SRV of Plant area are tested in Annual Overhauling if trouble does not arise at normal running

condition and as statutory requirement.

3. The SRVs which are difficult to take out from equipment is tested at field with the help of nitrogen cylinder regulated

pressure, others are taken to workshop to test at Test Bench with nitrogen regulated pressure.

4. Certified by a competent person and records are maintained.

HAZARDS 1. Hazard of finger injury. 2. Hazard of falling object.

3. Hazard of Spark.

PPEs

Safety shoe, Dungaree, Hand gloves ,Helmet

PREPARATION 1. Calibrate the pressure gauge.

2. Take clearance from Shift Engineer (operation)

STEP BY STEP

PROCEDURE

Testing of Safety Relieve Valve at Test Bench

Testing of Safety Relieve valve is done at test bench by allowing nitrogen to blow through the SRV and the pressure at

which the spring lifts to open the valve for releasing the gas is recorded. This pressure is known as set pressure of the valve.

Adjustment of the spring pressure is done by adjusting the screw provided on the top of the spring hub. The pressure at

which the SRV is required to be blown off is tested for 2 to 3 times to ensure proper functioning of the valve and

correctness of the set pressure.

Testing of Safety Relieve Valve at site

Inform the plant engineer before taking up the job. Close the isolation valve at the downstream of the SRV to be

tested. Open the vent valve (normally 15 mm size) of the spool piece


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provided between the SRV and isolation valve and ensure that

there is no leakage from the isolation valve. In case of leakage through the isolation valve, put a blind spade at downstream

of the valve. Connect the SS tubing with other fittings to the vent valve.

Connect the Nitrogen gas cylinder with regulator to the system.

Two calibrated pressure gauges of suitable range should be used, one at the outlet of the nitrogen cylinder and one near

the SRV. Open the cylinder valve and pressurize the system slowly with

the help of the regulator. Check the set pressure to operate

the valve. Test for at least three times. Adjust the set pressure if required. Recheck the test pressure

after tightening of the lock nut. Close the cylinder valve and slowly depressurize the system.

Remove tube with fittings. Close the vent valve and ensure opening of the isolation valve. Operating wheel/lever of the

isolation valve should be locked at open position.

Note: It is very important to calibrate the testing pressure gauges everyday before starting of the testing job. Certificates

are issued by competent person in case of SRVs of LPG storage vessels as per statutory norms.

Record : Safety Relief Valve Testing Registers

(LPG/MAINT/R11 & R12) & File in LPG/Maint(M)-04 and LPG/Manit(M)-27


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CHAPTER X

SOP for Maintenance and Inspection of LPG Storage vessels.

Maintenance and Inspection of LPG Storage vessels

ACTIVITY

1. The job “Servicing, Inspection and Testing of LPG storage Vessels as per SMPV (Unfired) Rules and OISD Std-128” is carried out through an inspection agency approved by Chief Controller of Explosives (CCE) .

2. The job is carried out through outsourcing contract.

3. The contractor carries out the jobs to the satisfaction of CE (LPG) or his representative and submits certificates as per SMPV (Unfired) rules.

HAZARDS


2. Hazard of falling objects. 3. Hazard of Spark.

4. Hazard due to absence of Oxygen (O2) inside the vessel

during entry.

PPEs Safety shoe, Safety Helmets Hand Gloves and Dungaree.

PREPARATION

1. Take cold permit and hot permit as per guide line OISD-

105.


1. Dispatch the LPG liquid to filling plant to the minimum level of Mounded Bullet or tripping of pump due to suction lose whichever is earlier. 2. Isolate the bullet by closing suction valves ( 8’’ & 10’’) except ROV, Product In 4’’ including ROV and 4’’ Vapour In including ROV. 3. Depressurization of bullet. : (a) Open the Sample Testing 1’’ valve and the remaining liquid will be sent to Flare Pit via. Knock Out Drum. (b) Fit a Vent Line of size 1’’ at top of bullet and release the LPG vapour to atmosphere by throttling ball valve. (c) After depressurization close the Sample testing valve. 4. Inform Instrument section in charge to isolate the measuring instruments which are attached at bullet. 5. Fit a Fire hose at sample line and feed hydrant water into the bullet maintaining pressure at 5 kg/cm2 or as per requirement by observing pump load. 6. Fill hydrant water till coming out through the 1’’ vent line at top of


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bullet. 7. Drain the filled water slowly from the bottom, keeping vent line open at the top. 8. After complete draining of water, measure the oxygen % inside the vessel and arrange to release air through a line inside the vessel so that the oxygen % inside the vessel becomes less 19.5% (by volume). 9. Maintain Work permit as per guide line OISD-105. 10. Hand over the bullet to carry out required test by contractor. 11. Arrange proper illumination (FLP based) inside the vessel. Required Test are as follows: a) THK -- Ultrasonic Thickness Test. b) MPT -- Wet Fluorescent Magnetic Particle Test. c) UFD -- Ultrasonic Flow Detection. d) HARD -- Hardness Test. e) Others if required f) Hydro test. 12. After completion of tests, refit the covers with new gaskets and remove inserted spade. 13. Pressurize the bullet up to 5.0kg/cm2 with LPG vapour and purge the same. 14. Purge till oxygen become nil. 15. Carry out Leak test by Soap solution. 15. Ready to reuse the Bullet.


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CHAPTER XI

SOP for Maintenance and Inspection of NG Storage vessels.

Maintenance and Inspection of NG Storage vessels

ACTIVITY

1. The job “Servicing, Inspection and Testing of NG storage Vessels as per SMPV (Unfired) Rules and OISD Std-128” is carried out through an inspection agency approved by Chief Controller of Explosives (CCE) .

2. The job is carried out through outsourcing contract.

3. The contractor carries out the jobs to the satisfaction of CE (LPG) or his representative and submits certificates as per SMPV (Unfired) rules. 4. Making Scaffolding with bamboos. 5. Evacuating and depressurizing the vessels. 6. Isolate the process pipes, dispatch lines with help of inserting blind , release of Hydraulic Valves and make it not in operating condition. 7. Injecting water and remove vessel man hole and breather valve to make gas free. 8. Vessel entry to carry out the inside vessel cleaning and NDT. 9. Radiography Test. 10. Hydro test. 11. Fitting of accessories to the vessel after test and put the vessel on line. Reference : SMPV(Unfired) Rules and OISD Standard-128

Records : Records in relevant contract file and in specific file of a particular LPG storage vessel.

Reference : SMPV(Unfired) Rules and OISD Standard-128

Records : Records in relevant contract file and in specific file of a particular LPG storage vessel.

HAZARDS


2. Hazard of falling objects.


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3. Hazard of Spark.

4. Hazard absence of Oxygen (O2).

PPEs Safety shoe, Safety Helmets Hand Gloves and Dungaree.

PREPARATION

1. Take cold permit as per OISD-105.

STEP BY STEP

PROCEDURE 1. Transfer NG from SV18.06 to CTF or F/Plant by running one

condensate dispatch pump.

2. Monitor LT reading in DCS, so that it attains “0%” level, as

well as the pump should loss the suction. Towards the end of

emptying process, throttle the discharge valve of pump.

3. Once level becomes “0%” then close isolation valve of suction

line-6”(1), Product filling line-1.5”(5), pump return line-1.5”(4), &

drain line-1.5”(3).

4. Open the flange at the downstream of drain point (12) in

product filling line-1.5” (4) and collect remaining condensate from

tank to drum.

5. Once ensured that there is no condensate in the tank then close

ROVs of product filling line-3” (2) and suction line-6” (1) by

closing the isolating valves of hydraulic lines.

6. Close the isolation valve-6” (6) of the suction line of other tank

(i.e. SV 18.07).

7. Put one blind at the downstream of isolation valve suction-6”

(1) line of SV 18.06.

8. Put one blind at the downstream of drain line-1.5” (3).

9. Put one blind at the downstream of Product filling line-1.5” (5).

10. Put one blind at the downstream of pump return line-1.5” (4).

11. Isolate/disconnect all instrumentation system from the tank

SV18.06.

12. Make arrangement for filling water into the tank SV18.06 from

hydrant system through the drain point (12) of product filling line.


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13. Arrange to overflow of water though the (½)” line at the

overhead of the Tank.

14. Then allow overflowing of water from the tank though the

manhole, which will help in degassing the vessel properly.

15. Drain all water.

16. After complete draining of water, measure the oxygen % inside

the vessel and arrange to release air through a line inside the vessel

so that the oxygen % inside the vessel becomes 21% (wt/wt) or

more.

16. Make arrangement to clean the sludge from the tank SV18.06

by removing the spool in between flange and isolation valve (1”)

of suction line.

17. Make arrangement to check the presence of O2 / flammable gas

inside the vessel before entering into it.

18. If sufficient O2 is not available inside the vessel, provide air to

the vessel by connecting one air supply line from outside (i.e.

Central air supply or deluge system).

19. Arrange for illumination (FLP standards) system inside the

vessel.

After Cleaning and Inspection, carry out the following jobs:

(a) Check thoroughly, so that no materials tools, equipments left

inside the vessel.

(b) For boxing up of the vessel follow the reverse procedure of

blinding the vessel.

© Purge the vessel with residue gas from the plant till O2 level

goes below 0.5%.

(d)However at the time of commissioning of the vessel review will

be done.


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CHAPTER XII

SOP for Hot job in Hazardous area. Hot job into Hazardous area

ACTIVITY 1. Identify the nature of Job. i.e. Hot job in hazardous area,

Entry to confined space, Vehicle Entry and Excavation of

Works. 2. Issue of Hot Work Permit.

HAZARDS 1. Hazard of spark. 2. Hazard of electrical live wire in side earth.

3. Hazard of Oxygen level deficiency.

PPEs Safety shoe, Safety Helmets, Dungaree, Safety Goggles,

Breathing Mask.

PREPARATION

1. Take hot work permit to execute the job.

STEP BY STEP

PROCEDURE

Hot Work in Hazardous Area:

1. Make a sketch to identify the location and point of hot job i.e. gas cutting, welding, grinding and chipping work.

2. Measure the presence of flammable/ hazardous gas by Quality Control Lab personnel or competent person and take

the test report. 3. Take the hot job permit from Installation Manager by

enclosing the above said relevant documents. 4. Alert the operation shift Engineer about the job.

5. Confirm the Fire water Pump “AUTO” position. 6. Make available of Fire Extinguisher and fire hose nearby

hot job area. 7. Alert the Fire Service Dept. about hot job.

8. Measure the presence of flammable gas at an interval that

escaped gas may available.

Entry to confined space, Vehicle Entry and Excavation


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Job:

1. Take the necessary action as specified action mentioned in

Hot Work Permit Format carefully.

site specific safe operating procedure mechanical … · 3) hazard of falling object during lifting...

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