mechanical maintenance section index - oil india · mechanical maintenance section pg.1 index...

Mechanical Maintenance Section

pg. 1

INDEX

Description SOP No Page No

1 Withdrawal and refitting of Main Bearingand Thrust Bearing of Allen Engine.

PL.ML047.MM.01. I 2 – 5 & 42

2 Allen Engine exhaust valve overhauling. PL.ML048.MM.02. I 6 – 9 & 43

3 Cylinder Head maintenance of AllenEngine.

PL.ML049.MM.03. I 10-13 & 44

4 Aldrich Pump Manifold valvesOverhauling.

PL.ML050.MM.04. I 14-18 & 45-47

5 Aldrich Pump Bearing maintenance. PL.ML051.MM.05. I 19-23 & 48

6 Hydraulic Test of Safety Relief Valves ofMain Line.

PL.ML052.MM.06. I 24-29 & 49

7 KOEL set withdrawal & Replacing atRepeater Stn.

PL.ML053.MM.07. I 30-33 & 50

8 KOEL Cylinder head Overhauling. PL.ML054.MM.08. I 34-37 & 51

9 Overhauling and Testing of handoperated trolley overhead crane of 3Tons, 6 Tons and 10 Tone.

PL.ML055.MM.09. I 38-41 & 52


pg. 2

STANDARD OPERATING PROCEDUREFor

WITHDRAWAL AND REFITTING OFMAIN BEARING AND THRUST BEARING FROM

ENGINE BLOCKDURING MAJOR OVERHAULING OR ANY OTHER

BEARING RELATED MAINTENANCE JOB OFALLEN ENGINE

Prepared by:

Sr. Engineer (M), PS8

Reviewed by:

CEPL (M), PHQ

Approved by:

CEPL(S&E),PHQ HEAD (PL-M&S), PHQ

GM (PLS), PHQ

SOP No.: Date of approval: Rev No:

PL.ML047.MM.01.I 27th Mar’ 2012 Initial


pg. 3

A Job Title:Withdrawal and refitting of Main Bearing and thrust bearing from Engine Block duringmajor overhauling or any other bearing related maintenance job of ALLEN Engine.

B. APPLICABILITY AND SCOPE

A Main and Thrust Bearing is a machine element to allow constrained relative motionbetween crankshaft journal and bearing surface, typically rotation movement, and arehydrostatically lubricated. They bear the load, provide low co-efficient of friction, restrictwear & tear, maintain pressure and temperature.

Scope of this Standard Operating Procedure (SOP) involves dismantling of bearinghousings after removal of the lubrication pipes, nuts and bolts of bearing housing; removaland refitting of bearings.

This SOP is to be applied during the above operation required to be performed duringeach Major Overhauling of the engine (MOH) or any other bearings related maintenances.

C. TOOLS & TACKLES REQUIRED:

(i) Heavy duty sockets.

(ii) Wooden planks for placing bearing and its housing.

(iii) Torque wrench (Range mini. 800 lb.ft)

(iv) Brass rod.

(v) Crowbar, lever, extension pipes.

(vi) Tool box with spanners & brass hammer.

D. PERSONAL PROTECTIVE EQUIPMENT (PPE) TO BE USED:

(i) Safety helmet

(ii) Hand gloves

(iii) Safety shoes

(iv) Ear plug (if necessary)

E. WORK TEAM:

Comprised of four members (Competent & Skilled) .

F. HAZARD INVOLVED & RISK ANALYSIS:

The subject maintenance job has the potential to expose workers to following commontypes of hazards:

Slippery or uneven ground;

Hazards associated with Manual handling;Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.

Each work site has some individual hazard characteristics. These hazards are to bespecifically taken care of by the concerned maintenance team and to be addressed in ToolBox Meeting/ Pit Level Safety Meeting.

SOP No.: Date of approval: Rev No:PL.ML047.MM.01.I 27th Mar’ 2012 Initial


pg. 4

G. STANDARD OPERATING PROCEDURE:

Tool Box Meeting:

a) Tool Box meeting (Pit level) should be held on regular basis.

b) Team members should be well conversant with the assigned job.c) “Job safety analysis” should be done and discussed on day today basis in

the tool box meetings & recorded the pertinent pointsd) Any ‘near miss’ to be discussed and recorded.

e) Gang in -charge should not allow his team members work without PPEs.

Obtain Work Permit:

a) Work permit to be taken from the Installation Manager under which the teamworks.

b) Gang In-Charge (Competent Person) should check in detail before signing thework permit.

c) Working area should be barricaded, and ‘UNDER OVERHAUL’ tag should bedisplayed in prominent place.

d) To avoid accidental AIR CRANKING of the engine while under maintenance,Starting Air Valve wheel should be either dismantled or locked with chain. Ifengine is to be run in isolation, Pin & Bush type coupling must be in decoupledcondition.

Specific preparation / arrangements for the job:

(i) Use wooden planks for placing the bearing and its housing, to avoid edgetempering.

(ii) Use suitable table for placing the bearing to carry out inspection, measurementand surface finishing jobs.

(iii) Use paraffin oil to clean bearings and crankshaft journals.

(iv) Proper illumination should be provided inside the engine block, with the flameproof lights.

Following tools & tackles need specific checks before performing the subject job:

(a) Heavy duty sockets to be used to be inspected for cracks or other abnormality.

(b) Torque wrench should be checked for any malfunctioning.

(c) Crowbar, Levers & extension pipes to be inspected for suitability of use.

Dismantling of Bearing Housings:

a) All lubrication pipes connected to the bearings needs to removed, using

proper size spanner. Isolation of the unit should be confirmed from water,

Electrical, Starting air etc.

b) Position the crankshaft in such a way that a workman can get enough space

to approach the bearing housing for removing it



pg. 5

Removal of Bearings:

a) Handle the bearings with care, check the position of the mark in the

bearings and place in a level ground over a wooden plank.

b) For baring the fly wheel, avoid using bend or damaged pipe or crow bar.

Refitting of Bearings and its housings:

a) The marked position will have to checked before placing the bearings and the

housings.

b) Bearing should be free of dirt, grease or oily substances.

c) During barring avoid placing or fitting anything inside the engine block.

d) Use torque wrench for tightening the bearing bolts.

e) Two skilled workman should be placed both the sides for the tightening job.

f) Tools and tackles should be free of grease on the surfaces.

g) Bearing clearance/ Alignment should be taken /Checked as per recommended

practice by the OEM (Manual).

h) Engine should be handed over to the operation group after satisfactory trial

run of the unit on “ NO LOAD” & “ LOAD CONDITION”.

H. REFERENCE:

Working Instructions Manual for Allen Four Stroke Diesel Engine, Type S37D &GS37D (W.I. 2034).

I: REVISION RECORD:

Revision Date Drafted/changed by Description of change


Mechanical Maintenance

pg. 6

OVERHAULING OF EXHAUST VALVE WITH COMPLETE ASSEMBLY

OF

ALLEN ENGINE

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:


GM (PLS), PHQ




pg. 7

Job Title:

Overhauling of Exhaust Valve With Complete Assembly of Allen Engine.

B. SCOPE AND APPLICABILITY:

Scope of this SOP involves lifting of the exhaust valve with complete assembly (mass45 kg approx.) after complete dismantling from cylinder head and cooling water pipingsystem, for inspection, servicing and measurement. The scope also involves refitting ofthe exhaust valve assembly into the cylinder head and re-adjustment of tappet clearance.

This SOP is to be applied, during the above operation required to perform, during eachRoutine Overhauling of the Engine (ROH), at 1500 running hours or any othermaintenance job involving dismantling of exhaust valve.


i. Feet or post supported platform.

ii. Dee shackle

iii. Wire rope sling of diameter 8 to 10mm.

iv. Chain pulley block of minimum 1 (one) tonne capacity.

v. Overhead crane.

vi. Tool box with spanners.

vii. Special tool for handling exhaust valve.

viii. Heavy duty socket box.

ix. Crowbar, lever etc.

x. Flexible hose for jacket water draining.


i. Safety helmet

ii. Hand gloves

iii. Safety shoes

iv. Ear plug (if necessary)

E. WORK TEAM:

Gang-in-charge plus three skilled work-persons (minimum).




Working at height;

Objects falling from height;

Hazards associated with Manual handling;

Stored energy, which can be released quickly and cause physical harm.Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.

Each work site has some individual hazard characteristics. These hazards are to bespecifically taken care of by the concerned maintenance team and to be addressed inTool Box Meeting/ Pit Level Safety Meeting.




pg. 8


Tool Box Meeting:


b) Team members should be well conversant with the assigned job.

c) “Job safety analysis” should be done and discussed on day today basis in thetool box meetings & recorded the pertinent points.

d) Any ‘near miss’ to be discussed and recorded.e) Gang in -charge should not allow his team members work without PPEs.

f) Competent person shall be competent enough to carry out the assigned job.

g) Workman/ contractor personnel shall be made well aware of the all riskinvolvement in the job.

h) All safety precautionary steps shall be discussed.

Obtain Work Permit:


b) Gang In-Charge (Competent Person) should check in detail before signingthe work permit.

c) Working area should be barricaded, and ‘UNDER OVERHAUL’ tag shouldbe displayed in prominent place.

d) To avoid accidental AIR CRANKING of the engine while undermaintenance, Starting Air Valve wheel should be either dismantled or lockedwith chain.


i. Use of feet (post) support platform in place of hanging platform, whereverpossible.

ii. While lifting the exhaust valve assembly from the cylinder head housing, thesling should be position properly.

iii. Arrangement to be made for draining of the engine’s jacket cooling water.Following tools & tackles need specific checks before performing the subject job:

a) All tools, Crowbars, Levers etc. to be inspected suitability of use before startingthe job.

b) Slings, D-shackle, etc. to be used for the job are to be visually inspected.

c) Chain pulley block & over head crane to be checked for proper operation bymoving both up-down and sideways.

d) Cooling water isolation valves should be checked for leakage or operatingproblems.

Before Lifting:

a) Isolate the engine’s cooling water system, by closing the inlet and outlet valvesand drain off the jacket water.

b) Remove all nuts and bolts connected with exhaust valve assembly.c) Properly arrange for lifting the exhaust valve assembly with the help of the

sling, chain block and overhead crane.




pg. 9

During Lifting & Placing:

a) Only one person should be involve to operate the chain pulley block, and thelifting force should be apply gradually to avoid any failure or accident,which may arise from valve jamming, due to heavy carbon deposits.

b) Only one person should instruct the whole lifting, handling and placingprocess.

c) No one should come or stand below the weight.

d) Chains pulley chain for lifting the weight should be hold firmly while theweight is in hanging position, to avoid downward movement of the weight incase of chain pulley failure.

e) Placing should be done in a suitable place where proper cleaning, inspection,grinding and measurement can be performed.

Refitting:

a) Similar procedure and caution should be taken for lifting the exhaust valveassembly and replacing it into the cylinder head.

b) Ensure all sealing washers and gaskets were placed.

c) Refit all the nuts and bolts, with required tightness.

d) Refill the cooling water gradually into the engine’s jacket, by proper airventing, from cooling water circuit.

e) Check for proper water circulation and any leakages form joints.

f) Re-adjustment of the tappet clearance (0.58mm), by placing respectivecylinder at TDC position.

H. REFERENCE:

Working Instruction Manual for Allen Four Stroke Diesel Engine, Type S37D &GS37D (W.I.2034)

I: REVISION RECORD:




pg. 10

WITHDRAWAL AND REFITTING OFCYLINDER HEAD FROM ENGINE BLOCK

DURING TOP OVERHAULING, MAJOR OVERHAULINGOR ANY OTHER MAINTENANCE JOB OF

ALLEN ENGINE MODEL S37D

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:


GM (PLS), PHQ




pg. 11

A JOB TITLE:

Withdrawal and refitting of Cylinder Head from engine block during TopOverhauling, Major Overhauling or any other maintenance job of Allen enginemodel S37D.


Scope of this Standard Operating Procedure (SOP) involves lifting of the cylinder headalong with inlet valve (mass 190 kg approx.), for each cylinder, after opening of nuts forcylinder head studs, water jacket bolts and inlet and exhaust manifold bolts. The cylinderhead is to be placed on stand placed on the ground for cleaning purpose. The scope alsoentails lifting of the cylinder head along with inlet valve from cleaning stand and itsplacement on the engine block for refitting.

This SOP is to be applied during the above operation required to be performed duringeach Top Overhauling of the engine (TOH), Major Overhauling of the engine (MOH) orany other maintenance job involving requirement for lifting of cylinder head.


i. Feet or post supported platform

ii. Stand for cylinder head placement at ground

iii. Cylinder head lifting clamp (special tool)

iv. Dee shackle / Eye bolt.

v. Wire rope sling of diameter 8 to 10 mm.

vi. Chain pulley block of minimum 1 (one) tonne capacity

vii. Overhead crane

viii. Crowbar, lever, extension pipes

ix. Tool box with spanners & hammer


i. Safety helmet

ii. Hand gloves

iii. Safety shoes


E. WORK TEAM:




Slippery or uneven ground

Working at height

Objects falling from heightGroup Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.





pg. 12


Tool Box Meeting:-



c) “Job safety analysis” should be done and discussed on day today basis in thetool box meetings & recorded the pertinent points


Obtain Work Permit:-



c) Working area should be barricaded, and ‘UNDER OVERHAUL’ tag shouldbe attached to the Engine in prominent place.

d) To avoid accidental AIR CRANKING of the engine while undermaintenance, Starting Air Valve wheel should be either dismantled or lockedwith chain.


i. Use of feet (post) supported platform in place of hanging platform, whereverpossible.

ii. Positioning of cleaning stands at suitable positions with proper leveling.

iii. Specific precautions should be taken during loosening and tightening ofcylinder head nuts as it involves much force and any unbalance may causefalling of the workman from the platform, which has potential for seriousbody injury. Hand tightness of nuts is to be checked properly before usingextension levers. Firm gripping on levers, balanced force application withfeet in balanced positions, co-ordination amongst team members etc. are fewareas to be taken specific care.

Following tools & tackles need specific checks before performing the subject job –a) Sockets to be used to be inspected for cracks or other abnormality.

b) Crowbar, Levers & extension pipes to be inspected for suitability of use.

c) Wire rope Slings, Dee shackle, Eye bolts etc. to be used for the job are to bevisually inspected.

d) Chain pulley block & over head crane to be checked for proper operation bymoving both up-down and sideways.

e) Cylinder head lifting clamp is to be inspected for any crack and damage threads.

f) Threaded holes on cylinder head for assembling the cylinder head lifting clampare to be thoroughly cleaned & threads inspected for any damage. If required re-tapping to be done.




pg. 13

Before Lifting -

(a) Removal of Cylinder head nuts, Manifold bolts & jacket bolts is to bechecked.

(b) Gang-in-charge is to be consulted for engagement of the manifold at leastwith two cylinder heads.

(c) Cylinder head lifting clamp should be fully tightened on respective threads.

(d) Clear instruction should be communicated by the gang-in-charge that NO oneshould come under the weight during lifting & should work from adequatesafe distance.

During lifting –(a) Minimum one person should be available at all time during the lifting

operation to operate the chains of chain pulley block and one person foroperating chains of overhead crane.

(b) Chains should be operated slowly and continuously without causing muchlateral movement of the weight.

(c) Chains pulley chain for lifting the weight should be hold firmly while theweight is in hanging position, to avoid downward movement of the weight incase of chain pulley failure.

(d) Nobody should come directly below the weight.

(e) In case of abnormal load, arrangement is to be rechecked in stead of usingexcessive force.

(f) To avoid lifting of cylinder liner along with cylinder head, if the case arises, alever from manifold side may be used to shake the cylinder head and hence toseparate it from liner.

Placement –Lifting hooks should only be removed after ensuring proper sitting of thecylinder head on the cleaning stand.

Refitting –Similar procedure and cautions should be taken for lifting the cylinder head from thecleaning stand till it is properly placed on the engine block.

H. REFERENCE:

(i) Working Instructions Manual for Allen Four Stroke Diesel Engine, Type S37D &GS37D (W.I. 2034).

I: REVISION RECORD:Revision Date Drafted/changed by Description of change




pg. 14

OVERHAULING OF SUCTION AND DISCHARGEMANIFOLD VALVES DURING SCHEDULED OR

BREAKDOWN MAINTENANCE

OF

ALDRICH PUMP

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:


GM (PLS), PHQ




pg. 15

A Job Title:

Overhauling of Suction and Discharge Manifold Valves of the Aldrich Pump.


Scope of this SOP involves evacuation of crude oil form Fluid End portion by closingthe inlet and outlet valves, isolation of pump and piping section, removal of manifold nutsfrom studs, shifting of manifolds by 6”(inch) away from the working barrel allowing themto rest on the studs, removal of valves for servicing and re-assembling the parts.

This SOP is to be applied, during the above operation required to perform, duringMajor Overhauling of the pump or any other breakdown maintenance manifold valves.


i. Wire rope sling of diameter 18 to 25mm.

ii. Chain pulley block of minimum 2 (two) tons capacity.

iii. Overhead crane.

iv. Tool box with sludge ring wrench (heavy duty).

v. I-bolts for handling manifolds.

vi. Crowbar, lever etc.

vii. Empty drums, bucket (10 ltrs), funnel and tray.


i. Safety helmet

ii. Hand gloves

iii. Safety shoes


E. WORK TEAM:

Gang-in-charge plus three skilled and one unskilled work-persons (minimum).




Working at height;








pg. 16


Tool Box Meeting:








Obtain Work Permit:




d) To avoid accidental AIR CRANKING of the engine while under maintenance,Starting Air Valve wheel should be either dismantled or locked with chain.

i. The pump shall be completely de-coupled from engine by removingall the coupling pins.


i. Arrangement to be made for evacuation of crude oil from the Fluid Endsection.

ii. Use of feet (post) support platform in place of hanging platform, whereverpossible.

iii. While lifting and shifting the manifolds from the working barrel portion, thesling should be position properly and overhead crane should be handlecarefully.

iv. As the job also involves handling of crude oil, extra precaution must be ensureto avoid any source for ignition.




pg. 17


a) All tools, Crowbars, Levers etc. to be inspected suitability of use before startingthe job.

b) Sling, I-bolts, etc. to be used for the job are to be visually inspected.

c) Chain pulley block & over head crane to be checked for proper operation bymoving both up-down and sideways.

d) Inlet and Outlet valves should be checked for leakage or operating problems.

Before Dismantling of the Manifolds:

a) Closed the Inlet & Outlet valves and evacuate the crude oil from Fluid Endsection.

b) Make arrangement to hold the manifolds, using overhead crane.c) Remove nuts and bolts of Manifold’s flanged with suction and discharge

piping sections with proper method. (The flange bolt nuts removal sequence& procedure are detailed in Annexure-II)

d) Proper care must be taken up while removing the Spiral wound metal gasket(i.e flexitallic gasket).

e) Remove all nuts from manifold’s stud, with the help of proper tools andmethod.(The stud nuts removal sequence & procedure are detailed in Annexure-II)

Removal of Manifolds Valve assemblies:

a) Only one person shall be assign to operate the chain pulley block, and restworkmen shall be positioned in such a way that, while shifting the manifold 6inch away from the working barrel, the manifold should move slowly,allowing it to rest on the studs and overhead crane should support it firmly.

b) Proper position, cleaning and care must be ensure, for safe handling, whileremoval of the valve assembles and gaskets.

Servicing of Valve assemblies:

a. All the valve seat, disc and spring shall be cleaned and inspectproperly for any kind of defects, re-conditioned/ replaced if required.

b. Seat and Disc valve shall be lapped with precision.




pg. 18

Re-Assemble:

c. Ensure proper cleaning of all gasket surfaces and replaced with new gaskets.

d. Grease and placed the valve parts properly. Grease must be free from dirt anddebris.

e. Re-fit the manifold, ensure all that the valves are centered in the bores in themanifolds and working barrel before tightening the nuts with proper tools andmethod.

(The Tightening Sequence & Procedure of the Stud Nuts are detailed inAnnexure-III)

f. Placed the spiral wound metallic gasket in between the manifolds flanges andpiping section, ensure proper tightening of the bolt nuts with proper tools andmethod.

(The Tightening Sequence & Procedure of the Flange Bolt Nuts are detailedin Annexure-III)

g. Refill the Fluid End section with crude oil from the inlet valve gradually andsimultaneously bleed out the air from vacuum chamber.

h. Before trail run make sure, the entire joints are leak proof.

H. REFERENCE:

Working Instruction Manual for Aldrich Pumps, Ingersoll-Rand Company, AldrichDivision, Allentown, PA.

I: REVISION RECORD:





pg. 19

WITHDRAWAL AND REFITTING OFSLEEVE TYPE BEARING FROM PUMP BLOCK

DURING MAJOR OVERHAULING OR ANY OTHERBEARING RELATED MAINTENANCE JOB OF

ALDRICH PUMP

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:

HEAD (PL-M&S), PHQ

GM (PLS), PHQ




pg. 20

A Job Title:Withdrawal and refitting of Sleeve Type Bearings from Pump Block during majoroverhauling or any other bearing related maintenance job of Aldrich Pump.

B. APPLICABILITY AND SCOPE

A Bearing is a machine element to allow constrained relative motion between crankshaftand bearing surfaces, typically rotation movement, and are hydrostatically lubricated.They bear the load, provide low co-efficient of friction, restrict wear & tear, maintainpressure and temperature.

Scope of this Standard Operating Procedure (SOP) involves dismantling of the plungerassembly, cradle cover assembly, crank end bearing assembly, cross head assembly withconnecting rod, journal bearing assembly, outboard assembly and refitting of the sameafter conducting required measurement, replacement and crankshaft realignment jobs.

This SOP is to be applied during the above operation required to be performed duringeach Major Overhauling of the engine (MOH) or any other bearings related maintenances.


(i) Heavy duty sockets.

(ii) Small Wooden blocks for placing in between bearing housing and pumpblock.

(iii) Torque wrench (Range mini. 1000 lb.ft).

(iv) Measuring Box (including deflection gauge, inside/outside micro meter etc)

(v) Crowbar, lever, extension pipes.

(vi) Tool box with spanners, brass hammer & rod.

(vii) Sludge wrench.

(viii) Hand Operated Over head crane.

(ix) Chain blocks (capacity one ton).

(x) Sling, D-shackle (capacity one ton).


(i) Safety helmet

(ii) Hand gloves

(iii) Safety shoes

(iv) Ear plug (if necessary)

E. WORK TEAM:

Comprised of four members (Competent & Skilled) and one labor (unskilled).




pg. 21




Working at Height;

Object falling from height;

Hazards associated with Manual handling;Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.



Tool Box Meeting:



c) “Job safety analysis” should be done and discussed on day today basis in

the tool box meetings & recorded the pertinent pointsd) Any ‘near miss’ to be discussed and recorded.e) Gang in -charge should not allow his team members work without PPEs.

Obtain Work Permit:




d) To avoid accidental AIR CRANKING of the engine while under maintenance,Starting Air Valve wheel should be either dismantled or locked with chain and“coupling between engine and pump must be detached”.


1) Use small wooden blocks for lifting journal bearing housing.

2) Use suitable table for placing the bearing to carry out inspection, measurementand surface finishing jobs.

3) Use paraffin oil to clean bearings crank end, crankshaft journals and other parts.

4) Proper illumination should be provided inside the pump block, with the flameproof lights.


a) Heavy duty sockets to be used to be inspected for cracks or other abnormality.

b)Torque wrench should be checked for any malfunctioning.




pg. 22

c)Crowbar, Levers & extension pipes to be inspected for suitability of use.

d)Over head crane and chain blocks to be checked for malfunctioning.

Dismantling Process:i. Plunger assembly- The complete plunger needs to dismantle after draining out

the crude oil from fluid end area, and removal of push rods, the same shouldhandle with care and the plunger should be properly place, using lifting tackleswith proper support.

ii. Cradle cover needs to be dismantled, using proper support and lifting

tackles. Care must be taken while removing out the cover from inside the

pump block and should be place down in a plain surface.

Crank end’s bottom half bearing with housing should be dismantled, afterremoving the holding nuts and bolts, the same should be remove and cleanedwith paraffin oil.

iii. Cross head with connecting assembly needs to be withdrawn from the pump blockusing lifting tackles and manual support, care must be taken to avoid anydamages, due to wrong handling practices.

The same should be placed in a plain surface and the top half bearingshould be taken out for cleaning.

iv. Journal Bearing should be dismantling after recording the initial deflection

readings of the crankshaft using deflection gauge.

The bearing housing should be withdrawn after removal of the holdingnuts, while doing this proper tools should be used to lift the housing, careshould be taken to bring it out manually and make sure the top half of thebearing got detached from the housing.

The top half can be taken out easily, but for bottom half, the special toolhas to be used or our conventional method can be use, without causing anydamage to the crankshaft, in the process care must be taken while rotating thecrankshaft slowly and safely.

v. Out board bearing can be withdrawn after removal of the end cover and its

casing. The top half can be taken out easily, but for bottom half the special

tool has to be used.

Note: All parts shall be clean properly with suitable clean paraffin oil and surface shall bedry, to eradicate manual handling hazards.

Inspection, Measurement and Replacement:a) All the bearings needs to be checked for wear and damages in the white metal

surfaces.

b) Measurement of the bearing thickness needs to be recorded and if requirednecessary replacement has to be carried out, if the lead clearances are notwithin permissible limits.




pg. 23

c) After inspection and measurement of the journal bearings, the replacementcriteria will be completely based on the reading of the crankshaft deflection,and bearings, which shall be as per the recommended practice by the OEM(Manual).

Re-assembling Process:

a) Make sure that, all the bearings and other parts were tighten with the requiredtorques, as per the manufacturer’s guideline.

b) While refitting the cross head assembly with connecting rod, the sling should betie properly, to insert the assembly correctly into respective chambers and thecradle cover shims has to be placed correctly.

c) The plunger assembly should be aligned properly with the pull rod, guide andthe cross head, so that no heat will generate, due to metal contacts.

d) The fluid end must be refilled with crude oil with proper air venting, thelubricating oil must be checked and the pump should be re-coupled before thetest run.

e) Engine should be handed over to the operation group after satisfactory trial

run of the unit on “ NO LOAD” & “ LOAD CONDITION”.

H. REFERENCE:

Working Instructions Manual for Ingersoll-Rand Company, ALDRICH PUMP.

I: REVISION RECORD:





pg. 24

HYDRAULIC TEST OF SAFETY RELIEF VALVESOF MAIN LINE ALDRICH PUMPSIN PIPELINE PUMP STATIONS.

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:

HEAD (PL-M&S), PHQ

GM (PLS), PHQ




pg. 25

A Job Title:

Hydraulic Test of Safety Relief Valves of Main Line Aldrich Pumps in PipelinePump Stations.

B. APPLICABILITY AND SCOPE:

Pressure Safety relief valve (SRV) is fitted on the discharge pipe of Aldrich main linecrude oil reciprocating pumps, before discharge isolation valve, as a mechanical means torelieve excessive pressure development beyond design limit, in case of any situationleading to such pressure development.

As per statutory norms, these SRVs are to be tested at regular intervals for theiroperability at set pressure. This SOP is to be applied during servicing and testing ofPressure Safety Relief Valve.

Scope of this SOP involves - Site selection for the testing job, evacuation of crude oilfrom inlet and discharge piping, dismantling of pressure relief valve from Aldrich pumppiping end, transport of SRV and hydraulic testing equipments to the testing site, to carryout hydraulic pressure test, re-fitting of the unit to the pump and refilling of Crude oil intothe line.


i. Empty drums for crude oil recovery (minimum 2 nos.)

ii. Funnel/ Bucket/ Tray.

iii. Hand Trolley.

iv. Portable Hand Operated Hydraulic Test Pressure Pump.

v. Pressure Gauge ( minimum range 120 kg/cm2)

vi. High pressure hose (approx. length 3 meters)

vii. Test Apparatus with piping & fittings.

viii. Cotton waste and cleaning cloth.

ix. Wire rope sling of diameter 8 to 10 mm.

x. Chain pulley block of minimum 1 (one) tonne capacity.

xi. Overhead crane.

xii. Tool box with spanners.

xiii. Spare nuts and bolts.

xiv. Torch Light.


i. Safety helmet

ii. Hand gloves

iii. Safety shoes


v. Eye protecting goggles

vi. Barricade tape.

E. WORK TEAM:





pg. 26









Tool Box Meeting:








i) Mobile phones are to be switched off while working near crude oil line.

Obtain Work Permit:




d) To avoid accidental AIR CRANKING of the engine while under maintenance,Starting Air Valve wheel should be either dismantled or locked with chain. Ifengine is to be run in isolation, Pin & Bush type coupling must be indecoupled condition.


i. Site selection to carryout testing job, it should be free of all kinds ofobstructions.

ii. Clean water should be use for the testing.




pg. 27


a) All tools, Crowbars, Levers etc. to be inspected suitability of use beforestarting the job.

b) Empty drums to be inspected for any damaged or holes.

c) Slings, D-shackle, etc. to be used for the job are to be visually inspected.

d) Chain pulley block & over head crane to be checked for proper operation bymoving both up-down and sideways.

e) Hydraulic test hand pump needs to be inspected for any malfunctioning.

f) Pressure gauge needs to be calibrated, before use.

g) High pressure pipe from pressurizing pump to mounting flange, valves & otherfittings, hose pipes etc. are to be visually inspected for any wear and tear. Ifany defect observed, job should start only after its correction.

Site Selection:

i. Hydraulic pressure testing site is to be selected in consultation with concernInstallation manager.

ii. Work site shall be free of all kinds of Obstructions.

iii. Sufficient space shall be provided for Trolley movements; Equipmentsplacing and Workman activities.

iv. Barricade the working area with provision for entry and exist points. Provide“Man at Work” sign board.

Evacuation of crude oil, at pump end:

a) Check for close conditions of Inlet and outlet valves; open condition of bypassvalve of Aldrich pump.

b) Clear the Drain off valve area, for placing Equipments, like tray; bucket; funneland empty drums, for crude oil recovery.

c) No person shall be allowed to enter into the working area, without permission.Mobile phones should be in switch off conditions.

d) Depressurize and drain crude oil from the isolated system. Rate of evacuationof crude oil shall be slow enough to avoid spillage.

Dismantling of Pressure Relief Valve:

a) Competent person shall redefine the activities to be carried out and eachworkman‘s role, before start of the task.

b) Recheck that the pump has been depressurized and drained.

c) Check for use of proper size of tools and tackles.

d) Check the operational condition of the Overhead crane, for safe operation.

e) Relief valve body should be properly supported and suspended with slingbefore removal of all studs from flanges.

f) The RTJ ring gasket shall be handled with care, to avoid any injury in itssurfaces, which may cause leakage after refitting.

g) After removing the relief valve, the opening in the piping fittings shall becovered, to restrict entry of any kind of materials inside the piping.




pg. 28

h) The relief valve shall be handle carefully and shall be transported to testingsite with the help of trolley, neither dragging or manually.

Hook up of Hydraulic testing apparatus and assembly of Relief valve:

a) Competent person shall redefine the activities to be carried out and eachworkman‘s role, before start of the task.

b) Ensure use of proper size of tools and tackles.

c) Check the condition of the equipment to be use for pressuring, for anymalfunctioning.

d) Maintain a safe distance of 3 meters in between person operating thepressuring pump and testing apparatus.

e) Pressure gauge shall be calibrated one; redundant pressure gauge may be usedfor added safety.

f) Soft and clean water shall be use.

g) All joints surfaces shall be cleaned.

h) Pressure gauge shall be handled with care.

Hydraulic Test of Relief valve:

a) The test shall be in accordance with the OISD-standard-132 and OEM’sInstruction manual.

b) Water is to be filled slowly with air vent valve in open condition. Aftercomplete removal of air, vent valve is to be closed.

c) There should not be any leakage points in the assembly. If any leakageobserved, it must be arrested before proceeding further.

d) Raise the pressure of water slowly and observe response in pressure gauge.Presence of air in the system will be indicated by vibrating movement ofpressure gauge indicator needle.

e) Test Pressure shall be 105 % of the Maximum Allowable Working Pressure.

f) Check pressure gauge response continuously.

g) Set pressure indication will be visible from the pressure gauge as suddendrop of pressure after rising to set pressure. If pressure does not get releasedtill its theoretical set pressure, depressurize the system, readjust the springtension to a lower level and repeat the pressurizing steps again.

h) Release of water at set pressure through the valve seat may be viewedthrough the open discharge flange of the SRV from a safe distance (usesafety goggles for protecting eyes), with torch light illumination.

i) Pressurization more than the safe limit may lead to bursting of pipe or otherfittings.

j) Never adjust the spring setting when the pressure is under the valve near itsseepage or leakage point, as the nozzle seat and disc seat will score and/orgall. Always lower the pressure in the valve at least 25% below the seepagepoint. This will put a loading on the seating surfaces, thus preventingrotation and damaged.




pg. 29

k) Release water pressure through vent opening after completion of hydraulictest and before loosening any flange or fitting for dismantling.

l) Site clearance after completion of the task.

Refitting of Relief Valve:

a) Check for any ingress of material or dust particle inside the valve or pipefittings.

b) Clean properly the flange surfaces and ring gasket grooves.

c) Check the condition of gasket surface of flange, RTJ ring etc.

d) Check the crude oil drain plug/valve of inlet line for close condition beforefilling crude oil into the pump suction and discharge lines.

Check for any crude oil leakage from the flanges or joint areas.

H. REFERENCE:

1) OISD-standard-132 ‘Inspection of pressure relieving devices’.2) OEM’s Instruction manuals –

(a) ‘Installation and maintenance instructions for Farris Safety Relief Valves’, GEC –Elliott Control Valves Limited.

(b) ‘Installation, care and maintenance – Farris Safety Relief Valves’ – Bulletin No.67 R, Farris Engineering Corporation, USA.

I: REVISION RECORD:





pg. 30

WITHDRAWAL AND RE-PLACING OF KIRLOSKARENGINE CUM GENSET, DURING OVERHAULING.

Make: Kirloskar Oil Engines Ltd., Mdel: HA-394

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:

HEAD (PL-M&S), PHQ

GM (PLS), PHQ




pg. 31

A Job Title:Withdrawal and Replacing of Koel Engine cum Genset, During Overhauling.

B. SCOPE AND APPLICABILITY:The KOEL HA 394 Engine cum Generator Set is deployed in the Repeater Station foruninterrupted power supply and at Pump station for emergency power backup.

Scope of this Standard Operating Procedure (SOP) involves: Removal of electrical connection,Removal of foundation bolts, Loading/Lifting and unloading the unit, and mobilization ofequipment.

This SOP is to be applied for Withdrawal of KOEL HA394 Engine cum Generator setfrom Pump stations/repeater Stations, during MOH or any breakdown maintenances.


i. Tool box with spanners.

ii. Rolling pipe 4 nos.

iii. Cotton waste and stocky net.

iv. Wire rope sling of diameter 8 to 10 mm, D Shackle.

v. Crow bar, heavy hammer, nylon rope, tarpaulin and wooden blocks.


i. Safety helmet

ii. Hand gloves

iii. Safety shoes


E. WORK TEAM:

Comprised of four members (Competent & Skilled)




Hazards associated with Manual handling,Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.



Tool Box Meeting:

a) Competent person shall be competent enough to carry out the assigned job.

b) Crane operator shall be present in the tool box meeting.

c) Workman/ contractor personnel shall be well aware of all risk

a. involvement in the job.




pg. 32

G. d) All safety precautionary steps shall be discussed.

e) Check all workman/ contractor personnel for use of PPE items.

Obtain Work Permit:

a) Work permit to be taken from the Installation Manager under which the job is tobe carried out.

b) Working area should be barricaded, and cleared from any disturbances.


a. Cleaning of the surrounding area, it should be free of all kinds of obstructions.

b. Vehicle Mounted Lifting Crane of capacity 2 Ton(min) for lifting andmobilization job.


a) All tools to be inspected for any damages.

b) Crowbar & Levers to be inspected for suitability of use.

c) MS rolling pipe needs to be checked for any damages.

d) Slings, D-shackle, etc. to be used for the job are to be visually inspected.

Dismantling and lifting of KOEL Engine:

a) Competent person shall redefine the activities to be carried out and eachworkman’s role, before start of the task.

b) Check use of proper size of tools and tackles.c) Check the operational condition of the crane, for safe operation.d) Put the panel in Local Mode. Switch off all electrical circuits of the engine to be

dismantled. Remove all electrical connections.e) Shift the unit by using rolling pipes, upto crane approachable position.f) Fasten the rope of 3m length at four legs of the engine base frame to control the

direction of the engine during hoisting.g) Tie the sling in such a way that it shouldn’t damaged any section of the unit and

there shouldn’t be any slag in the sling.h) Lift the unit with the help of the crane, as slowly as possible.i) Place properly and fasten firmly the unit on the vehicle.

Unloading/ lowering of KOEL unit at Site:

a) Competent person shall redefine the activities to be carried out and eachworkman’s role, before start of the task.

b) Check use of proper size of tools and tackles, slings & D Shackles.

c) Remove all fastening ropes carefully.

d) Fit the slings and D shackle in proper place and lower the engine from crane.

e) Use ropes to control the direction of the engine while lowering form a distanceof 3 m.

f) Place the engine at the required place.




pg. 33

H. REFERENCE:

Working Instructions Manual for Kirloskar Oil Engines Limited.

I: REVISION RECORD:





pg. 34

WITHDRAWAL AND REFITTING OF

CYLINDER HEAD FROM ENGINE BLOCK

DURING TOP OVERHAULING,

MAJOR OVERHAULING

OR ANY OTHER MAINTENANCE JOBS OF

KIRLOSKAR DIESEL ENGINE

MODEL HA-394

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:

HEAD (PL-M&S), PHQ

GM (PLS), PHQ




pg. 35

A Job Title:

Withdrawal and refitting of cylinder head from engine block during Top, MajorOverhauling or any other maintenance job of Kirloskar Diesel Engine, Model HA-394 .


Scope of this SOP involves removal of exhaust enclose parts, dismantling ofcomplete cylinder head top section, inlet and exhaust manifolds, removal of rocker armand push rod assemblies, fuel injection systems, removal of cylinder bolts and headsand re-assembling with serviced heads.

This SOP is to be applied during the above operation required to be performed duringeach TOH, MOH or any other maintenance involving requirement for lifting of cylinderhead.


i. Tool box with light duty socket box.

ii. Torque wrench.

iii. Outside Micro meter, filler gauge.

iv. Lead wire.

v. Air Blower.


i. Safety helmet

ii. Hand gloves

iii. Safety shoes


E. WORK TEAM:





Inadequate space to work;

Manual handling;

Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.





pg. 36


Tool Box Meeting:





Obtain Work Permit:





a) The power supply to self starter and fuel supply to the engine must be

isolated (if on-site).

b) Trays for placing the dismantled parts of the engine and clean paraffin oil is

required for cleaning purpose.


a) Torque wrench needs to be check for any malfunctioning.

b) Sockets and tools needs to be visually inspected.

Before Dismantling the Cylinder Head:

a) Isolate the inlet & return lines of the fuel line by closing the valves and alsoisolate the power supply to the self starter of the engine.(if on-site)

b) All parts like exhaust manifold encloser, exhaust and inlet manifolds, fuelpiping system, injector nozzles with holders, tappet cover, rocker arms, pushrods and locking screws of the cylinder heads need to removed and placecarefully.

Withdrawal of Cylinder Head and Re-fitting:

a) Remove the cylinder head along with the cylinder head bolts and alsoremove the intermediate ring and place carefully.

b) Retrieve the cylinder head bolts and washer after complete cleaning.




pg. 37

c) Placed each serviced cylinder heads, along with cylinder bolts on therespective liners in the engine block, and cross tight each cylinder’s boltsmanually, before applying required torque of 7.5 kg.m, to ensure properseating & sealing of the of the cylinder heads.

d) Measure and record the bumping clearances (permissible limits 1.00 to 1.30mm) of all the cylinders with the help of the lead wire and by cranking theengine manually.

Refitting :

a) Similar procedure and cautions should be taken for refitting the other

parts of the engine, and if required renew the damaged parts.

b) Re-adjust the tappet clearance (permissible limit is 0.15mm).

c) Before trail run make sure to restore the fuel line valves in open position and

power supply to the self starter of the engine.

H. REFERENCE:

Kirloskar Diesel Workshop Manual, HA- Series.

I: REVISION RECORD:





pg. 38

OVERHAULING AND TESTING OF HAND OPERATED TROLLEYOVERHEAD CRANES OF 3 TONS, 6 TONS AND 10 TONS

Prepared by:


Reviewed by:

CEPL (M), PHQ

Approved by:

HEAD (PL-M&S), PHQ

GM (PLS), PHQ


PL.ML054.MM.08.I 24th July 2012 Initial


pg. 39

A Job Title:

Overhauling and Testing of Hand Operated Trolley Overhead Cranes of capacity3 tons, 6 tons and 10 tons.

B. APPLICABILITY AND SCOPE:The HOT overhead cranes are used for lifting and shifting of mechanical components of

Engines, Pumps and other heavy equipments, during maintenance jobs, within the confinedareas of Engine House, Pump House, Alternator House and workshops in our pumpinginstallations.

As per statutory norms, under Factory Act 1948, section 29, it should be inspectedperiodically, in an interval of one year.

Scope of this SOP involves –1. Overhauling of the Overhead crane, which include servicing and

replacement of damaged parts.

2. Testing and Certification by third party.


i. Ladder/ Platform.(Minimum 15 ft)

ii. Tool box with spanners.

iii. Sling, D-shackle. (Maximum 6 Tons capacity)

iv. Nylon rope. (for handling weight up to 15 kg)v. Dead Weights. ( up to 6 Tons)


i. Safety helmet.

ii. Hand gloves.

iii. Safety shoes.

iv. Ear plug. (if necessary)

v. Eye Goggles. (if necessary)

vi. Safety Belt.

vii. Barricade tape.

E. WORK TEAM:

Gang-in-charge plus three workmen (minimum).



Slippery.

Working at height.

Objects falling from height.

Inadequate space to work


Stored energy, which can be released quickly and cause physical harm




pg. 40

Group Risk Assessment for above hazards are detailed in sheet OIP 301 in Annexure-I.Each work site has some individual hazard characteristics. These hazards are to bespecifically taken care of by the concerned maintenance team and to be addressed inTool Box Meeting/ Pit Level Safety Meeting.


Tool Box Meeting:








i) Mobile phones are to be switched off in Hazardous zones.

j) Ensure working persons are in sound health and without vertigo.

k) Proper Hand signal to be use, during operations of the crane.

Obtain Work Permit:

a) Work permit to be taken from the Installation Manager under which theteam works.


c) The Third party, who will be involve for Testing and Certification job, shallproduce their competency certificate before obtaining work permit.


i. Proper arrangement of work platform at suitable required height.

ii. Proper Cleaning of overall structure & mechanical components of theequipment prior to overhauling.

iii. Positioning of the crane at a suitable site free from any obstructions.

iv. Proper arrangement for lifting dead weight is to be provided.

v. Barricade the working area with provision for entry and exist points.Provide “Man at Work” sign board.




pg. 41


(a) Working Platform should be firm and balanced.

(b) All tools, D-shackles, Ropes, Slings etc. to be inspected before starting the job.

(c) Safety Belts are to be properly checked for any kind of wear and tear.

(d) Before subjected to load test, all the linkages, joints and hookup portion withthe dead weight, to be checked for any abnormalities.

H. REFERENCE:

1. Factories act 1948. Section 29.

2. OISD RP 205

3. IS 3177

4. OISD GDN 203

I: REVISION RECORD:




pg. 42

Annexure – I to SOP No- PL.ML047.MM.01.I

GROUP RISK ASSESSMENT [OIP – 301]

Station & Department: PS8 SONAPUR Mechanical Maintenance Base

System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by:

Activity

Activitytype Concern/

Hazardinvolved

Impact/severity

explanationExistingcontrols

Consequence(Impact/

severity) rating(0.5/2/4/7/10)

Probabilityexplanation

(Possible causeof incident to

occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)

Recommendationfor improvement

Residualrisk levelD/I R/NR

1 2 3 4 5 6 7 8 9 10 11 12 13

Ref. Tab 1 Ref. Tab2 Ref. Tab 4 Ref. Tab 3 Ref. Tab 4 Ref. Tab 4 7 x 9 x 10

Withdrawal and refitting ofMain bearings and Thrustbeaings from engine blockduring Major Overhauling orany bearings relatedmaintenances of Allen enginemodel S37D.

D+I

R H.1.1H.1.4

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

4

1.52.44.55.15.3

4 0.5 14(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.4 Inadequate space to work.

Existing controls:A.1. Work instructions defined and/or documented, implemented and maintainedA.2. Standard Operating Procedures defined, communicated, implemented andmaintainedA.3. Planned inspections carried outA.6. Work permits issued before work commencement

A.7. Compliance to use of PPEs ensuredA.8. Work is adequately supervisedA.9. Adequate communication regarding work takes placeB.1. Work personnel are competent and periodic trainingsgiven

C.3. Right tools & tackles are availableC.7. Appropriate PPEs providedC.8. Appropriate material handling equipments provided

CONSEQUENCE Level 4: Injury or illness, requiring medical treatment.LIKELIHOOD level 4: Unusual but possibleEXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.

Probability explanation:1.5. Lack of knowledge and/or skill2.4. Inadequate PPE4.5. Inadequate tools5.1. Inadequate leadership and/or supervisions5.3. Inadequate communication of work standards/procedures

pg. 43

Annexure – I to SOP No- PL.ML048.MM.02.I


Department: PIPELINE - MECHANICAL MAINTENANCE

System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by: PS8,Mech. Maint. officials & work-persons.

Activity


Hazardinvolved

Impact/severity


Consequence(Impact/




occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13


Overhauling ofExhaust Valve WithComplete Assemblyof Allen Engine.

D+I

R

H.1.1H.1.2H.1.3H.1.6

H.1.12H.4.2

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

4

1.52.44.55.15.3

1 2 8(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.2 Working at Height.H.1.3 Objects falling from height;H.1.6 Manual handling;H.1.12 Stored energy, which canbe released quickly and causephysical harm to the bodyH.4.2 Lack of communication




CONSEQUENCE Level 4: Serious injury or illness requiring medical treatment.LIKELIHOOD level 4: Unusual but possible.EXPOSURE level 2: At least once monthly.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 44

Annexure - I to SOP No- PL.ML049.MM.03.I



System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by: PS3 Mech. Maint. officials & work-persons.

Activity


Hazardinvolved

Impact/severity


Consequence(Impact/




occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13


Withdrawal and refitting ofCylinder Head from engineblock during TopOverhauling, MajorOverhauling or any othermaintenance job of Allenengine model S37D.

D+I

RH.1.1H.1.2H.1.3

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.6C.7C.8

7

1.52.44.55.15.3

4 0.5 14(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.2 Working at height;H.1.3 Objects falling from height;



C.3. Right tools & tackles are availableC.6. Proper arrangement made for working at height,excavated sites, and enclosed spaces.C.7. Appropriate PPEs providedC.8. Appropriate material handling equipments provided

CONSEQUENCE Level 7: Serious injury or illness (temporary disablement or loss of work for more than a day)LIKELIHOOD level 4: Unusual but possibleEXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 45





ActivityActivity

type Concern/Hazardinvolved

Impact/severity


Consequence(Impact/



(Possible cause ofincident to occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13Ref. Tab

1 Ref. Tab 2 Ref. Tab 4 Ref. Tab 3 Ref. Tab 4 Ref. Tab 4 7 x 9 x 10

Overhauling ofSuction and Dischargeof Manifold Valves ofAldrich Pump

D+I

R

H.1.1H.1.2H.1.3H.1.6

H.1.12H.4.2

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

4

1.52.44.55.15.3

1 2 8(D) - - - ---

Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.2 Working at Height.H.1.3 Objects falling from height;H.1.6 Manual handling;H.1.12 Stored energy, which canbe released quickly and causephysical harm to the bodyH.4.2 Lack of communication




CONSEQUENCE Level 4: Serious injury or illness requiring medical treatment.LIKELIHOOD level 4: Unusual but possible.EXPOSURE level 2: At least once monthly.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutionse.g. Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 46

Annexure - II to SOP No- PL.ML050.MM.04.I

pg. 47

Annexure - III to SOP No- PL.ML050.MM.04.I

pg. 48



Station & Department: PS8 SONAPUR Mechanical Maintenance Base

System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by:PS-8, Mech.Maint.Officials/work-persons

Activity


Hazardinvolved

Impact/severity


Consequence(Impact/




occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13


Withdrawal and refittingof Sleeve Type Bearingsfrom Pump Block duringmajor overhauling or anyother bearing relatedmaintenance job ofAldrich Pump.

D+I

R

H.1.1H.1.2H.1.3H.1.4H.1.6

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

4

1.52.44.55.15.3

4 0.5 14(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.2 Working at height;H.1.3 Objects falling from height;H.1.4 Inadequate space to work;H.1.6 Manual Handling.




CONSEQUENCE Level 4: Injury or illness, requiring medical treatment.LIKELIHOOD level 4: Unusual but possibleEXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 49




System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by: PS3 & PS8 Mech. Maint. officials & work-persons.

ActivityActivity


Impact/severity


Consequence(Impact/


Probabilityexplanation (Possiblecause of incident to

occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)

Recommendation forimprovement


1 2 3 4 5 6 7 8 9 10 11 12 13


Hydraulic Testof PressureRelief Vavle

D+I

R

H.1.1H.1.3H.1.6

H.1.12H.4.2

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

4

1.52.44.55.15.3

4 0.5 8(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.3 Objects falling from height;H.1.6 Manual handling;H.1.12 Stored energy, which canbe released quickly and causephysical harm to the bodyH.4.2 Lack of communication




CONSEQUENCE Level 4: Serious injury or illness requiring medical treatment.LIKELIHOOD level 4: Unusual but possibleEXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 50





Activity

Activity typeConcern/Hazardinvolved

Impact/severity


Consequence(Impact/




occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13


Withdrawal and re-placing of KOELEngine cum Genset,HA394

D+I

RH.1.1H.1.3H.1.4

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9A.12B.1C.3C.7C.8

10

1.52.44.55.15.3

4 0.5 20(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.1 Object Falling from height;H.1.4 inadequate space to work;

Existing controls:A.1. Work instructions defined and/or documented, implemented and maintainedA.2.Safe operating procedures defined, communicated, implemented and maintained.A.3. Planned inspections carried outA.6. Work permits issued before work commencement

A.7. Compliance to use of PPEs ensuredA.8. Work is adequately supervisedA.9. Adequate communication regarding work takes placeA.12 Statutory licenses obtained, regulatory tests and

Inspections carried out.B.1. Work personnel are competent and periodic trainingsgiven


CONSEQUENCE Level 10: Fatal or permanent disability or loss of body parts.LIKELIHOOD level 4: Unusual but possible.EXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 51





ActivityActivity


Impact/severity


Consequence(Impact/



(Possible cause ofincident to occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13


Withdrawal &Refitting ofCylinder head ofKirloskar dieselengine.

D+I

RH.1.1H.1.4H.1.6

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9B.1C.3C.7C.8

2

1.52.44.55.15.3

0.1 2 0.4(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.4 inadequate space to work;H.1.6 Manual handling;

Existing controls:A.1. Work instructions defined and/or documented, implemented and maintainedA.2. Standard operating procedures defined, communicated, implemented andmaintained.A.3. Planned inspections carried outA.6. Work permits issued before work commencement



CONSEQUENCE Level 2: injury or illness requiring first aid.LIKELIHOOD level 0.1: Virtually impossible.EXPOSURE level 2: At least once monthly.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.


pg. 52




System/ Job: As detailed in SOP Scope: As detailed in SOP Assessment by: PS8 Mech. Maint. Official & work-persons.

ActivityActivity


Impact/severity


Consequence(Impact/ severity)

rating(0.5/2/4/7/10)

Probabilityexplanation (Possiblecause of incident to

occur)

Likelihoodrating

(0.1/1/4/7/10)Exposure

(0.5/2/4/7/10)Current

risk level(A/B/C/D)



1 2 3 4 5 6 7 8 9 10 11 12 13Ref. Tab 1 Ref. Tab 2 Ref. Tab 4 Ref. Tab 3 Ref. Tab 4 Ref. Tab 4 7 x 9 x 10

Overhauling ofHOT crane

D+I

R

H.1.1H.1.2H.1.3H.1.4H.1.6

H.1.12H.4.2

Medical aidinjury

A.1A.2A.3A.6A.7A.8A.9

A.12B.1B.4C.3C.6C.7C.8

7

1.51.62.22.32.44.55.15.35.4

4 0.5 14(D) - - - ---

Explanation of terms (Ref. APPENDIX TO QUALITY, ENVIRONMENTAL, OH & S MANAGEMENT SYSTEM MANUAL of OIL INDIA LIMITED, PIPELINE DEPARTMENT):Direct (D) [activity done by regular employees inside or outside of installations] or Indirect (I) [activity done by contracted employees inside the installation or outside].Routine (R) and Non-routine (NR) depending upon the nature of occurrence of the activities: (a) regularly conducted as per plan [R]; (b) activities carried out in long intervals or not in regular interval [NR].Concern/ Hazard :H.1.1 Slippery or uneven ground;H.1.2 Working at heightH.1.3 Objects falling from height;H.1.4 Inadequate space to workH.1.6 Manual handling;H.1.12 Stored energy, which can bereleased quickly and cause physicalharm to the bodyH.4.2 Lack of communication


A.7. Compliance to use of PPEs ensuredA.8. Work is adequately supervisedA.9. Adequate communication regarding work takes placeA.12 Statutory license obtained, regulatory tests andinspections carried out.B.1. Work personnel are competent and periodic trainingsgivenB.4 Periodic medical examination of temporary andcontractor person ensured.

C.3. Right tools & tackles are availableC.6 Proper arrangement made for working at heightC.7. Appropriate PPEs providedC.8. Appropriate material handling equipments provided

CONSEQUENCE Level 7: Serious injury or illness requiring medical treatment.LIKELIHOOD level 4: Unusual but possibleEXPOSURE level 0.5: Once a year or not in a year.RISK LEVEL AND CLASSIFICATION: Up to 20 ‘Tolerable’ - No additional controls are required. Considerations may be given to more cost effective solutions e.g.Administrative monitoring is required to ensure that the controls in the form of PPEs are maintained.

Probability explanation:1.5. Lack of knowledge and/or skill1.6 Improper Motivation2.2 Inadequate Repair2.3 Excessive wear and tear2.4. Inadequate PPE

4.5. Inadequate tools5.1. Inadequate leadership and/or supervisions5.3. Inadequate communication of workstandards/procedures5.4 Inadequate maintenance of workstandard/Procedure

mechanical maintenance section index - oil india · mechanical maintenance section pg.1 index...

Documents