INDEX [oilweb.oilindia.in] · 2016. 3. 10. · 22. Provisions under Clause No. 3.5 of OISD STD 153...

Telecom, Telemetry & Instrumentation Section, Pipeline

pg. 1

INDEX

Description SOP No Page No

1. Monthly Calibration of Instrument PL.ML028.T&I.01. I 2-7

2. Repair of Tank Level Gauge PL.ML029.T&I.02. I 8-13

3. Flow Meter Repairing andOverhauling

PL.ML030.T&I.03. I 14-17

4. Maintenance Jobs. PL.ML031.T&I.04. I 18-23

5. Lead Acid Battery Maintenance PL.ML032.T&I.05. I 24-28

6. Trenching for laying of HDPEducts and Chamber for OFC

PL.ML033.T&I.06. I 29-32

7. Maintenance of OFC on RailwayBridges.

PL.ML034.T&I.07. I 33-35

8. Fusion Splicing of OFC in OIL’sROW

PL.ML035.T&I.08. I 36-38

9. Working at heights (UHF towers,Bridges)

PL.ML036.T&I.09. I 39-41

10. Installation of RCC Chambers inOIL’s ROW

PL.ML037.T&I.10. I 42-43

11. Shifting of RTU 560 at RepeaterStations

PL.ML108.T&I.11. I 44-46


pg. 2

FOUR MONTHLY CALIBRATION OF INSTRUMENTS

Initiated by:

Sri I. Neog, SE (T)I, PHQ

Reviewed by:-1. Sri A.K. Devchoudhury, DyCE(T)I,PHQ.2. Sri N. Lahakar, DyCE(T)I,PS33. Sri Arindam Das, Dy.CE(T)PS14. Sri J.N.Das, Dy.CE(T)PS8.

APPROVED:

Dy.CE(T)I Head(TTI & FC)

CEPL (S&E) Head(PL Ops) GM(PLS)

SOP No: Approval date: Rev. No:

PL.ML028.T&I.01.I 10.01.2012 Initial.


pg. 3

A) SCOPE AND OPERABILITY:The procedures are applicable to the Four Monthly Calibration of Instrumentsactivities carried out as part of periodic maintenance in the Pump Stations,Repeater Stations ,Terminal Stations and other installations of OIL’s Pipelinedepartment by the personnel of Pipeline Telecom Section.

B) SUMMARY OF METHOD:-

Maintenance personnel normally carry out the following jobs during Calibration ofInstruments:

(a) Set points of Pressure, Temperature and Level switches are checked and corrected ifany deviation is found.

(b) Output of Pressure, Temperature and Level Transmitters verified with a StandardInput and corrected if any deviation is found.

C) TOOLS/EQUPMENTS/APPARATUS USED

a) Dead Weight Tester, b) Temperature Calibrator, c) Multi Function calibrator d)Digital Multi meter e) Electric Heater f) Foot Pump g) Tool box containing requiredtools h) Hydraulic Oil i) Analog Multi meter j) Screw Driver set

D) HAZARDS INVOLVED:

a) Electric shockb) High decibel noisec) Fall due to slippaged) Burn due to contact with hot surfacee) Physical injury due to hit by tools

E) STANDARD OPERATING PROCEDURES:-

a) At Engine/Pump/Alternator House

1. The “COLD WORK PERMIT” and permission should be obtained from theInstallation Manager of the Station before carrying out the job. A pit levelmeeting should also be conducted beforehand. All workers shall be apprised ofthese Standard Operating procedures, hazards involved and the same shall bestrictly followed. The job must be carried out in the presence of a CompetentPerson and he has to ensure the above is strictly adhered.

2. The Pump Engine / Alternator for which the calibration of instruments is to becarried out should be stopped by Station Operational Personnel before the start ofinstrument calibration work .


PL.ML028.T&I.01.I 10.01.2012 Initial.


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3. PPE like safety goggles, safety shoe, helmet and gloves should be worn.

4. Required no. of portable fire extinguishers must be kept near work –site.

5. First Aid box should be present at the work site.

6. Mobile phones should be switched off.

7. Ear plugs should be worn due to the high decibel noise.

8. Proper tool bags must be provided for carrying tools to the work site.

9. ‘Maintenance work in progress’ board shall be put up at work-site before thecommencement of the job and the work-site should be cordoned off.

10.Care must be taken to prevent electric shock. Regular check of the electric heatermust be ensured and the junction box should be carefully handled. Beforecarrying the electric heater to the work site it should be tested in workshop. Thewater heater/ calibrator must not be taken to Pump House (Zone 1 area).

10. It should be taken care that wires do not get entangled inside the junction box.

11. All instruments must be calibrated with reference to master / ETDC calibratedinstruments.

12. While carrying out temperature calibration care must be taken while removingthe hot RTD probes from their respective positions.

13. Due to contact with boiling water and heat probes of temperature switch there isa possibility of burn. So extra caution must be maintained while calibratingtemperature switches.

14. While calibrating pressure switches it has to be ensured that valves are properlyclosed so as to isolate the instrument from other pressure inputs except the linevalve that is coming from pressure calibrator.

15. The supply from the RTU to the junction box should be disconnected forcalibration of Pressure Transmitters.

16. Floor should be kept clean from oil etc in order to prevent fall due to slippage..


PL.ML028.T&I.01.I 10.01.2012 Initial.


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17. Proper care must be taken while calibrating so as to avoid injury and damage topersonnel and instrument respectively.

18. Procedure must be repeatedly checked to ensure correct calibration results asper the approved requirement of the particular station.

19. After carrying out the calibration the instruments and other items must berestored back its original condition.

20. After the work is completed, the work and surrounding area must be cleanedand Installation Manager/ Station Engineer should be informed

21. The calibration of all the instruments of whole plant requires many days so the“COLD WORK PERMIT” should be extended accordingly and finally whenthe calibration of all the instruments of whole plant is completed the “COLDWORK PERMIT” should be closed.

22. Provisions under Clause No. 3.5 of OISD STD 153 will be followed.

23. Provisions under Clause No. 4.5.1 of OSHAS 18001, Clause no 4.5.1 of ISO14001 and Clause no. 7.6 and Clause no. 8.23 of ISO 9001 will be followed.

PPE TO BE USED:-

1. Safety shoes2. Gloves3. Safety Helmet4. Ear Plugs5. Safety goggles

b) Instrument Pit Calibration

1. The COLD WORK PERMIT and permission should be obtained from theInstallation Manager of the Station before carrying out any calibration. Allworkers shall be apprised of these Standard Operating procedures, hazardsinvolved and the same shall be strictly followed. The job must be carried out inthe presence of a Competent Person and he has to ensure the above is strictlyadhered.

2. All the running pump engines should be put in “LOCAL” mode and parametersshould be monitored locally by Pump Station Operational Personnel.

3. All those, which are applicable as mentioned in E(a)


PL.ML028.T&I.01.I 10.01.2012 Initial.


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4. Before undertaking any work it must be ensured that there is no accumulatedwater/ oil etc inside the pit.

5. It should be ensured that the process valves are properly closed beforeremoving the instrument’s flanges.

6. Proper care and adequate precautions must be taken while climbing down andup the ladder/ stairs in the pit.

7. Proper care and adequate precautions must be taken while working inside thepit.

8. The field, local control room and PHQ readings of the transmitters shouldmatch with each other. This should be confirmed from Despatch Control Room,PHQ.

9. After the completion of calibration of all the instruments of the Instrument Pitthe Installation Manager/ Station Engineer should be informed and “COLDWORK PERMIT” should be closed.

PPE TO BE USED:-1. Safety shoes2. Gloves3. Safety Helmet4. Safety goggles

c) Repeater Stations

1. All those which are applicable as mentioned in E (a) and E (b).2. All readings should be confirmed from Despatch Control Room, PHQ after

completing the calibration.

PPE TO BE USED1. Safety shoes2. Gloves3. Safety Helmet4. Safety goggles.

d) Terminal Stations

1. All those which are applicable as mentioned in E (a) and E (b).

2. All readings should be confirmed from Despatch Control Room, PHQ aftercompleting the calibration.


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PPE TO BE USED:-

1. Safety shoes2. Gloves3. Safety Helmet4. Safety goggles

F) REFERENCES:-

Industry standards followed for the S.O.Ps are as follows:-

1. S. O. Ps for FOUR MONTHLY CALIBRATIONS :-

i) Point E a.1 :- OISD – STD – 105Point E b.1

ii) Point E.a.23:- Clause No. 3.5 of OISD STD 153

iii) Point E.a.24:- Clause No. 4.5.1 of OSHAS 18001, Clause no 4.5.1 ofISO 14001, Clause no. 7.6 and Clause no 8.23of ISO9001

G) REVISION RECORD

Revision DateDrafted/changed

byDescription of Change


PL.ML028.T&I.01.I 10.01.2012 Initial.


pg. 8

REPAIRING OF TANK LEVEL GAUGE

Initiated by:


Reviewed by:-

5. Sri A.K. Devchoudhury, DyCE(T)I,PHQ.6. Sri N. Lahakar, DyCE(T)I,PS37. Sri Arindam Das, Dy.CE(T)PS18. Sri J.N.Das, Dy.CE(T)PS8.

APPROVED:




PL.ML029.T&I.02.I 10.01.2012 Initial.


pg. 9

A) SCOPE AND OPERABILITY:The procedures are applicable to the maintenance activities carried out for Repairof Tank Gauge in the Pump Stations, Repeater Stations, Terminal Stations andother installations of OIL’s Pipeline department by the personnel of PipelineTelecom Section.


Maintenance personnel normally carry out the following jobs during Repair of TankLevel Gauge:

a) Isolation of Power Supply to Level Gaugeb) Climbing up and down the stairs of the Tankc) Removal of the tank top hatch and drum compartment coverd) Carrying out the repair worke) Putting back of the tank top hatch and drum compartment coverf) Restoration of Power Supply to Level Gauge

C) TOOLS/EQUPMENT/APPARATUS USED

a) Digital Multi meter b) Electronic cards c) Tool box containing required tools d)Asbestos cloth e) Analog Multi meter f) Rope and pulley g) Tool box containingrequired tools h) Screw Driver set

D) HAZARD:

i) Fall due to slippageii) Fall of an object on person workingiii) Fire due to continuous presence of associated gas and probable sparkiv) Toppling of the equipmentv) Electric shockvi) Physical injury due to hit by toolsvii) Oil spillage


a) TOP TANK MOUNTED

1. The COLD WORK PERMIT should be obtained from the Installation Managerof the station before carrying out any repair/maintenance job. A pit levelmeeting should also be conducted beforehand. All workers shall be apprised of

these Standard Operating procedures, hazards involved and the same shall bestrictly followed. The job must be carried out in the presence of a CompetentPerson and he has to ensure the above is strictly adhered.


PL.ML029.T&I.02.I 10.01.2012 Initial.


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2. ‘Maintenance work in progress’ board shall be put up at work-site before thecommencement of the job.

3. Required no of portable fire extinguishers and asbestos cloth must be kept nearwork –site.


5. Proper tool bags must be provided for carrying tools to the work site.

6. While working on top of the Tank at least two nos. of personnel should bepresent.

7. The tank top hatch and drum compartment cover must be opened cautiously.

8. PPE like safety shoe, helmet, gloves, safety belt and goggles should be wornand care must be taken while climbing up and down the Tank stairs and a safedistance should be maintained between two persons climbing up the ladder.


10. Dismantling and fitting must be done very carefully as there may spark due tofall of tools / objects and fire due to associated gas. People are cautioned not tobe present below the roof mounted tank gauge while the tank gaugemaintenance work is in progress.

11. All necessary precautions must be taken as per the manufacturer’s guidelinesfor maintenance.

12. Use of rope pulley must be ensured while lowering and lifting of equipment.The rope and pulley condition should be checked before use.

13. Manual hold must be ensured, while transporting the equipment, to preventtoppling.

14. Tank top platform floor should be kept clean from oil etc in order to preventfall due to slippage.

15. The person carrying out the repairing, calibration and testing job must beskilled / competent. Proper care must be taken while calibrating / mounting etcso as to avoid injury and damage to personnel and instrument respectively.

16. Tank gauge high / low stop and alarm must be placed at specified levels.


PL.ML029.T&I.02.I 10.01.2012 Initial.


pg. 11

17. To prevent electric shock gloves and safety shoes must be worn.

18. It is to be ensured that drum compartment and electronics compartment arenever opened simultaneously in the presence of AC power supply.

19. Before climbing, the condition of the safety belts shall be checked for any signsof damage and must conform to IS Code 3521. Safety belt shall be attached bymeans of a lifeline to a fixed anchor and adjusted to allow a drop not exceeding1.8 mtr in case of fall.

20. After the work is completed, the work and surrounding areas must be cleaned,Installation Manager/ Station Engineer should be informed and COLD WORKPERMIT should be closed.

21. Other relevant clauses of OISD - GDN 192 will be followed.

PPE TO BE USED:-

1. Safety shoes2. Gloves3. Safety Helmet4. Safety Goggles5. Safety Belt

b) TANK BOTTOM MOUNTED

1. The COLD WORK PERMIT should be obtained from the Installation Managerof the station before carrying out any repair/maintenance job. A pit levelmeeting should also be conducted beforehand. All workers shall be apprised ofthese Standard Operating procedures, hazards involved and the same shall bestrictly followed. The job must be carried out in the presence of a CompetentPerson and he has to ensure the above is strictly adhered.



4. PPE like safety shoe, helmet, gloves, safety belt and goggles should be worn.

5. Dismantling and fitting must be done very carefully as there may be spark dueto fall of objects and fire due to presence of associated gas and use of Spark-proof tools to be ensured.


PL.ML029.T&I.02.I 10.01.2012 Initial.


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6. Manual hold must be ensured, while transporting the equipment, to preventtoppling of the equipment.

7. Tank bottom floor should be kept clean from oil etc in order to prevent fall dueto slippage.

8. The person carrying out the repairing, calibration and testing job must beskilled/competent. Proper care must be taken while calibrating / mounting etcso as to avoid injury and damage to personnel and instrument respectively.

9. Tank gauge high / low stop and alarm must be placed at specified levels.

10. To prevent electric shock gloves and safety shoes must be worn.

11. It is to be ensured that drum compartment and electronics compartment arenever opened simultaneously in the presence of AC power supply.

12. The tank top hatch and drum compartment cover must be opened cautiously. Itis recommended to lay an asbestos cloth just below so as to avoid generation ofany spark due to falling object.

13. After the work is completed, the work and surrounding areas must be cleaned,Installation Manager/ Station Engineer should be informed and COLD WORKPERMIT should be closed.

14. Care must be taken while dismantling and fitting of the tank gauge as theremay be falling of objects and fire due to associated gas. Portable FireExtinguishers and asbestos cloth should be carried along with.

PPE TO BE USED:-

1. Safety shoes2. Gloves3. Safety Helmet4. Safety Goggles


PL.ML029.T&I.02.I 10.01.2012 Initial.


pg. 13

F) REFERENCES:-


1. S.O.Ps for REPAIR OF TANK GAUGE:-

i) Point E. a.1 :- OISD – STD – 105Point E. b.1

ii) Point E. a.19 : - IS Code 3521

iii) Point E. a.21: - OISD – GDN 192

G) REVISION RECORD




PL.ML029.T&I.02.I 10.01.2012 Initial.


pg. 14


Initiated by:


Reviewed by:-1. Sri N. Lahakar, DyCE(T)I,PS32. Sri Arindam Das, Dy.CE(T)PS13. Sri J.N.Das, Dy.CE(T)PS8.

APPROVED:




PL.ML030.T&I.03.I 10.01.2012 Initial.


pg. 15

A) SCOPE AND OPERABILITY:The procedures are applicable to the maintenance activities carried out forFlowmeter Repairing and Overhauling in the Pump Stations, Repeater Stations,Terminal Stations and other installations of OIL’s Pipeline department by thepersonnel of Pipeline Telecom Section.

B) SUMMARY OF METHOD:-Maintenance personnel normally carry out the following jobs during FlowmeterRepairing and Overhauling:g) Isolation of Power Supply to Flowmeterh) Diversion of Flow to the stand-by line if it exists otherwise ensure stoppage of

pumping operationi) Isolation of Flowmeter must be carried out by closing the line valves on either

sidej) The process fluid trapped in the spool piece is to be collected after

depressurizationk) Removal of the Flowmeter from the pipeline if necessaryl) Carrying out the repair workm) Putting back of the Flowmeter in pipelinen) Opening the line valves on either side of Flowmetero) Stopping of Flow to the standby linep) Restoration of Power Supply to Flowmeter

C) TOOLS/EQUPMENT/APPARATUS USEDa) Digital Multi meter b) Electronic cards c) Tool box d) Asbestos cloth e) Analog

Multi meter f) Multi Function Calibrator g) Laptop Computer i) Screw Driver set j) Toolbox containing required tools

D) HAZARD:i) Injury due to hit by heavy objectii) Physical injury due to hit by toolsiii) Fire due to associated gasiv) Electric shockv) High pressure release


1. The “COLD WORK PERMIT” and permission should be obtained from theInstallation Manager or the Station Engineer of the Station before carrying outany repair/maintenance job. All workers shall be apprised of these StandardOperating procedures, hazards involved and the same shall be strictlyfollowed.. The job must be carried out in the presence of a Competent Personand he has to ensure the above is strictly adhered.


PL.ML030.T&I.03.I 10.01.2012 Initial.


pg. 16

2. ‘Maintenance work in progress’ board shall be put up at work-site before thecommencement of the job and the work-site should be cordoned off.

3. PPE like safety shoe, helmet and gloves should be worn.

4. The power supply of the connected flow meter must be switched off if it is tobe removed / replaced.

5. In case the flow meter spool is required to be replaced the flow should bediverted to the stand-by line if it exists. Proper isolation of the flowmeter undermaintenance must be done by closing the line valves on either side. Thereafterthe process fluid trapped in the spool piece is to be removed afterdepressurization.

6. Dismantling and fitting must be done very carefully as there may be fall ofobjects and fire due to associated gas. Portable Fire Extinguishers and asbestoscloth should be carried along with.

7. While loading/unloading during transportation there might be injury due to hitby heavy object. Floor and pathways should be kept free of oil , grease etc andtrolleys must be used.

8. Manual hold must be ensured, while transporting the equipment, to preventtoppling of the equipment.

9. The person carrying out the repairing and testing job must be skilled. Righttools must be used and regular check of these tools must be carried out toprevent unnecessary hazards. Tools must be insulated and gloves and safetyshoes must be used.

10. Correct and proper size tools and tackles must be used during the work

11. Fitting back of the flowmeter must be done very carefully. The line valves ofthe flowmeter should be opened. The line valves in the standby line should beclosed. Then power should be restored to the flowmeter.

12. After completion of the work monitoring is required for sufficient duration tocheck for any leakage.

13. After the work is completed, the work and surrounding areas must be cleaned.Installation Manager/ Station Engineer should be informed and Cold WorkPermit should be closed.


PL.ML030.T&I.03.I 10.01.2012 Initial.


pg. 17

F) PPE TO BE USED

1. Safety shoes2. Gloves3. Safety Helmet4. Safety Goggles

G) REFERENCES:-


1. S. O. Ps for FLOWMETER REPAIRING :-

i) Point E a.1 :- OISD – STD – 105

H) REVISION RECORD




PL.ML030.T&I.03.I 10.01.2012 Initial.


pg. 18


Initiated by:


Reviewed by:-

9. Sri A.K. Devchoudhury, DyCE(T)I,PHQ.10. Sri N. Lahakar, DyCE(T)I,PS311. Sri Arindam Das, Dy.CE(T)PS112. Sri J.N.Das, Dy.CE(T)PS8.

APPROVED:




PL.ML031.T&I.04.I 10.01.2012 Initial.


pg. 19

A) SCOPE AND OPERABILITY:The procedures are applicable to the Maintenance activities carried out as part ofperiodic maintenance in the Pump Stations, Repeater Stations ,Terminal Stationsand other installations of OIL’s Pipeline department by the personnel of PipelineTelecom Section.


Maintenance personnel normally carry out the following jobs during Maintenance jobs:

a) RTU Maintenanceb) Rectification of various faults at Engine / Pump/ Alternator Housec) Repair and Testing of various Electronics Modules inside labd) Repairing, Calibration & Suitability testing of various instruments inside

workshop


a) Dead Weight Tester, b) Temperature Calibrator, c) Multi Function calibrator d) DigitalMulti meter e) Electric Heater f) Foot Pump g) Tool box containing required tools h)Hydraulic Oil i) Analog Multi meter j) Soldering station k) Bench Vice l)Screw Driverset

D) HAZARD:

i) Electric shockii) Sharp Edgesiii) Fall due to slippageiv) Contact with hot surfacev) High decibel Noisevi) Physical injury due to hit by tools


a) RTU Maintenance at Pump Stations and Repeater Stations.

1. Permission should be obtained from the Installation Manager or StationEngineer of the station before carrying out any repair/maintenance job. Allworkers shall be apprised of these Standard Operating procedures, hazardsinvolved and the same shall be strictly followed. The job must be carried out inthe presence of a Competent Person and he has to ensure the above is strictlyadhered.


PL.ML031.T&I.04.I 10.01.2012 Initial.


pg. 20


3. The person carrying out the repairing and testing job must be skilled.

4. Proper measures should be taken to prevent any electric hazards. Due to thepresence of 230 / 110 VAC power supply inside panel there can be electricshock. Proper caution must be taken while using meters. Gloves, insulated toolsand safety shoes should be worn.

5. Sharp edges of panels, equipment etc may cause cuts and bruises. Propercaution should be taken in this regard.

6. It should be taken care that the wires inside the cabinet should not getentangled while working. After completion of work proper dressing workinside the RTU must be carried out. All the connected devices must beidentified marked / tagged as per the wiring diagram for easy maintenance andrectification work.

7. Wired connections must be carefully handled.

8. Lugs, terminals, wires, MCBs etc of specified / correct rating must be usedinside panels.

9. After the work is completed, the work and surrounding areas must be cleaned.Installation Manager/ Station Engineer should be informed.

PPE TO BE USED

1. Safety shoes2. Gloves3. Safety Helmet

b) Rectification of various faults at Engine / Pump/ Alternator House.

1. Permission should be obtained from the Installation Manager or the StationEngineer of the Station before carrying out any repair/maintenance job. Allworkers shall be apprised of these Standard Operating procedures, hazardsinvolved and the same shall be strictly followed. The job must be carried out inthe presence of a Competent Person and he has to ensure the above is strictlyadhered.


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pg. 21

2. The person carrying out the repairing and testing job must be skilled.

3. Correct and proper size tools and tackles must be used during the work.

4. Special care must be taken while working inside Pump House, being a Zone 1area.

5. Proper measures should be taken to prevent any electric hazards. Gloves,insulated tools and safety shoes should be worn.

6. Ear plugs should be put in due to the high decibel noise.

7. Both wired and mechanical connections should be carefully handled.

8. Floors should be kept clean from oil etc to prevent fall due to slippage.

9. Due to contact with boiling water and heated probes of temperature switchesthere is a possibility of burn injuries. Gloves and safety shoes are must.

10. After the work is completed, the work and surrounding areas must be cleaned.Installation Manager/ Station Engineer should be informed.

PPE TO BE USED:-

1. Safety shoes2. Gloves3. Safety Helmet4. Ear plugs

c) Repair and testing of various Electronics Modules in laboratory.

1. Installation Manager should be intimated for the job concerned.

2. The job must be carried out in the presence of a Competent Person.

3. Correct and proper size tools must be used during the work.

4. All the repairing and testing of electronic modules must be done as per itstechnical catalogue / manual.

5. Gloves, insulated tools and safety shoes should be worn.


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pg. 22

6. Proper care must be taken while doing soldering works. The soldering rodshould be placed back in the stand each time it is being used.

7. Repaired modules, device must be tested prior to use at actual / originallocation.

8. The modules should be handled carefully to prevent any damage caused bymanual handling.

PPE TO BE USED

1. Safety shoes2. Gloves

d) Repairing, Calibration & Suitability testing of various instruments inworkshop.

1. Installation Manager should be intimated for the job concerned.

2. The job must be carried out in the presence of a Competent Person.

3. All the repairing, calibration and testing of various instruments must be doneas per the procedure mentioned in its technical catalogue / manual suppliedalong with. “Dos and Don’ts”, if any, must be strictly followed.

4. Gloves, insulated tools and safety shoes should be worn.

5. Correct and proper size tools must be used during the work.

6. Proper care must be taken while doing soldering works. The soldering rodshould be placed back in the stand each time it is being used.

7. The modules should be handled carefully to prevent any damage caused bymanual handling.

PPE TO BE USED

1. Safety shoes2. Gloves


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pg. 23

F) REFERENCES:-

1. S. O. Ps for Maintenance Work:-

iii) Point E.d.3:- Clause No. 4.5.1 of OSHAS 18001, Clause no 4.5.1 ofISO 14001, Clause no. 7.6 and Clause no 8.23of ISO9001

G) REVISION RECORD




PL.ML031.T&I.04.I 10.01.2012 Initial.


pg. 24

LEAD ACID BATTERY MAINTENANCE

Initiated by:

Sri K. Chowdhury, SE (T)CS, PHQ

Reviewed by:-

1. Prakritish.Barua, SE(T)PS62. Arindam Das, Dy.CE(T)PS1

APPROVED:

Dy.CE(T)R CEPL (T) Head(TTI & FC)

CEPL (Safety&Env) Head(PL Ops) GM(PLS)


PL.ML032.T&I.05.I 03.12.2011 Initial.


pg. 25

A. SCOPE AND APPLICABILITY:-

The procedures are applicable to the Lead acid battery maintenance activitiesconducted as part of routine/periodic maintenance in the Pump Stations,Repeater Stations, Terminal Stations, Refinery Terminals and otherinstallations of OIL’s Pipeline department by the personnel of PipelineTelecom(Communication Systems) Section.

B. SUMMARY OF METHOD :-

Maintenance personnel normally carries out the following jobs during batterymaintenance:-

a) Cell voltage and specific gravity is checked.b) Lead Sulphate deposition on Terminals and housing, if any, is cleaned.c) Electrolyte levels are topped up .d) Nuts and bolts for Inter Cell Links and Cable joints are tightened wherever

necessary.

C. TOOLS /EQUIPMENT/APPARATUS USED:-

a) Digital Multimeter b) Hydrometer c) Insulated wrench d) Plastic Jug e) PlasticFunnel; f) Distilled Water g) Baking soda h) Petroleum Jelly & i) Emery paper.

D. HAZARDS INVOLVED:-

1. Electrical hazards :-Electric shock due to direct contact with the battery terminals or short circuit ofbattery terminals leading to injury/fatality.

2. Fire and explosion hazards:-Direct contact of the combustible gases (Hydrogen, Oxygen) present inside thebattery room with the source of a naked flame leading to injury /fatality.

3. Chemical hazards:-Skin burn /eye injury caused by spillage /splashing of electrolyte if theymishandle or improperly maintain the rechargeable battery. Acidic fumeinhalation for prolonged period.

4. Other related hazards:-Musculoskeletal disorders resulted from the improper handling of batteries thatare usually heavy, especially during replacing battery cells.


PL.ML032.T&I.05.I 03.12.2011 Initial.


pg. 26

E. SAFE OPERATING PROCDURES :-

1. Before starting the work, proper ventilation of the battery room must be ensured.Windows should be kept open to allow light and air in the room and to expel thehazardous gases. The battery room should be clean, dry & cool, with properlighting & ventilation.

2. Once proper ventilation is made sure, electric lamp can be switched ‘ON’.

3. Exhaust fan of the battery room should always be in running condition.

4. Verification of the circuit polarities should be made before measurement orconnection.

5. In case of dual battery bank, the bank on which maintenance has to be carried outshould be isolated from the power supply / Load

6. In case of single battery bank, before isolating the battery bank the equipmentsmust be connected to one redundant power supply. Only then the battery bankshould be isolated.

7. It must be ensured that vent plug of all the batteries are free from blockage.

8. The work should not be started without checking any inadvertent groundconnection with the battery cells.

9. Measurements: Measurement of Cell Voltage and Specific gravity should bedone 1 hour after the charger is switched off and batteries are put on load. Cellvoltage and Sp. Gravity readings should be noted for all the cells in both thebanks.

10. To prevent shock, two terminals should not be touched at the same time, or anykind of short circuiting with any metallic tools should be avoided. Short-circuitingthe batteries or other electrical parts which may result in a spark, which couldcause an explosion.

11. Battery housing should be observed for any cracks which will lead to leakage ofsulphuric acid. If any cracks are found, the cell should be replaced immediately.

12. Topping up: While topping up distilled water, only plastic funnel should be used.

13. Cleaning of battery and Terminals:- Whitish/greenish Sulphates deposited onthe terminals and battery housing can be cleaned with a clean cloth soaked inbaking soda water solution. Remaining moisture should be dried off by a dry


PL.ML032.T&I.05.I 03.12.2011 Initial.


pg. 27

clean cloth / tissue paper. After cleaning the connection terminals of sulphates, athin layer of petroleum jelly or grease battery terminal protector should beapplied. Rubber gloves should be worn throughout.

14. Nut / bolt tightening: - The cable clamping nuts should be tightened by insulatedwrenches only. If the terminals are loose, the loose contact occurring between thetwo terminals may cause heating at these points. They should also not beexcessively tightened to avoid damage to terminals.

15. Overcharging of the battery, indicated by the excessive bubbling of theelectrolyte, must be avoided.

F. PRECAUTIONS :-

1. There should not be any source of naked flame in the battery room. Smoking isprohibited in the vicinity of batteries.

2. Competent person should supervise the job.

3. Touching of eyes must be avoided while working with batteries. Hands must bewashed with baking soda water solution after carrying out the batterymaintenance work.

4. Additional person should always be present near the personnel working withbatteries who can come to his aid in case of emergency.

5. A bucket of clean, cold water should be kept at the disposal of the personnelworking on batteries, in order to clean their eyes periodically.

6. Plenty of fresh water and soap must be kept nearby in case battery acid contactskin, clothing, or eyes.

7. Baking soda / ammonia neutralizes lead acid battery electrolyte. This may be kepthandy in the battery area as first aid.

8. If acid contacts skin or clothing, it should be immediately washed with soap andwater. If acid enters eyes, immediately eyes should be flooded with running coolwater for at least 15 minutes and rushed for medical aid.

9. The personnel, working on batteries, should wear goggles in order to protect theireyes from acid spillage or gases.

10. Personnel working on batteries should be wearing apron to avoid any acid spillageover their body.

11. Proper wrench with insulated handle should be used to tighten or to loosen thecable clamp nuts.


PL.ML032.T&I.05.I 03.12.2011 Initial.


pg. 28

12. The working personnel should use all the required PPEs.

13. In case to avoid acid related burnings, bicarbonate should be kept ready.

14. While lifting battery cells, the workers should use PPEs like gloves and safetyshoes.

15. No metallic ornaments like rings, bracelets and watches should be worn whilehandling battery cells. A battery can produce short-circuit current high enough tocause severe burns.

16. No metallic parts should be kept on the top of the batteries.

17. Metallic vessel should not be used. Only the use of plastic vessel should bepermitted.

18. Prolonged exposure to the battery should be avoided.

G . PPEs TO BE USED :-

1. Safety glasses/ goggles2. Rubber Gloves3. Apron4. Safety shoes5. Respirator breath mask

H. REFERENCES:-

1. ANSI/IEEE Std 450-1987, IEEE Recommended Practice for Maintenance, Testing,and Replacement of Large Lead Storage Batteries for Generating Stations andSubstations.2. ANSI/IEEE Std 484-1987, IEEE Recommended Practice for Installation Designand Installation of Large Lead Storage Batteries for Generating Stations andSubstations.

I. REVISION RECORD




PL.ML032.T&I.05.I 03.12.2011 Initial.


pg. 29

TRENCHING FOR LAYING OF HDPE DUCTS and RCC CHAMBER

Initiated by:


APPROVED:




PL.ML033.T&I.06.I 22.07.2010 Initial.


pg. 30

I. OPERATIONAL AREAS: OIL ’s Pump and repeater stations , ROW and ROU.

II. ACTIVITY: Trenching to a depth of 1.65m (5.5ft) , laying of two nos HDPE ducts,Cable pulling, Earth filling , installation of RCC Chambers etc.

III. HAZARDS :-

The potential risks in trenches are from caving-in of the trench wall, leading to fatality orinjury. Other risks are falls, injury by shovel, being struck by falling objects (or abackhoe) etc.

IV. STANDARD OPERATING PROCEDURES :-

1) A trench or excavation deeper than 1.2 metres (4 ft) falls under the classification ofconfined space and requires “Confined Space Entry Permit” in the format laid down inthe composite work permit (OISD GDN 105, Annexure II-Hot work/excavation permit)

2) Protection to any excavation is mandatory. An excavation deeper than 1.2 mtr shall beproperly protected by sloping or shoring. Since our Trench depth requirement is 1.65 m(5.5ft), hence sloping or shoring will be required.

3) Sloping is a method to prevent trench collapse; the angle of the slope is determined bythe soil type classification. (45° to be used in our case).

4) Shoring braces one side of the trench against the other using timber etc. and is requiredwhen collapsing soil is encountered during trenching.

5) Excavations adjacent to backfilled areas or subjected to vibration from railroads,highway traffic, or operation of machinery shall have shoring precautions taken inaddition to slope.

6) Safe access/exit shall be provided into trench excavations. An emergency exit like aladder (within 25 feet of a worker) may be provided.

7) In case the trenching continues for more than a day, sloping and shoring shall beinspected daily for damage and defects by the contractor involved in trench work.

8) Every excavation that a worker may be required to enter shall be kept reasonably freeof water.


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pg. 31

9) The stability of a wall of an excavation shall be maintained by stockpiling excavatedsoil or rock or construction materials at a distance from it. The spoil pile shall be kept at adistance of 2 feet or more from the edge of the trench. Materials, rocks, or soil should beprevented from falling into the trench by use of barriers, if needed.

10) Work should be stopped if there is any unsafe condition. Hence,manual digging of atrench that is seen to be caving in should be continued only after adequate sloping orshoring measures are undertaken.

11) Work shall not be performed in a trench unless at least another worker is workingabove ground in close proximity to the trench or to the means of access to it.

12) Adequate barrier/ physical protection, shall be provided at all excavations. All, pits,trenches, etc shall be barricaded or covered. Upon completion, all trenches shall be totallybackfilled.

13) All workers who are or may be involved in excavations or trenching are to receivetraining regarding the above Standard Trenching procedures from the Contractor. Thisis mandatory for all workers regardless of what or how much experience the individualmay have.

14) Slinging and movement of loads above workers shall be prohibited.

16) A First Aid Box shall be provided at the worksite.

17) Trilingual safety signboards regarding notice for open excavation and hazardawareness shall be provided by the contractor at the work sites. The language hierarchyin the states of Assam and W.Bengal shall be:- Regional language (Assamese/Bengali) atthe top, Hindi in the middle and English at the bottom. In the state of Bihar, thesignboards will be bilingual.

18) On completion of job, it must be ensured that the site is left in a tidy, pollution freeand non hazardous condition.

19) Prior intimation should be given to other departments like Electrical, Civil andPipeline Maintenance, before commencement of any excavation work in Pump andRepeater station installation premises.


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pg. 32

V. PPEsTO BE USED:-

1. Safety Helmet:- Most fatalities in caving in of trench occur due to head injuriesbecause of non use of safety helmets. Every worker working in a trench shall beprovided with a safety helmet.

2. Safety Shoes:- Safety shoes shall be provided to all workers working in trenchesfor their foot protection during digging of earth.

I. REVISION RECORD




PL.ML033.T&I.06.I 22.07.2010 Initial.


pg. 33

FUSION SPLICING OF OPTICAL FIBERS

Initiated by:


APPROVED:




PL.ML034.T&I.07.I 22.07.2010 Initial.


pg. 34

I. OPERATIONAL AREAS: OIL’s ROW, OIL’s Pump Stations, Repeater stations,Terminal Stations etc.

II. ACTIVITY: Fusion Splicing of 24 fibers, unarmored Optical Fibers.

III. HAZARD: i) Eye Retina Injury due to Laser radiation.ii) Internal Hemorrhage due to fiber pieces piercing the body and

entering the blood stream.iii) Injury due to sharp tools.

IV. STANDARD OPERATING PROCEDURES:-

1. It shall be ensured that the Automatic Laser Shutdown facility (ALS) is enabled atthe OFC Equipments in Pump/Repeater Stations. If ALS is found disabled at the OFCNodes adjacent to the cut fiber on either side, it should be enabled from either endsthough remote access, before any pre-splicing activity is attempted on the fibers.

2. It shall be ensured that no OTDR ( Optical Time Domain Reflectometer) is keptconnected to any of the fibers at the Pump/Repeater Stations, before attempting towork on the fibers.

3. After splicing is completed, the personnel manning the OFC Nodes shall enable theLasers only after receiving confirmation from the on-site personnel.

4. The following points needs to be taken care off, before any splicing acitivity.

i) A fiber optic power meter to make certain the fiber is dark before working onthem.

ii) No working personnel shall look into the bare fiber under any condition.

iii) Cleaving and Splicing should be done on a black background so as to identifythe bare fiber cut pieces. Black is the best, because it creates a marked contrastbetween the work surface and the bare fiber glass.

iv) Extreme care shall be taken to collect the bare fiber cut pieces after everycleaving action to prevent injury and to dispose them off in an environmentfriendly manner.


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pg. 35

v) Isopropyl Alcohol, used for cleaning of fibers is inflammable and hence shallbe handled with care. A portable fire extinguisher shall be kept ready for anyfire hazard.

vi) Proper designated tools shall only be used for stripping of various layers ofthe OF Cable to prevent bodily injury.

vii) All wastes shall be collected from the worksite after the work is completed

viii) Fiber scraps can get into food or drink ,be swallowed and cause internalhemorrhage. Hence eating and drinking anywhere near the Cleaving andSplicing area shall not be done.

ix) Smoking is prohibited in the Splicing area due to the presence of inflammableIsopropyl Alcohol vapors.


V. PPEs TO BE USED:-

1. Safety shoes2. Safety Glasses with side shields.3. Aprons4. Gum Boots ( for Marshy areas only)5. Safety Helmet

I. REVISION RECORD




PL.ML034.T&I.07.I 22.07.2010 Initial.


pg. 36

STANDARD OPERATING PROCEDURES FOR WORKING AT HEIGHTS

Initiated by:


APPROVED:




PL.ML035.T&I.08.I 22.07.2010 Initial.


pg. 37

I. OPERATIONAL AREAS: Antenna mast tower in Pipeline Pump Stations, Repeaterstations, Refinery/Marketing Terminal stations and AP Communication areas and OFCRailway Bridge crossings.

II. ACTIVITY: Replacement of Aviation lamps, lamp holders, electrical wiring, antennaalignment, tightening of nuts and bolts, lightening arrestor maintenance, earthing , GIPipe/Clamp maintenance & painting on Railway Bridges etc.

III. HAZARD: Accidental fall from heights leading to severe injury / fatality.


1. Only specific earmarked competent personnel shall be allowed to work at heights.2. Before allowing any personnel to work at heights, it shall be ensured that the

Periodic medical test for the concerned rigger has been done as per norms.Documentary evidence to this effect must be recorded.

3. It is mandatory to confirm that the personnel working at heights do not sufferfrom vertigo. Relevant medical records to this effect must be present.

4. Personnel working at heights should not be under any sort of medication that maylead to drowsiness in general and specifically on the date of the job.

5. Under no condition shall any personnel be allowed to work at heights if he/she isfound to be under the effects of intoxication or sleep deprivation.

6. Necessary insurance coverage shall be provided for the personnel who work atheights.

7. The weather conditions must be conducive for working at heights. Under nocondition shall any personnel be allowed to work at heights during rainy ,stormyor other adverse weather conditions.

8. No personnel shall be allowed to work at heights without the proper PPEs likesafety Helmets, safety shoes/other special shoes, safety belt/harness etc.

9. In all towers where there is risk of eagle / kite attack, eye goggles shall beinvariably worn.

10. The condition of the safety belts shall be checked for any signs of damage andmust conform to IS Code 3521. Safety belt shall be attached by means of a lifelineto a fixed anchor and adjusted to allow a drop not exceeding 1.8 mtr in case offall.

11. The ladders and /or scaffoldings shall be in good condition.12. Before ascending any antenna mast tower, electrical AC supply for aviation lamps

shall be disconnected by removal of fuse.13. Rigger shall carry communication equipment like walkie talkie sets with them to

communicate with the supervisor on the ground.14. The walkie talkie batteries must be in fully charged condition before ascending

the tower.


PL.ML035.T&I.08.I 22.07.2010 Initial.


pg. 38

15. Restoration of supply to tower lamps by supervisor shall be done only afterreceiving verbal confirmation via walkie-talkie from the personnel working atheights.

16. Proper tool bags must be provided for carrying tools and drinking water.17. All safety measures to be adopted during execution of above work have to be

explained and fully understood by the personnel working at height and thesupervisor on ground.

18. Other relevant clauses of OISD - GDN 192 will be followed.


1. Safety Belt / Harness2. Safety Helmet3. Safety Shoes/ other type of shoes for safe working at heights4. Eye protection such as goggles against eagle/kite attacks.

I. REVISION RECORD




PL.ML035.T&I.08.I 22.07.2010 Initial.


pg. 39

SAFE OPERATING PROCEDURES FOR WORKING ON RAILWAY BRIDGES

Initiated by:


APPROVED:




PL.ML036.T&I.09.I 22.07.2010 Initial.


pg. 40

I. OPERATIONAL AREAS:- Railway /Highway Road bridges across rivers alongOIL’s ROW

II. ACTIVITY: Replacement of OFC Clamps, replacement/tightening of nuts and bolts,GI Pipe sections, Scrapping and painting of 4” GI Pipes and Clamps, Bridge Inspectionetc.

III. HAZARDS: i) Falling from heights leading to severe injury / fatality /drowning.ii) Collision with Trains leading to fatality.


1) The standard operating procedures and PPEs for working at heights shall be fullyapplicable for personnel working on Railway bridges too and relevant clauses ofOISD GDN 192 shall be followed.

2) Additionally, the following procedures need to be followed:-2.1.Permission from Indian Railway authorities as per laid down procedure shall be

obtained prior to working on any Railway Bridge.2.2.All conditions and stipulations set by the Railway authorities shall be adhered to.2.3.Updated Railway timetable shall be obtained from the competent Railway

authorities and working schedule framed as per the timetable.2.4.The nearest Railway Station, the Bridge signal man and bridge security personnel

shall be intimated prior to commencement of work.2.5.For every team working on a Railway Bridge, there shall be a signal man at either

ends of the bridge. Each signal man shall carry two flags, red and green, foralerting the personnel working on the bridge about the arrival of a train (risk) andbridge clear (safe) condition.

2.6.Inspection / supervising personnel shall walk on the bridge only after crossing ofa train, remain vigilant and coordinate his duration of stay on the bridge, strictlywith reference to the signal men’s directions.

2.7.In case an Inspection/supervising personnel is stranded on a Railway bridgeduring the signaling of a Train’s arrival, he/she shall immediately station himselfon the nearest maintenance platform on the bridge till the train has passed.

2.8. Special precautions need to be taken for open bridges without maintenanceplatforms.

2.9.Under no circumstances, maintenance work on the bridge shall be allowed aftersunset.

2.10. All workers and signalmen shall be apprised of these Standard Operatingprocedures, hazards involved and the same shall be strictly followed. Training andtoolbox meetings shall be carried out invariably,

2.11. First aid box shall be provided at the site.2.12. Inflated air tube with nylon ropes (lifeline) must be present at the site for

saving a drowning victim.


PL.ML036.T&I.09.I 22.07.2010 Initial.


pg. 41

V. PPEs REQUIRED :-

1) Safety Belt/ Harness2) Safety Helmet3) Safety Shoes4) Hand Gloves5) Goggles for eye protection during painting6) Air tubes tied to lifeline rope

I. REVISION RECORD




PL.ML036.T&I.09.I 22.07.2010 Initial.


pg. 42

SAFE OPERATING PROCEDURESINSTALLATION OF RCC SPLICING / LOOPING CHAMBER

Initiated by:


APPROVED:




PL.ML037.T&I.10.I 22.07.2010 Initial.


pg. 43

I. OPERATIONAL AREA: OIL’s ROW

II. ACTIVITY: Placement of RCC Chamber used for OFC Splicing and Looping in a pit.

III. HAZARD: Severe injury due to accidental falling of RCC Chamber on body part.

IV. SAFE PROCEDURES:-

1. Chain and Pulley should be used while shifting the RCC Chamber into the pit dugfor the purpose.2. Proper PPEs like safety shoes/ hand gloves/ Safety Helmet are to be used by thepersonnel.3. First Aid box should be present at the work site.


1. Safety shoes2. Hand gloves3. Safety Helmet

I. REVISION RECORD




PL.ML037.T&I.10.I 22.07.2010 Initial.


pg. 44

RTU 560 SHFTING AT REPEATER STATIONS

Initiated by:

Kamal Das, Sr. E (T) I, PHQ

Reviewed by:-

13. Jayanta Narayan Das, CEPL (T) I, PHQ14. N Lahkar, CEPL (T) TLY, PHQ15. A. K. Devchoudhury, CEPL (T) T & I, PHQ

APPROVED:

CEPL (T) TLY, PHQ CEPL (T) T & I, PHQ Head (TTI & FC)

CEPL (Safety&Env) Head (PL Ops) GGM (PLS)


PL.ML108.T&I.11.I 18.08.2016 Initial.


pg. 45

A) SCOPE AND OPERABILITY: The procedures are applicable to the RTU 560shifting job to accommodate the new RTU under NBPS Up-gradation project at RepeaterStations of OIL’s Pipeline department by the personnel of Pipeline Telecom Section.

B) SUMMARY OF METHOD:-The following jobs will be carried out while shifting the RTU 560.

1) Installation of new RTU base at ground.2) Installation of the new Junction box on the wall at the back side of the existing

RTU.3) Dismantling of the RTU 560 from its existing location.4) Installation and commissioning of RTU 560 at the new location.


a) Electric drill machine, b) Tool box containing required tools, c) Digital Multimeter, d) Screw Driver Set, e) Hammer, f) Cables and connectors etc.

D) HAZARD:

a) Electric Shockb) Physical Injury due to hit by toolsc) Injury due to hit by heavy objectd) Cut by sharp edges of panels, equipment etc.


1) Cold Work Permit from the Installation Manager of the concerned RepeaterStation must be obtained before starting the job. All personnel involved shall beapprised of these Standard Operating procedures, hazards involved etc, in thetool box meeting and the same should be recorded. The job must be carried outin the presence of a Departmental Competent Person and he has to ensure theabove is strictly adhered to.

2) After entering the repeater station, duty despatcher at the MCS shall be reportedand the pneumatic Kidde system shall be locked.

3) For installation of new RTU base at the ground, proper care should be takenwhile using the Electric Drill machine to prevent electric shock. Also while drillingat the tiles/ ground, proper PPEs such as Gloves and Safety Goggles should beused to prevent injuries to hands, eyes etc.

4) Prior to starting the dismantling job of the existing RTU, the following should beensured:i) MCS to be informed regarding the job.ii) Permission to be obtained from Head-Operations for supply cut-off to the

Crude line and NSPL RCM Valves.iii) DC supply to the RTU from the DCDB to be cut off.iv) AC supply to the RTU to be cut off.v) AC supply to the field RCM Valves to be cut off.


PL.ML108.T&I.11.I 18.08.2016 Initial.


pg. 46

vi) Proper illumination to be provided.vii) Proper documentation of the wirings to be prepared.

5) The Junction Box of the crude line RCM Valves at the back side of the RTUpanel should be lowered to a level to accommodate the new junction box. Propermeasures should be taken to prevent any electric hazards. Gloves, insulatedtools and safety shoes should be worn.

6) Before starting the dismantling job of the RTU, wires shall be removed from theexisting TBs of RTU 560 panel after making proper identification tags on eachcable. After marking the cables, glands of the instrument cables shall beremoved.

7) Once the new junction box is placed and the cables are properly marked, thedismantling job of the existing RTU can be started. Sharp edges of panels,equipment etc. may cause cuts and bruises. Proper caution should be taken inthis regard.

8) Before connecting power to the RTU, continuity testing of all the signal cablesshould be ensured as per the documentation.

9) After completion of work, proper dressing work inside the RTU must be carriedout. All the connected devices must be identified marked / tagged as per thewiring diagram for easy maintenance and rectification work.

10) After complete installation, AC supply to the RCM Valves of Crude and ProductLine shall be provided and their operability should be tested in collaboration withOperations personnel.

11) Necessary panel/ chassis earthing to be connected.12) Finally, before leaving the repeater station, the pneumatic Kidde System shall be

unlocked and final clearance to be obtained from MCS.

F) PPE TO BE USED

i) Safety Shoesii) Gloves (PVC & Leather)iii) Safety Goggles

G) REVISION RECORDS


byDescription of

ChangeInitial Release 18.02.2016 Kamal Das -


PL.ML108.T&I.11.I 18.08.2016 Initial.

INDEX [oilweb.oilindia.in] · 2016. 3. 10. · 22. Provisions under Clause No. 3.5 of OISD STD 153...

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