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OIL INDIA LIMITED

Date of Issue Prepared by Issued by

A publication of

SAFETY & ENVIRONMENT DEPT.

Oil India Limited

Duliajan, Assam

SAFE OPERATING PROCEDURES

30-03-2012Sri C. Bose

Head (S & E)

Cover Designed by :

Sri Rudra Dutta, Personnel Department

Prepared by

Mine Safety Officers,

Departmental Safety Officers and

Officers of S&E Department

OIL INDIA LIMITED


Section – 1 : HSE Management

– 2 : Electrical Activities

– 3 : Fire Service Activities

– 4 : Field Engg. Activities

– 5 : Transport Engg. Activities

– 6 : Civil Engg. Activities

– 7 : Drilling-TS Activities

– 8 : Instrumentation Activities

OIL INDIA LIMITED


Revision History

Sl. Date of Issue Rev. No. Reasons & Prepared by Issued by

No. Issue No Nature of Rev.

01 11-11-2005 1 0 1st Issue Sri. A.K. Acharya Sri S. Bora

02 30-03-2012 1 1 1st Issue Mine Safety Officers, Sri C. Bose

Departmental Safety

Officers and

Officers of

S & E Department

Message

OIL/D(HR & BD)/01

January 17, 2012

Modern industry is replete with technological breakthroughs on one hand and

technological obsolescence on the other. Whether state-of-the art or world class, technology

will keep changing for the better but what will always remain constant is the technology-human

interface. This takes a critical dimension for a technology intersive E & P company such as

ours in all our vaied functions and operations. Safe management of man, machine and

technology and sustaining a culture of safety has therefore remained a prime prerogative for

comprehensive Safety policy, Safety Management Manuals, compilation of Safe Operating

Procedures (SOP), Safety Training programmes are all aimed at helping our workforce imbibe

safety culture in their behavior and practicing ‘Safety first’ at workplace.

Documentation of Safe Operating Procedures (SOP) listing out the step-by-step

instructions for doing a job or task the right way, is vital step towards ensuring safe operations.

I am extremely happy to see that Safety and Environment Department, in consultation with

other concerned groups, is now bringing out a revised edition of the SOP Manual. This manual,

amongst others, provide specific information on the hazards and associated risks involved and

the precautions to be ensured before commencement of different operations. The overarching

goal of this initiative is to minimize human error at work, prevent injury, damage or accident

and maintain a smooth technology-human-machine interface.

My ardent request to all our employees to keep oneself abreast of these safety procedures,

adopt them individually and collectively and create a safe and accident-free workplace.

Let SAFETY be a value and a way of life for each and every OIL Indian. Our families

very heavily depend on our safe being.

(N. K. Bharali)

Director (HR & BD)

Message

Message

Foreword

Preface

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Functional Committee for preparation / compilation of SOPs

pertaining to various operational / field departments.

Sl. No. Name Department

1. Sri S. K. Dutta N.E.F.

2. Sri P. Borthakur Production (Gas)

3. Sri G. V. J. Rao Geophysics

4. Sri R. Borkakati Chemical

5. Sri Jayanta Bordoloi S & E

6. Sri B. N. Sahoo S & E

7. Sri S. Kumar Eletctrical

8. Sri R. Bhowmik F. E.

9. Sri P. Gogoi W/L

10. Sri A. Gogoi Production (Oil)

11. Sri A. Baruah Transport

12. Sri B. Bhuyan Instrumentation

13. Sri A. Das Drilling

14. Sri A. Bairagey Civil

15. Sri R. K. Singh S & E (FS)

16. Sri R. Dutta Drilling (TS)

17. Smt. M. B. Sarma S & E

18. Sri B. K. Buragohain LPG

19. Sri H. Phookan S & E

TEN LITTLE WORKERS

Ten little workers feeling fit and fine,

One worked under the boom

Then there were nine,

Nine little workers thought they would be late,

One took a short cut,

Then there were eight.

Eight little workers looking up to heaven,

One fell off the rig floor,

Then there were seven,

Seven little workers putting in hard licks,

One struck at the gas,

Then there were six,

Six little workers glad to be alive,

One forgot his goggles,

Theni there were five,

Five little workers standing near the door,

One thought that wire was dead,

Then there were four,

Four little workers, one cut his knee,

Didn’t go to first aid,

Then there were three,

Three little workers with nothing to do,

One indulged in horseplay,

Then there were two,

Two little workers took stairways on the run,

One missed his footing,

Then there was one,

One little worker, thought of the other nine,

Began to practice safety,

Now he’s doing fine.

1Safe Operating Procedures – Oil India Ltd.

HSE Management

OIL INDIA LIMITED

Safe Operating Procedures

Volume - II

Section - 1

HSE MANAGEMENT

ACTIVITIES

2 Safe Operating Procedures – Oil India Ltd.

HSE Management

OIL INDIA LIMITED


Volume - II

Section - 1

HSE MANAGEMENT

ACTIVITIES


HSE Management

HSE MANAGEMENT SYSTEM

The ultimate goal of HSE Management is to reduce the degree of risk in the oil field activities and

prevention of losses due to accidents/incidents. The issues of HSE management are not only

limited to the fulfillment of statutory requirement but also it encompasses the achievement of HSE

standards in the entire gamut of the company’s activities and operations. Hence an integrated

approach to Health, Safety and Environmental Management in a comprehensive manner is the

need of the hour. HSE functions & systems have been made as a part of the total management

and work culture of OIL INDIA LTD. The system also provides structured paths for improvement of

communication, accomplishment of goals, development of personnel and overall improvement of

business process. Following are the few technical principles and practices to be followed in oil

field areas as the elements of HSE management system.

1) Management’s concern for HSE Management.

2) Defined H.S.E. Policy.

3) Company’s laid down procedures.

4) Organisational set up for HSE management.

5) Accident reporting, investigation & analysis.

6) Hazard identification & control.

7) Personal Protective Equipment.

8) Emergency preparedness.

9) Employees participation in HSE management.

10) Safety Audit.

11) Training, Development & awareness programme.

12) Occupational Health Services.

13) Environmental protection measures & continual improvement.

14) Record keeping/documentation.

15) Duties & Responsibilities as per statutory requirement (Mines Act-1952, OMR -1984 etc.)

1.0 MANAGEMENT’S CONCERN FOR HSE MANAGEMENT

A great deal of emphasis is given by the Board of Directors displaying their commitment and

concern for Safety, Environment and Occupational Health Services. Enhancement of HSE

standards in our oil field activities is one of the prime corporate objectives as well as vision of our

Company.


HSE Management

In the changed scenario of liberalization of economy and globalization of trade & business, OIL

management gives priority to HSE functions by guiding and supporting HSE management group

and the line management personnel. A system exists to review the HSE management objectives

and achievement by periodical monitoring & follow up.

2.0 DEFINED HSE POLICY :

For the first time, a well defined HSE policy called “Safety Policy” was adopted at the Board level

on 22nd October, 1984. The same has been reviewed and updated in the context of changed

scenario and adopted by the Board of Directors on 01.11.2003.

The policy gives broad guidelines on the corporate approach and individual approach to ensure

safer, cleaner and healthier work environment. The policy has been widely circulated to all concerned

to develop awareness amongst all sections.

The HSE policy covering Occupational Health and Safety, Environment aspects is given

overleaf .

HSE in mind and action,

Provides complete Protection


HSE Management


HSE Management

3.0 COMPANY’S LAID DOWN PROCEDURES

Company’s laid down procedures are considered to be an effective tool in achieving HSE

management. All the concerned employees must follow and implement these laid down procedures

in our oil field activities. These procedures help in implementing HSE policy of our company by

providing various guidelines and practices . Following are the few broad laid down procedures,

which are not exhaustive. In addition to these procedures, prevailing standing orders of various

departments/sections are also to be taken into account.

3.1 Safe Operating Procedure.

3.2 Departmental Safety Meeting & Management Safety Meeting.

3.3 Pre-commissioning stage inspection of new installation.

3.4 Pre-spudding Safety Audit and pre work over safely audit.

3.5 Siting clearance on existing/modification of installation.

3.6 Implementation status of external & internal Safety audits.

3.7 Statutory record keeping.

3.8 Mock drills.

3.9 Resolving Pollution complaints (in-house & outsourcing external experts).

3.10 Periodical Medical Examination.

3.11 Obtaining Environmental Clearance i.e. (EC) from MOEF as required.

3.12 Monitoring of various environmental parameters.

3.13 Taking consent to establish and operate from statutory authorities.

3.14 Liaisoning with statutory & advisory bodies.

3.15 Work Permit System.

3.16 Obtaining statutory approval.

4.0 INTERNAL SAFETY ORGANIZATION (ISO) SET UP FOR HSE MANAGEMENT

4.1 The Internal Safety Organisation at Duliajan plays the role of recommending strategies for

continuous improvement in Safety, Health & Environmental performance by developing and

maintaining HSE management systems, working on the principle of management of risks &

reduction of losses. These systems are designed to follow & complete the management

cycle i.e. “PLAN, DO, CHECK, ACTION” for achieving the objectives.

4.2 The Mines organization has been made based on the activity and the Mines Manager is

appointed in each mine to exercise direct control on the mining activity or operation. Mines

Safety Officer (MSO) against each mine has been appointed to assist the Mines Manager

on day today works and in reporting system.

Apart from Mines Safety Officer, there are Departmental Safety Officers (DS0s) to take

care of HSE aspects of departmental activities in oil field operation.

The MS0s and DS0s work in close co-ordination with Internal Safety organization i.e. ISOs.


HSE Management

5.0 ACCIDENT/INCIDENT/DANGEROUS OCCURRENCE- REPORTING SYSTEM

A system as per Annex-’A’& ‘B’ have been adopted for reporting the accident/incident to

statutory/advisory bodies to cut down avoidable delays within our organization. (Circular No. S&E/

S/17/459 of 04.09.1996 & S&E/S17/386 of 26.05.1999).

5.1 DEFINITIONS

5.1.1. Loss : Avoidable waste of any resource.

5.1.2. Hazard : A condition or practice with the potential for accidental loss.

5.1.3. Accident : An event which results in unintended harm or damage.

5.1.4. Incident : An unplanned event (occurrence, condition or action) which did

or could have resulted in unintended harm or damage.

5.1.5. Near Miss : An incident which does not result any injury or damage to property

but has the potential to result in injury and/or property damage.

5.1.6. Safety : Safety is defined as freedom from accidents or the condition of

being safe from pain, injury, illness or loss.

5.2 INCIDENT/ ACCIDENT INVESTIGATION & ANALYSIS

Every incident/dangerous occurrence/nearmiss/accident is to be investigated by the team

constituted by the management. The team should study the accident/incident, the probable cause

of the accident/incident and suggest the remedial measures to avoid recurrence of such incident/

accident in future. The management in turn will advise the concerned deptts to take immediate

action to reduce such risks in oil fields within a stipulated time frame.

The minimum broad outlines of the analysis report should include the following

5.2.1. Date/time of incident & location of the incident.

5.2.2. Description of the incident.

5.2.3. The factors contributed to the incident.

5.2.4. Recommendations resulting from the investigation including long term & short term

preventive measures.

6.0 HAZARD IDENTIFICATION & CONTROL

The identification of potential hazards in vulnerable areas and specific hazards is the

fundamental prerequisite to loss prevention. This is an ongoing activity starting from the

drawing board stage to commissioning, operation and maintenance stages of the

equipment.

A regular Safety / Environmental audit and Occupational Health Hazard Survey help in

critical examination with the objective of identifying strength, weakness & main areas of

risk hazards. These techniques predict the requirement of modification or additional features

to enhance HSE standards of our installations.


HSE Management

Such type of audits may be carried out departmentally, then by ISO and also sometimes by

outsourcing expert services. HAZOP & Risk Analysis study needs to be carried out in

vulnerable installation & plants at an interval of every five years.

7.0 PERSONAL PROTECTIVE EQUIPMENT

The best way of preventing accidents is undoubtedly by elimination of hazards or controlling

the hazards as close to the source as possible but it is necessary to provide an important

line of defence to each employees in the form of Personal Protective Equipment (PPEs).

Various types of PPEs as listed below are to be used by the employees while at work at site

to safe guard themselves from the risks/hazards depending upon the requirement While

selecting such PPEs, various standards, guidelines & Rules/Acts etc. must be referred. All

Personal Protective Equipment as the name implies, fit the person in question, otherwise

its value becomes purely cosmetic and the employee is given a false sense of security.

7.1 Personal Protective Clothing :- The Personal Protective clothing must provide adequate

protection against the specific hazard. The clothing must be light to wear and durable, and

should cause the minimum discomfort but allow maximum mobility etc.

7.2 Eye Protection :- Welding goggles/suitable type of safety glasses to be used to protect

the eyes as per the requirement.

7.3 Safety Shoes :- Every employee at work must wear safety shoes provided by the company.

Ordinary leather/canvas shoes should not be allowed to be used by the employees at work

sites since safety shoes with built-in steel toes caps and with steel soles inside the leather

ones protect against accidents caused by heavy objects failing on the feet, protruding nails,

metal and acid etc. However, special kinds of safety shoes for specific nature of works may

be used.

7.4 Gloves :- The types of gloves required will vary according to the injury to be prevented such

as cut, heat burn, chemical burn & electrical shock etc. Proper gloves as provided by OIL

should be used while at work.

7.5 Helmets :- It is mandatory and statutory to use helmet to prevent injury caused due to flying/

failing object. Any one entering into “hard hat area” should put on a hard hat i.e. helmet.

7.6 Safety belt :- Approved type safety belt provided by the company should be used while

working on height. Any other special type personal protective equipment as per the

requirement should be used. Besides above mentioned PPEs.

Any other special type personal protective equipment time to time as per the requirement

should be used.

8.0 EMERGENCY PREPAREDNESS

8.1 In every installation, an approved copy of Emergency Response (ERP) Plan named as

“ON-SITE DISASTER MANAGEMENT PLAN” should be available covering following

informations:

8.1.1.Action to be taken in the event of any major accident/dangerous occurrence.


HSE Management

8.1.2.Duties & responsibilities of each key personnel including measures to be adopted to avert

or minimize the consequence of emergency.

8.1.3.Alarm & communication system including the system of notifying concerned authorities.

8.1.4.Equipment plan viz : Make, type, capacity, location of operation & operating procedure for

each equipment.

8.1.5.Plan for training of personnel

8.1.6.Mock drills

Time to time the ON-SITE Emergency Plan may be modified/updated depending upon the

requirement.

8.2 OFF-SITE DISASTER MANAGEMENT PLAN

Similarly a copy of District level crisis management plan called OFF-SITE DISASTER

MANAGEMENT PLAN (popularly known “Mutual Aid Scheme”) for the hazardous industries

located within operational areas should be made available at each installation. This copy

should contain the informations on the requirement of resources to manage a crisis situation

(depending upon type and magnitude of the emergency), resources available in neighbouring

industries, list of member industries & their contact numbers, role & responsibilities of various

co-ordinators and financial aspects of Mutual Aid Scheme etc.

9.0 EMPLOYEES PARTICIPATION IN HSE MANAGEMENT

OIL has taken utmost care to involve the employees in Safety circle & Safety culture through

their obligations and commitment towards achieving HSE performance.

- Different Safety motivation programme/competitions are conducted.

- Employee’s participation in Pit level safety committee meeting & Departmental Safety

Committee meeting, Management Safety committee meeting & Tripartite meeting.

- Suggestion schemes

- Regular interaction through meetings with employee’s union.

10.0 SAFETY AUDIT

Internal Safety Audit should be carried out by a multi-disciplinary team of personnel having

adequate experience in operation and maintenance of t he facility, plant or installation.


HSE Management

Following methodology needs to be followed.

10.1 Every installation should be audited at least once in a year.

10.2 A calendar in this respect should be prepared and circulated.

10.3 Areas to be audited should be logically grouped based on the functions.

10.4 Detailed guidelines & checklist should conform to OISD-145 and other relevant stds.

10.5 A timebound action plan should be prepared by the respective I.M./ MSO/DSO for

implementing audit recommendations.

10.6 Implementation status to be reviewed on quarterly basis.

11.0 TRAINING, DEVELOPMENT & AWARENESS PROGRAMME

11.1. TRAINING & DEVELOPMENT ACTIVITIES

11.1.1 The Training & Development department was established to cater to the various training &

developmental needs of the employees of the organization. The department functions from

Management Training & Development Center (MTDC) complex.

11.1.2 The mission of the department is to align T&D processes with the corporate-strategy and

plan of the company in the changing business scenario.

The Objective of OIL’s Training & Development (T&D) policy are to:

• Develop employee skills and competencies and improve performance

• Develop people to take on higher responsibilities

• Reduce the learning time for employees on appointment, transfer or promotion so

they can start being effective in optimum time.

1.1.3 T & D department plays a catalytic role to make OIL a truly knowledge driven organization

by drawing line managers and business heads into a close partnership with T&D. This is

integrated with the other HR systems in our company, such as job rotation and succession

planning, to ensure that the necessary Human Resources development activity takes place

at the point where it is required.

1.1.4 The T&D department caters to the need of development of the workforce by organizing

various types of training programs based on training Need Identification. They are

categorized as under

In house : Training organized in House with reputed External Faculties and Internal

Faculties. In house training may be - Technical, Behavioral, Managerial, Safety

related including various statutory training such as Mines vocational Training

(MVT), Refresher training, Gas Testing, First Aid training and specialised

training in particular discipline or area etc.

In Country : Based on need; technical as well as behaviour & managerial, employees are

trained at various reputed agencies in the country.


HSE Management

Overseas : For specialized technical and managerial courses, employees are sent

Overseas for training.

The department also caters to the need of the various apprentices passed from the ITI’s

and Polytechnics by providing them training. Summer training is also provided to students

from different institutes/Universities.

11.2 AWARENESS PROGRAMME

Various methods are adopted in oil field to develop awareness. These are -

i) Displays of statutory/prohibitory signboards/warning signs.

ii) 5 minutes safety talks at the beginning of shift particularly at the starting of job.

iii) Pit level safety committee meeting.

iv) Departmental safety committee meeting.

v) Observation of safety week/World Environment Day etc. once in a year.

vi) Counselling the employee who met with the accident/dangerous occurrence.

vii) Safety bulletin/Publication of articles in in-house journals.

12.0 OCCUPATIONAL HEALTH SERVICES

The successful implementation of Management Plans and Policies greatly depend upon

the adaptability by the employees, who are the prime movers of the progress of company.

Maintaining their health is very much vital for productivity & effectiveness. To promote the health of

our employees, OIL has made a structured Occupational Health Monitoring system so as to have

scientific basis for decisions aimed at protection of employee’s health from any possible adverse

consequences of exposure to occupational health hazards. Following systems are followed in

OIL towards providing Occupational Health Services.

12.1. An OHS (Occupational Health Service) Centre is established at Duliajan.

12.2. Various activities co-ordinated are pre-employment, periodical and pre-retirement medical

examination.

12.3. Administering special tests like Lung Function Test, Audiometry Test and Vision Test etc.

for identified target groups.

12.4. Conducting First Aid Training & other awareness programme related to Occupational Health

Hazards & remedial measures.

12.5. OHS in peripherial areas are provided through dispensaries located in our Oil fields at

Moran, Jorhat and Sonapur etc.

The scope of Occupational Health Services will be widened in due course to encompass

all the dimensions of health services.

13.0 ENVIRONMENTAL PROTECTION MEASURES & CONTINUAL IMPROVEMENT

The exploration and production activities involve various operations in oil field areas having

a direct bearing on the environment, OIL INDIA LTD. is always concerned about the


HSE Management

disturbance which may be caused due to its operations in upsetting all sorts of balance

that exist between the living creatures and the environment for sustainable existence.

Environment is OIL’s common heritage. OIL has adopted following few measures to

conserve, preserve and protect the clean and green environment in and around our field

areas.

13.1 DRILLING INSTALLATIONS

13 .1.1. Effluent pits are scientifically designed with compartmentalization for effective mopping

of floating oil and helps in avoiding contamination of all the pits.

13.1.2. The water management and preservation of water sources is carried out by following

Recycle system.

13.1.3. Central effluent pit/Emergency pit has been identified for pumping effluent from the drill

site to cope up with the situation of heavy rain & prolonged monsoon.

The efluent pits need to be provided with improvise linings conforming to condition of

E.C.

• E.T.P needs to be provided in addition in all drilling work.

• Land reclamping to be done following practice after drilling is completed.

13.2 PRODUCTION INSTALLATIONS

13.2.1 Formation water is disposed off in the disposal well drilled for the purpose or re-injected

into the formation for reservoir pressure maintenance.

13.2.2. Monitoring wells are drilled for close monitoring of water sample to check any

contamination.

13.2.3. W ater clarification plants are installed wherever necessary to reduce the oil content less

than 10 ppm.

13.2.4. Oil Soluble Demulsifiers are used with proper flocculants to maximize the oil separation

for safe disposal.

13.2.5. Flare pits are properly designed with multiburner facilities with arrangement of abundant

supply of air for proper combustion.

13.2.6. Proper enclosure around the flare pit conforming to provision of EP Act 1986 helps in

combating the effect of heat & light on the crops/environment.

13.2.7. Efforts are taker to reduce the gas flaring further by effective utilization and getting up low

pressure boosters/compressors.

13.3. NOISE POLLUTION

13.3.1. Regular noise survey carried out in high noise prone areas.

13.3.2 Noise attenuators/barriers provided at the source

13.3.3. Ear plug/Ear muff are used by the employees while working in high noise prone areas

13.3.4 No set to be procured without accoustic encloser

13.4. SOLID WASTE DISPOSAL

The municipal solid waste and biomedical waste are disposed as per Municipal Solid

W aste Rules & Bio-medical Waste Rules respectively.


HSE Management

Apart from the above measures, OIL undertakes various environmental project to assess

the effect of OIL’s operation on the flora, fauna and wide bio-diversity.

14.0 RECORD KEEPING /DOCUMENTATION

14.1 The record keeping is an important aspect of HSE Management System. The records

helps us in visualizing the actual status of man, machine and materials. This is also

considered as a reference guide to the people reminding the history of the past incidents

and lessons learnt in those incidents. Record keeping is the best mean to communicate

information and avoid waste of time in duplication of effort. The written report prompts

people to remember what they have to and how to do it. This shows people’s commitment

and concern for HSE aspects of the installation.

14.2 The list of some important records/documents are given in Annexure - ‘C’to Annexure - ‘F’

including various forms as per the requirement of first schedule of Mines Rule - 1955

OMR - 1984 and EP Act, 1986.

15.0 DUTIES & RESPONSIBILITIES AS PER MINES ACT / OMR-1984 )

1) It shall be the duties & responsibilities of the line management and field personnel to achieve

the best safety standards and HSE performance in the area of their functioning.

2) It shall be the responsibility of the line management to create, operate effective HSE

management system to achieve HSE standards set by the company.

3) The role of ISO (Internal Safety Organisation) i e: Safety & Envt. Deptt. is to assist the field

groups/line management to bring down accidents in our oil field activities & to reduce

losses. ISO will advise, study, monitor, inspect, inform the line management for attaining

goal set by the company. ISO will also apprise the top management. ISO will work as an

advisory body and function as by the guidelines of DGMS for ISO.

However, the primary responsibilities for achieving the goal will lie on the line management/

operational groups.

4) The goal for HSE performance shall be set by the top management.

5) ‘Duties & responsibilities’ as per OMR-1984 for a few Mines Officials such as Mines Manager,

Installation Manager, Mines Safety Officer, Fire Officer and Workmen Inspector are given

for ready reference. However duties and responsibilities of all the Mine Officials/competent

persons are not covered in the following chapters. Hence respective Mines Rule/Regulation/

Acts should be referred.

15.1 DUTIES OF MINES MANAGER (REGULATION NO.19 OF OMR-1984)

(1) The manager, shall be responsible for the safe and proper working of the mine by exercising

supervision and control.

(2) The manager shall see that sufficient supply of proper material, and appliances for the

purpose of carrying out the provisions of the Act., the regulations and orders made there

under and for ensuring the safety of the mine and persons employed therein is always

provided at the mine; and if he is not the owner or agent of the mine he shall report in

writing to the owner or agent when anything which he is not competent to order, is required

for the aforesaid purpose.


HSE Management

A copy of every such report shall be recorded in a bound-paged book kept for the purpose.

(3) The manager shall assign to every competent person and official his specific duties and

no .his appointment make over to him a copy of the regulations, rules and bye-laws and

any orders made there under which affect him and he shall take all possible steps to

ensure that every such person understands, carries out and enforces the provisions

contained therein in a proper manner.

(4) The manager shall examine all reports, registers and other records required to be made or

kept in pursuance of the Act, the regulations and orders made there under and shall

countersign the same and date his signature. He may, however, by an order in writing

delegate this duty to an installation manager or other official.

(5) The manager shall pay attention to and cause to be carefully investigated any specific

representation or complaint that may be made to him in writing by a work person of the

mine as to any matter affecting the safety or health of persons in or about the mine.

(6) When an accident resulting in any serious bodily injury to any person or in loss of life

occurs in a mine, the manager shall inspect the site of accident immediately and shall also

either himself or through safety officer have an enquiry made into the causes of and

circumstances leading to the accident. The results of every such enquiry and a plan and

section of the site of the accident showing the details shall be submitted to the Regional

lnspector within seven days of the date of occurrence.

(7) The manager shall perform such other duties as have been specified in this behalf under

this Act, the regulations and orders made there under.

(8) The manager may suspend or take such disciplinary action as he thinks fit against the

work persons for contravention of any provision of the Act, regulations and orders made

there under.

(9) The manager shall maintain in a bound-paged book kept for the purpose, a diary, and shall

record therein the findings of each of this inspections and also the action taken by him to

rectify the defects mentioned, if any.

15.2 DUTIES OF INSTALLATION MANAGER (REG. NO. 20 OF OMR-1984)

The Installation Manager shall carry out the following duties:

(1) He shall have responsible charge and control of such installations and shall carry out such

duties, as may be assigned to him by the manager.

(2) He shall see that a notice of his appointment is posted at a place in the installation in such

a position that in can be easily and conveniently read.

(3) He shall see that in the installation assigned to hi, all work is carried out in accordance with

the provisions of the Act and the regulations and orders made there under.

(4) (a) He shall visit and examine the installations under his charge on every working day to

see that safety in every respect is ensured.


HSE Management

(b) He shall maintain a detailed record of the results of each of his inspections and also the

action taken by him to rectify the defects noticed, if any.

(5) He shall see, when any drilling rig, work-over rig and associated equipment or production

equipment or pipeline is shifted or newly installed, that it is given a trial-run before it is put

into use and shall be present during every such trial-run.

(6) He shall see that all persons employed at the installation are thoroughly instructed and

familiar with the provisions of the standing orders made under these regulations relating to

prevention of blow-out and fire.

(7) He shall see that the provisions of the Act and the regulations or orders made there under

relating to the installation, maintenance, operation or examination of machinery and

equipment are properly carried out by himself or by competent persons or work persons,

as the case may be appointed for the purpose.

(8) (a) When, during the construction of an installation or any operation threat, there is an

emergency or apprehended emergency endangering the life or the safety of any person or

the stability and safety of the installation, he shall himself take or cause to be taken such

measures as are necessary or expedient to avoid the emergency.

(b) No requirement in these regulations shall be taken as prohibiting or restricting the taking of

such measures.

15.3 DUTIES OF SAFETY OFFICER (REGULATION NO. 21 OF OMR-1984)

The Safety Officer shall carry out the following duties :

(1) He shall inspect, as often as may be necessary, the installations of the mine with a view to

identify the dangers which may cause bodily injury or impair health of any person.

(2) He shall advise the manager on measures necessary to prevent dangerous situations.

(3) He shall enquire into the circumstances and causes of all accidents whether involving

persons or not and advise the manager on measures necessary to prevent recurrence of

such accidents.

(4) He shall collect, compile and analyse information in respect of accidents and dangerous

occurrences with a view to promote safe practices and improvement of working environment.

(5) He shall organise regular safety education programmes and safety campaigns to promote

safety awareness amongst persons employed in the mine.

(6) He shall see that all new workers and workers transferred to new jobs receive adequate

safety training instructions and guidance.

(7) He shall maintain a detailed record of work performed by him every day.


HSE Management

(8) If any duties other than those specified above are assigned to the safety officer by the

manager, a written notice thereof shall be sent to the Regional Inspector within three days

of such assignment.

15.4 DUTIES OF FIRE OFFICER (REGULATION NO. 22 OF OMR-1984)

The Fire Officer shall carry out the following duties :

(1) He shall ensure the observance of the provisions of the Act, regulations and orders made

there under concerning fire-detection and fire-fighting systems and shall advise the man-

ager on measures necessary to ensure adequate protection against fire.

(2) He shall ensure proper layout, installation and maintenance of fire-fighting equipment.

(3) He shall see that contingency or emergency plan for likely fire situations are prepared.

(4) (a) He shall organise regular training of persons in-charge of fire-fighting duties with par-

ticular reference to contingency or emergency plan for fire, correct assessment and han-

dling of fire problem.

(b) He shall see that persons in-charge of fire-fighting duties undertake simulated fire drills at

least once in every month to study promptness of response and effective tactics.

(5) He shall examine at least once in every quarter all devices and equipment of fire detection

and fire-fighting systems in the mine and report any defect in the same to the manager.

(6) He shall exercise a general supervision and co-ordination during control and extinguish-

ment of any fire in the mine.

(7) He shall enquire into the causes and circumstances of all fires with a view to prevent

recurrence.

(8) He shall maintain detailed record of work performed by him every day.

(9) If any duties other than those specified above are assigned to the fire officer by the man-

ager, a written notice thereof shall be sent to the Regional Inspector within three days of

such assignment.

15.5 DUTIES OF WORKMEN’S INSPECTOR (MINES RULE-29R OF MINES RULE-1955)

(1) The duties of the Workmen’s Inspector shall be -

(a) to inspect all shafts, inclines, roads, work places and the equipment there including the

equipment for conveyance and transport of workers.

(b) in case of any urgent and immediate danger that come to his notice-

(i) to inform the manager and the Inspector about same and ; and

(ii) to suggest remedial measures necessary to avoid the danger; and

(c) to accompany the Inspector in the course of complete inspection of the mine and also

during such other inspections as may be considered necessary by the Inspector.


HSE Management

“Saftey has no Destination,

It is a Continuous Journey...”

(2) The Workmen’s Inspector shall record a full report of the matters ascertained as a result

of his inspection in an interleaved, paged and bound register kept for the purpose at the

mine in Form U. The Workmen’s Inspector making the entry in the register aforesaid shall

duly sign such entries with date and take a copy of the entries for his record.


HSE Management

ANNEXURE - ‘A’

SAFETY AND ENVIRONMENT DEPARTMENT

OIL INDIA LIMITED

CHANNEL OF REPORTING FOR WORK ACCIDENT

WORK ACCIDENT WITH PHYSICAL INJURY

Immediate action

MSO/DSP/I.M. to fill up ACCIDENT REPORT FORM AND SEND TO Medical Department for

classification. Departmental Officer to liaise with Medical Department personally to know the

extent of injury. Simultaneously Department should inform S&E Department over telephone.

Immediate action

Medical Department to inform Department concerned and S&E Dept. over telephone whenever

work accident cases are received.

MINOR ACCIDENT SERIOUS/FATAL ACCIDENT

No further statutory Forthwith

Formalities required

Fax/Telegram/Telephonic message to DDMS, Digboi & DMS, Sitarampur, by the concerned

deptt. (MSO/DSO) in liaison with S&E Dept.

Within 24 hours

FORM IV-A to be filled by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.

would forward the same to the statutory authorities.

Within 7 days (For Serious Accident only)

FORM IV-B to be filled by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.


Within 7 days (For both Serious & Fatal Accidents)

Enquiry report with sketch to be prepared by MSO/DSO/I.M. Enquiry Committee would be

constituted either by the Agent/Mines Manager/GM concerned/HOD depending of the severity

of the accident. Concerned dept. would forward it to the statutory authorities.

Within 15 days after resumption of duty

(For Serious Accident only)

FORM IV-C to filled up by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.


� MSO - Mines Safety Officer

� DSO - Departmental Safety Officer

� IM - Installation Manager

NOTE : (i) Copies of all correspondence/returns to be sent to GM (F&A) & Head-ER for assessment

of compensation as per Workmen Compensation Act and also to lodge insurance claims and

also to the Agent, Mines Manager, Head - S&E.

(ii) Sample copies of reporting formats are given in Annexure -= ‘G’ to Annexure - ‘J’

�


HSE Management

ANNEXURE - ‘B’

SAFETY AND ENVIRONMENT DEPARTMENT

OIL INDIA LIMITED

FIRE ACCIDENT/DANGEROUS OCCURRENCE

Forthwith

Fax/Telegram to DDMS and DMS, Sitarampur OR

Telephonic message, Department concerned

would do the same in liaison with S&E Dept.

Within 24 hours.

FORM IV-A to be filled up by MSO/DSO/IM in

consultation with S&E Dept. The concerned dept.

would forward the same to the Statutory

authorities.

Within 7 days

Enquiry report with sketch to be prepared by

DSO/IM. Enquiry Committee would be

constituted either by the Agent/Mines

Manager/GM concerned/HOD depending on the

severity of the incident. Concerned dept. would

forward it to the statutory authorities.

� MSO - Mines Safety Officer

� DSO - Departmental Safety Officer

� IM - Installation Manager

Note : (i) A circular or guideline in this respect for reporting the incidents to OISD is given in

Annexure - B1

(ii) Sample format copy is given in Annexure - B2

To inform OISD, PCBA

and CCE depending upon

the severity of the

incident. S&E dept. would

take necessary action in

this regard.

��


HSE Management

ANNEXURE - B1

GUIDELINES FOR FILLING THE OISD QUARTERLY INCIDENT REPORT

1. All Major, Minor and Nearmiss incidents shall be reported in the quarterly report.

2. Incident Reporting form shall be filled up for all Major, Minor and Nearmiss incidents.

3. Summary report shall be enclosed with every quarterly report.

4. Investigations shall be carried out for all Major, Minor and Nearmiss Incidents.

5. Investigation report of all Major incidents shall be submitted to OISD. An incident shall be

treated as Major if any of the following occurs ;

� Fire for more than 15 minutes.

� Explosion/Blowout

� Fatal Incident

� Loss above Rs. 5.0 lac.

� Cumulative man-hours lost more than 500 hrs.

� Plant Shutdown/Outage due to the incident.

6. Loss time accident shall be monitored till the affected person joins duty. In case the affected

person is yet to join the duty, then the status of report submitted will be preliminary. Final

report against the same Incident shall be sent once he joins duty and the man-hours lost are

known.

7. All columns must be filled up.

8. For any additional information use separate sheets as required.

9. Quarterly report shall be sent to OISD within 45 days of end of the quarter.

10. Immediate reporting of incident through fax/telephone shall continue as per the prevailing

system.


HSE Management

ANNEXURE - B2

OISD INCIDENT REPORTING FORM

1. Organization 2. Sector :

3. Location 4. Incident Sr. no :

5. Date of Incident 6. Time of Incident

7. Major / Minor / Nearmiss 8. Report - Preliminary / Final

9. Fire / Accident 10. Duration of fire - hrs / min

11. Type of incident with loss of life/injury ; Fire, Explosion, Blowout,

Electrocution, Fall from Height, Inhalation of Gas, Driving, Slip/Trip, Others, NA

12. Location of the Incident (Name of the Plant / Unit / Area / Facility /

Tank farm / Gantry / Road / parking area etc.)

13. Whether plant shutdown / caused outage of the facility ? Yes / No.

14. Fatalities nos. a) Employee = b) Contractor = c) Others =

15. Injuries nos. a) Employee = b) Contractor = c) Others =

16. Man-hours lost a) Employee = b) Contractor = c) Others =

17. Direct Loss due the incident (Rs. in Lacs). Loss to

equipment / Machinery as per Insurance claim etc.

18. Indrect Losses : T’Put / Production Loss

19. Status of the Facility : Construction / Commissioning /

Operation / Shutting down / Turn around, Maintenance /

Start up / Any others.

20. Brief Description of the Incident

including post incident measures.

(Attach details in separate sheet)

21. Whether Similar Incident has

occurred in past at the same location,

If yes, give brief description of the

incident and attach details in separate

sheet

22. Whether Internal Investigation

has been completed. If no, likely

date by which it will be completed.

23. Whether internal investigation

report (Major Incident) has been

submitted to OISD. If no, likely

date by which it will be submitted.

Continued.....


HSE Management

INCIDENT REPORTING FORM

24. Cause of the incident (Tick the most relevant cause preferably one, maximum two)

a) Deviation from Procedures i) Not using the PPE

b) Lack of Job knowledge j) Equipment failure

c) Lack of supervision k) Poor design / Layout etc.

d) Improper Inspection l) Inadequate facility

e) Improper Maint (Mech/EI/Inst) m) Poor house keeping

f) Improper material handling n) Natural Calamity

g) Negligent Driving o) Pilferage / Sabotage

h) Careless walking/climbing etc. p) Any other (give details) : Carelessness &

Lack of Co-ordination

25. Cause of leakage - Oil, Gas or Chemical (Tick one only) - N/A

a) Weld leak from equip / lines e) Leakage due to improper operation

b) Leak from flange, gland etc f) Leak due to improper maintenance

c) Leak from rotary equipment g) Normal operation-Venting/draining

d) Metallurgical failure h) Any other

26. Cause of ignition leading to fire (Tick only one cause) - N/A

a) Near to hot work f) Static Electricity

b) Near to furnace / flare etc g) Hammering / Fall of object

c) Auto-ignition h) Heat due to friction

d) Loose electrical Connection i) Lightning

e) Near to hot surface j) Any other (pyrophoric etc)

27. Was the incident Avoidable ? (Yes / No)

28. The incident could have been avoided by the use of/or by;

(Tick the most relevant point preferably one, maximum two)

a) Better supervision f) Personal Protective Equipment

b) Adhering to specified operating procedure g) Better equipment

c) Imparting Training h) Management Control

d) Giving adequate time to do the activity i) Adhering to specified maintenance

through proper planning. procedure

e) Adhering to the work permit system j) Adhering to specified Inspection /

Testing procedures.

k) Any other :

By being careful & proper co-ordination amongst the working personnel.


HSE Management

ANNEXURE - C

LIST OF BOUND-PAGED BOOKS (BPB) TO BE MAINTAINED

AS PER OIL MINE REGULATION

SL OMR BRIEF DESCRIPTION PERIODICITY REMARKS/CP

NO. WHEREVER REQD.

1. 9-(4) List of all plans, sections, field books, To be updated in case of Installation Manager

other notes required changes made

2. 16-(3) Copies of all appointments made under As & when appointments Installation Manager

16(1) & duties assigned to competent made

persons.

3. 19-(2) Copy of reports written to the owner or As & when required

agent when anything which he is not

competent to order is required for

ensuring the safety of the mine and

persons employed therein.

4. 19-(9) List of findings during inspection and As & when inspected. Inspection by Mines

actions taken to rectify the defects Manager

5. 28-(3) Inspection of every part of emergency Once in every day Rig in-charge

escape device on every derrick

6. 36-(1) Visual examination of all casing lines Once in 7 days Rig-in charge

and the condition of the wire as to

wear, corrosion, brittleness & fracture

shall be noted.

7. 36-(3) Cutting of at least 30 mts. of casing After every 3000 ton-km Driller

lines of wearing points. or at shorter intervals

where necessary

8. 44-(3a) Function testing of BOP Once in each trip (Blind) Driller

Once daily (pipe ram)

Once every weak (Bag)

Pressure testing BOP After initial installation, Driller

re-installation, following

repair & before drilling

out cement plug

9. 55-2(b) Pressure testing of storage tanks after Wherever installed or Installation Manager

installation or re-installation & before reinstalled

use

10. 55-4(b) Effectiveness of earthing of storage tanks Once in 12 months Electrical Supervisor

11. 58-2(b) Inspection of X-mass trees for leakage Once in 30 days Field Supervisor

12. 66-(3) Detection of flammable gas (Place & As and when detected Field Supervisor/

time) and its percentage OCS Operator

13 69-(2) Copies of Hot Work Permit issued Whenever issued Installation Manager

14. 69-(3) Measurement of gas concentration in Before any welding or Field Supervisor/

hazardous area before starting of cutting works in OCS Operator

welding & cutting works in those areas hazardous area

15. 70-5(b) Examination of Fire extinguishers. Once in 3 months Fire officer

16. 78-(3) Hydraulic testing of all pressure vessels Once in 3 years Installation Manager

17. 78-4(c) Testing of Safety valves on pressure Once in 6 months Installation Manager

vessels.

18. 81-(4) Thorough inspection of all machinery Once in 7 days Mechanical Engineer/

and plant in use Electrical Engineer/

Concerned Engineer

19. 97-3(b) Examination of fencing around wells Once in 7 days Field Supervisor


HSE ManagementANNEXURE - D

LIST OF DIARY MAINTAINED BY RESPECTIVE PERSONS

AS PER OIL MINES REGULATIONS

SL OMR BRIEF DESCRIPTION PERIODICITY RESPECTIVE

NO. PERSON

1. 19-(9) Findings of each of his inspections As and when inspected Mines Manager

and also actions taken by him

to rectify the defects mentioned, in any

2. 20-4(b) Detailed record of the results of Every working day Installation Manager

each of his inspections and also the

actions taken by him to rectify

the defects noticed, if any.

3. 21-(7) Detailed record of work performed Every working day Safety Officer

by him

4. 22-(B) Detailed record of work performed Every working day Fire officer

Each one, Teach one,

Safety is best one


HSE ManagementANNEXURE - E

STATUTORY FORMS TO BE MADE AVAILABLE AT SITE OFFICE

A. Various forms as per the requirement of First Schedule of Mines Rule

SL. FORM TITLE REFERENCE : MINES

NO. RULE/OMR

1. FORM - A Notice of commencement & end of work Rule - 48 (1)

2. FORM -B BIODATA Rule - 48(3), 51 77 & 77-A(2)

3. FORM -E Persons employed in the mine Rule - 48(3) & 78

4. FORM - F Compensatory days of rest Rule - 49 (4)

5. FORM - G Register of leave Rule - 53

6. FORM - J Return of Reportable Accidents Rule - 76 (1)

7. FORM - U Workmen Inspector’s Inspection Report Rule - 29 (R)

8. FORM - VI Construction & Alternation of GCS/OCS OMR : Reg 51

& Production Set up

9. FORM - VII Safety Report OMR : Reg 51

10. FORM - VIII Permission for laying new pipeline OMR : Reg 61

B. Form V under rule 14 of the Environment (Protection) Rules, 1986.

C. Form VIII, under rule 10(2) (ii) of the Batteries (Management & Handling) Rules, 2001

D. Form IV, under rule 9(2) of Hazardous Wastes (Management, Handling & Transboundary Movement)

Rules, 2008.

E. Form II under rule 10 of Bio-Medical Waste (Management & Handling) Rules, 1998.

Sample copies of above forms such are enclosed.


HSE Management

OIL INDIA LIMITED

(A Govt. India Enterprise)

ANNEXURE - ‘F’


HSE Management

ANNEXURE - ‘F’


HSE ManagementF

OR

M -

A[S

ee R

ule

48 (

1)]

No

tic

e o

f C

om

me

nc

em

en

t a

nd

en

d o

f w

ork

Nam

e o

f Min

e........................................

Nam

e o

f Ow

ner.....................................

It is

here

by n

otified that pers

ons e

mplo

yed a

t th

is m

ine s

hall

begin

and e

nd their p

eriod o

f w

ork

betw

een the h

ours

set out

belo

w.

Serial

No.

Class or

kind of

employment

Sex

Place of work

Above Ground/Open cast

working/Below ground

Set or

Relay

Number

(ABC

etc.)

1. Set or Relay

2. Shift

A

123

B

123

C

123

D

123

Etc.

12

34

5Period of work

3. Begins

Ends*

*Interval

for rest if any

4. Begins*

Ends*

5. System of

change of

shifts

A.M

P.M

.

A.M

P.M

.

A.M

P.M

.A

.M

P.M

.

6. Date on which this notice was first exhibited

Signature of Magager

Date........................................


HSE Management

FO

RM

- B

[See R

ule

s 4

8 (

3),

51, 77 a

nd

77-A

(2)]

1.Serial No.

2.Name and surname of the employee.

3.Father’s or Husband’s name.

4.Age and sex.

5.No and date of the certificate, if any, held, under the Mines Vocational Training Rules, 1966.

6.a)

Designation of the employee.

b)Nature of employment (whether above or below ground, and if above ground whether in open cast working or other-wise)

c)Whether employment is permanent or temporary or casual.

7.Home Address of the employee, giving Village, Thana, Post Office and District.

8.Date of commencement of employment.

9.Date of first appointment, with the present owner.

10.

Date of termination or leaving of employment.

11.

In case of an adolescent reference to certificate of fitness granted under section 40.

12.

Mark of identification on the body.

13.

Name, address, relationship of person to be informed in case of accident / emergency.

14.

Token number and other particulars by which the employee may be identified.

15.

Passport size photograph of the person employed.

16.

Signature or Thumb impression of the employee.

17.

Remarks.

N.B. : A Photograph of the employee to be affixed.

Signature of Manager


HSE ManagementF

OR

M -

E[S

ee R

ule

s 4

8 (

3)

an

d 7

8]

Register of person employed above ground [otherwise than in open cast workings] during the week commencing...........................................

and ending.....................................20.............

Name of Mine.............................................Part of Section of mine................................................

Begins

Name of Owner...............................................................................................Hours of shift Ends

A.M

P.M

.

A.M

P.M

.

Serial

No.

Name and

surname of

employee

Age

&

Sex

Class

or kind

of

employ

ment

Relay

or set

No.

Serial

No.

from

Form B

Regis-

ter

Time should be recorded against each entry

-day

-day

-day

-day

-day

-day

-day

No. of

days

worked

No. of

hours

worked

Total

Remarks

12

34

56

78

910

11

12

13

14

15

16

17

18

19

20

21

22

23

InO

utIn

Out

InO

utIn

Out

InO

utIn

Out

InO

ut

Weekly Abstract

Total No.

or attendances

Tota No.

of absentees

Men

Women

Initials of Register Keeper


HSE Management

FO

RM

- F

[See R

ule

s 4

9 (

4)]

Reg

iste

r o

f C

om

pen

sato

ry D

ays o

f R

est

Name of Mine............................

Name of Owner.........................

Year..................

Serial No. from Form B

RegisterName and surname of

employee

Class or

kind of

employ-

ment

with set

or Relay

No.

No.

of

days

of

com

pen

sato

ry r

est

due

in t

he

prev

ious

cale

nder

year

Dates on which weekly

days of rest have no

beer allowed

Dates on which com-

pensatory days of rest

have been allowed

No. of

compensatory

days or rest due

on 31st

December

Remarks

1st Jan. to 31st

March

1st April to 30th

June

1st July to 30th

Sept.

1st Oct. to 31st

Dec.

1st Jan. to 31st

March

1st April to 30th

June

1st July to 30th

Sept.

1st Oct. to 31st

Dec.

12

34

56

78

910

11

12

13

14


HSE ManagementF

OR

M -

G[S

ee R

ule

s 5

3]

Reg

iste

r o

f L

eave A

cc

ou

nt

du

rin

g t

he

Ca

len

da

r Y

ear

Name of Mine............................

Name of Owner.........................

Year..................


Register

Name and surname of

employee

Nature of employment,mention whether above of

below ground

Category of employment,mention whether monthly,

weekly, daily or piece-rated.

Actu

al n

um

ber of days w

ork

ed d

uring the y

ear

January

February

March

April

May

June

July

August

September

October

November

December

Total

Days of leaveentitiled

Arrears fromprevious year

Total

Remarks

Leave p

eriod d

ue in

ensuin

g y

ear

12

34

56

78

910

11

12

13

14

15

16

17

18

19

20

21


HSE Management

FO

RM

- H

[See R

ule

s 5

3]

Reg

iste

r o

f L

eave W

ag

es A

cc

ou

nt

du

rin

g t

he

Ca

len

da

r Y

ear

Name of Mine............................

Name of Owner.........................


Register

Name and surname of

employee

Leave In

sta

lment

Remarks

Arr

ears

of

leave

12

34

56

78

910

11

12

13

14

15

16

17

18

19

20

21

Total leave period due in

the year (From Form G)

Calculated daily rateof wages of earnings

including conces-sions

Period of leave

availed

Calculated wages for

the period

Leave wages

actually paid

Date of payment

Leave In

sta

lment



Period of leave

availed

Calculated leave

wages for the period

Leave wages

actually paid

Date of payment

Leave In

sta

lment



Period of leave

availed

Calculated leave

wages for the period

Leave wages

actually paid

Date of payment

Note : The date of payment of arrears of leave wages shall be entered in this Remarks column.


HSE ManagementF

OR

M -

I[S

ee R

ule

s 5

9]

Reg

iste

r o

f o

vert

ime W

ag

es

Name of Mine............................

Owner........................................

Month.........................................


Register

Name and surname of

employee

Nature of work above orbelow ground

Week e

ndin

g

12

34

56

78

910

11

12

13

14

15

16

17

18

19

20

21

Class or kind of employ-ment

Ordinary rate of wages

Overtime rate of wages

Date on whichovertime worked

Number of overtime hoursworked on that date

Number of overtimehours in the week

Overtime earning

Date of payment




Overtime earning

Date of payment

Week e

ndin

g




Overtime earning

Date of payment

Week e

ndin

g


HSE Management

FO

RM

- I

CO

NT

D.

[See R

ule

s 5

9]

Reg

iste

r o

f o

vert

ime W

ag

es

Name of Mine............................

Owner........................................

Month.........................................

Week e

ndin

g

22

23

24

25

26

27

28

29

30

31

32


Number of overtimehours worked on

that date


Overtime earning

Date of payment

Week e

ndin

g


Number of overtimehours worked on

that date


Overtime earning

Date of payment

Remarks


HSE ManagementF

OR

M -

J[S

ee R

ule

s 5

9]

Retu

rn o

f R

ep

ort

ab

le A

ccid

en

t

Name of Mine.................................

State................District....................

Owner..............................................

Mineral Worked..............................

Quarter ending...............................

Sl. No.

Date of entry

Date of accident

Time of accident

By place ofaccident

Cla

ssific

ation By Cause

Brief description ofcase

of accident

Name of injuredworker

Sl. No. from Registerform in - B

Name of employment

Nature of injury

Part of body injured

Date of return ofinjured person to work

Duration of enforcedabsence (in days)

Initials of attendingMedical practitioner

Remarks

12

34

56

78

910

1112

13

14

15

16

Instr

uctions

:C

ol. (

5)

: S

pecify a

s in

dic

ate

d in

Annexure

1. C

ol. (

6)

: S

pecify a

s in

dic

ate

d in

Annexure

II.

Col. (7)

:G

ive b

rief description the c

ircum

sta

nces a

ttendin

g the a

ccid

ent.

Col. (11)

:S

pecify w

heth

er sim

ple

wound, la

cera

tion, abra

sio

n o

r fr

actu

re (only

toes, fingers

and thum

b e

tc.)

Col. (14)

:M

ention the d

ays in

terv

enin

g the d

ays o

f occure

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nd d

ay o

f re

join

ing a

nd n

ot in

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din

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ither th

e d

ate

of occure

nce o

f re

join

ing.

Col. (16)

:In

case o

f inju

ry p

roves “S

erious” or “F

ata

l” o

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hen in

jure

d p

ers

on p

roceeds o

n le

ave o

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hould

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in this

colu

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) and w

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ontinued to a

bsent in

this

quart

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ubm

itte

d s

epara

tely

.


HSE Management

FO

RM

- K

[See R

ule

s 7

6 (

2)]

RE

TU

RN

OF

MIN

OR

AC

CID

EN

TS

Name of Mine............................................................................................................................................................................................................

State.................................................................................................District...........................................................................................................

Owner.....................................................................................................................................................................................................................

Mineral Worked............................................................................Quarter ending on.................................................................................................

Sl. No.

Date of entry

Date of accident

Time of accident

Classification

Brief description of

Name of injured

by place of by cause

cause of accident

worker

accident

12

34

56

78

1. 2. 3. 4. 5.

Sl. No. from

Nature of

Nature of

Part of body

Date of return

Initials of attending

Remarks

Register in

employment

injury

injured

of injured person

medical practitioner

Form ‘B’

to work

910

11

12

13

14

15

1. 2. 3. 4. 5.

Instructions :

Col. (5)

:Specify as indicated in Annexure I to Form J.

Col. (6)

:Specify as indicated in Annexure II to Form J.

Col (7)

:Give brief description of circumstances attending the accident.

Col. (11):

Specify whether simple wound, laceration, abrasion, etc.

Col. (15):

In case an injury proves ‘reporable’, serious or ‘fatal’ or when injured person proceeds on leave or leavs his employment,

particular should be entered in this column.

1.

Subs. by G

.S.R

. 316, date

d 1

4th

April, 1

986.


HSE ManagementF

OR

M -

U[S

ee M

ines R

ule

s 2

9-R

an

d 2

9-S

]

Sp

ot

Ins

pe

cti

on

Re

po

rt

Name of Mine.......................................................................................Owner.......................................................................................................

Manager........................................................................................................................................................................................Place/Installation

Inspected...............................................................................................................................................................................................................

Inspected by...............................................................................................on........................................................................................................

Accompanied by.....................................................................................................................................................................................................

Observ

atio

ns

Rem

edia

l measu

res

suggest

ed

Act

ion ta

ken fo

r rem

edia

l measu

res

Date

on w

hic

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ken

Rem

ark

s

Sig

na

ture

of

Wo

rkm

en

’s I

nsp

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r w

ith

da

te :

...

....

....

....

....

....

....

....

....

....

....

....

....

....

..

Sig

na

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o

f m

ine

o

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acco

mp

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....

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HSE ManagementFORM IV-A

(See Regulation 7)

NOTICE OF ACCIDENT / OCCURRENCE

From

...................................................

...................................................

...................................................

To,

1. The Chief Inspector of Mines, Dhanbad-826001

2. The Regional Inspector of Mines

....................................Region...............................

3. The District Magistrate

4. The Electrical Inspector of Mines (in case of electrical accident only),

Dhanbad-826001

Sir,

I have to furnish the following particulars of a fatal accident/serious accident/dangerous

occurrence/major accident which occurred at..................mine of.................................... (Owner).

1. Particulars of the mine :

Situation of mine Name and postal address of owner

(Also state telephone & telex numbers)

Village

Post Office

Police Station

District

State

Place and location in mine (site) of accident/occurrence :

Nature of operation undertaken at the place of accident/occurrence :

2. Particulars of the accident/occurrence

(a) Date, shift and hour of accident/occurrence

(b) Classification of accident/occurrence (**)

(c) Cause, circumstance and description of accident/occurrence,

(If cause not yet established information to be sent as soon as possible).

3. Nature of extent of damage

Within the Outside the

establishment establishment

(i) Number of persons

—exposed to the accident/occurrence

—killed

—seriously injured

—affected by gas

(ii) Particulars of material damage

(iii) State whether the danger is still present/no longer exists.

1. Subs, by G.S.R. 399, dated, 9th September, 1996 (w.e.f. 21st September, 1996).


HSE Management4. Particulars of injuries etc.

Name of person(s) Nature of employment Age Sex Nature of injury

(in block capital) and if fatal, cause

of death

Killed :

1.

2.

3.

4.

5.

Injured :

1.

2.

3.

4.

5.

5. Measures taken or envisaged :–

(a) to alleviate the effects of the accidents occurrence

(i) short term

(ii) medium or long term.

(b) to prevent recurrence of similar accident occurrence.

6. Any other relevant information ............................

Particulars in respect of every person killed or injured, in Form IV - B are enclosed/shall be

forwarded within a week.

Yours faithfully,

Signature

Designation/Owner/Agent/Manager

Date :

INSTRUCTION

(**) Under one or other of the following heads, namely :-

1. (a) Explosion of ignition of inflammable gas or liquid.

(b) Blow out.

(c) Out break of fire.

2. Hazardous emission of petroleum.

3. In drilling/workover rig.

4. Suffocation by gases.

5. Explosives.

6. Machinery.

7. Electricity.

8. Miscellaneous.

Attach separate sheet, where necessary.”;]


HSE ManagementFORM IV-B

(See Regulation 7)

PARTICULARS OF DECEASED / INJURED PERSON

(To be given separately in respect of every person killed or injured in an accident in the mine)

1. General

(i) Name of mine................................................

(ii) Owner ..........................................................

(iii) District .........................................................

(iv) State ............................................................

2. Name of injured worker

3. Time of Accident.........................................................

(i) Date................................................................

(ii) Time ..............................................................

(iii) Shift ...............................................................

(iv) Number of shift worked per day at the mine ................................................

(v) Time when the worker began work on the day of the accident.......................................

4. Occupation and experience of the worker

(i) State the nature of job he was doing at the time of accident............................................

(ii) Was is his regular occupation ? ..........................................................

(a) If “yes” state length of experience at the occupation at your mine..................................

previous experience. If any.........................................

(b) If no, state how long employed at this job................................................................

(iii) State total experience in mining..........................................................

(iv) Give details of experience in mining work............................................

5. Place of accident :

6. Nature of injury :

(i) State whether fracture, amputation, laceration, bruise, sprain, crushing injury or other

(to be specified) .......................................

(ii) Part of body injured (to be specified precisely) ................................

7. Degree of disability :

(i) If fatal, date and time of expiry..........................................

(ii) If permanent disablement, specify...................................................

(a) The part or parts of the body lost, if any...............................................

(b) The part or parts of body gone out of use...............................................

(c) Whether disablement was total or partial..................................................

(iii) If temporary disablement, state number of days forced to remain idle..........................

8. Responsibility for the accident :

(i) Was any safety provision(s) contravened.

(ii) If so, by whom ?

(iii) What action was taken against the offender ?

(iv) could the accident have been avoided ?

(v) If so, how ?

Signature..................................................

Designation: Owner/Agent/Manager

Date.............................


HSE ManagementFORM IV-C

(See Regulation 7)

PARTICULARS OF INJURED PERSON RETURNED

TO DUTY

(To be given separately in respect of every person within 15 days of his return to duty)

1. General

(i) Name of mine................................................

(ii) Owner ..........................................................

(iii) District .........................................................

(iv) State ............................................................

2. Date of accident...........................................

3. Name of injured worker.........................................................

4. Return to duty :

(i) Date when returned to work................................................................

(ii) Whether returned to regular job or some other job (To be specified...............................

5. Compensation

State amount of compensation paid or to be paid if any......................................................

Signature..................................................

Designation : Owner/Agent/Manager

Date.............................


HSE Management

FORM VI

(See regulation 51)

NOTICE OF CONSTRUCTION OF OR ALTERATION IN

A GROUP GATHERING STATION.

From

.....................................

.....................................

.....................................

TO,



.............................. Region ...............................

3. The District Magistrate,

....................................

....................................

Sir,

I hereby give notice of our intention to construct a new group gathering. station/carry out

alteration in .................................... group gathering station and furnish the following particulars in

that behalf :

(a) name and address of the mine to which the group gathering station belongs;

(b) name and address of the owner;

(c) name and full address of the site of group gathering station;

(d) date on which it is intended to commence the activity (for in case of an existing station,

date of commissioning thereof);

(e) information relating to the site, namely:-

(i) area of site covered by the group gathering station

(ii) name, location and maximum quantity of petroleum (gas/liquid) likely to be on the site;

(iii) constructional details of the installation and description of the process of storage/

handling of petroleum (in case of alteration, details thereof);

(f) organisational structure for the proposed activity and set up for ensuring occupational

safety and health and for testing, maintenance and patrolling of the installations and safety gad-

gets;

(g) information relating to the potential for major accidents (viz. fire, explosion, bursting or

failure of equipment, hazardous escape and accumulation of flammable substances etc.) namely:-

(i) identification of major accident hazard;

(ii) conditions or events which could be significant in causing a major accident;

(iii) brief description of the measures taken to prevent any major accident and to limit

the consequences thereof;

(iv) area likely to be affected by any major accident and population distribution therein;

(v) maximum number of persons likely to be present at any time on the site and of

whom the number likely to be exposed;

(h) arrangement for training of persons working on site and equipment necessary to ensure

their safety;

(i) providing persons off the site who are likely to be in an area liable to be affected by any

major accident, with the information about the nature of hazard and measures which should be

adopted in the event of an emergency arising therefrom

(j) any other relevant information

Signature ................................

Designation: Owner/Agent/Manager

Date ...................................


HSE ManagementFORM VII

(See regulation 51)

SAFETY REPORT

From

........................

........................

To,


2. The Regional Inspector of Mines.

........................ Region .........................

3. The District Magistrate

.........................

.........................

Sir,

I have to furnish the following particulars in respect of........................................... group

gathering station:

1. The name and address of:-

(a) Mine.

(b) Owner.

(c) Group-gathering station.

2. Description of the installation, namely:-

(a) site.

(b) construction design.

(c) identification of hazardous area and safety distances.

(d) accessibility of plant.

(e) maximum number of persons working on the site and particularly of those persons

exposec to the hazard,

3. Description of the process, namely

(a) technical purpose of the activity:-

(b) basic principles of the technological process.

(c) process and safety-related date for the individual process stages.

(d) process description,

(e) safety-related types of utilities.

4. Description of the hazardous substances namely:-

(a) quantities, substances data, safety-related date, toxicological date and threshold values.

(b) the form in which the hazardous substance may occur on or into which it may be

transformed in the event of the abnormal conditions.

(c) the degree of purity of the hazardous substance.

5. Information on the preliminary hazard analysis, namely:-

(a) type of accident.

(b) system elements or events that can lead to a major accident.

(c) hazards.

(d) safety-relevant components.


HSE Management6. Description of safety-relevant units, amongst others :-

(a) special design criteria.

(b) controls and alarms.

(c) special and alarms.

(d) quick-acting valves.

(e) collecting tanks/dump tank.

(f) sprinkler-system.

(g) fire-fighting etc.

7. Information on the hazards assessment, namely:-

(a) identification of hazards.

(b) the course of major accidents.

(c) assessment of hazards according to their occurrence frequency.

(d) assessment of accident consequences.

(e) safety systems.

(f) known accident history.

8. Description of information of organisational system used to carry on the activity safety, namely:-

(a) maintenance,, and inspection schedules.

(b) guidelines for the training of personnel.

(c) allocation and delegation of duties for plant safety.

(d) implementation of safety procedures.

9. Information on assessment of the consequences of major accidents, namely:-

(a) assessment of the possible release of petroleum

(b) possible dispersion of released of petroleum.

(c) assessment of the effects of the releases (size of the affected area, health effects,

property damaged.)

10. Inforrnation on the mitigation of major accidents, namely :-

(a) fire bridgade.

(b) alarm system.

(c) emergency plan containing system of organisation used to fight the emergency the

alarm and communication routes, guidelines for fighting the emergency, information about

hazardous substance, examples of possible accident sequences.

(d) co-ordination with the district emergency authority and its off-site emergency plan.

(e) notification of the nature and scope of the hazard in the event of an accident.

(f) antidotes, if any, in the event of a release of a hazardous substance.

Signature ..................................

Designation: Owner/ Agent/ Manager.

Date ...........................


HSE ManagementFORM-VIII

(See regulation 61)

PERMISSION FOR LAYING A NEW PIPELINE OR MAKING

ANY SIGNIFICANT ALTERATION IN EXISTING PIPELINE

From

........................

........................

TO,


.......................... Region ..........................

......................... ............................................................

Sir,

I hereby submit my application for permission for laying of pipeline/carrying out significant

alternation (a) in pipeline and furnish the following particulars in that behalf

(a) name and address of the mine to which the pipeline belongs;

(b) name and address of the owner;

(c) full postal addresses of the places where the pipeline would originate and terminate as

also of the places from where the pipeline activities would be controlled;

(d) constructional details of proposed pipelines including all associated works and appara-

tus;

(e) diameter and length of the pipeline and maximum quantity of petroleum gas or liquid

likely to be contained therein at any time and transported on any day;

(f) normal operating pressure and the pressure for which the pipeline designated;

(g) anticipated date and scheme of commissioning of the pipeline activity;

(h) organisational structure for the proposed activity and set up for ensuring occupational

safety and health including testing, maintenance and patrolling test pipeline and safety gadget;

(i) provision proposed to be made or steps to be taken for:-

(i) protection against uncontrolled escape of fluids from the pipeline;

(ii) prevention and control of fire or explosion or major emission of petroleum and

limiting consequences thereof;

(iii) providing to the persons working on the site with the information, training and

equipment required to ensure their safety; and

(iv) providing to persons off the site who are likely to be in an area liable to be affected

by any major accident, with the information about the nature of hazard and measures which

should be adopted in the event of an emergency arising therefrom;

(v) any other relevant information.

Signature ..................................

Designation:Owner /Agent/ Manager.

Date ...........................


HSE Management

OIL INDIA LIMITED


Volume - II

Section - 2

ELECTRICAL ENGG. ACTIVITIES


Electrical Engg.

VOLUME - II SECTION - 2

ELECTRICAL ENGINEERING ACTIVITIES


Electrical Engg.


Electrical Engg.

SAFE OPERATING PROCEDURE OF ELECTRICAL DEPARTMENT

1.0 PART-I

1.1 SAFETY PRECAUTIONS FOR GIVING ELECTRICAL SHUTDOWN

a. Any Electrical line/feeder/equipment/cable must always be considered to be ‘LIVE’ unless

it is made ‘DEAD’

b. Any work on the HT Electrical line/feeder/equipment/cable shall be carried only by the

“Competent Person” as assigned by the Mines Manager. Before starting the work “Electrical

Permit to Work” (EPW) (Ref.OISD-137 para 4.0) must be given by the “Engineer

Concerned” of that section not below the rank of AEE of the department to the Work In-

Charge, who has to be a “Competent Person”. This form is self-explanatory & must be

carefully read before filling up & carrying out operations. The ‘EPW’ must be handed over

to the “Engineer Concerned” after completion of the work & before energizing the line/

feeder/equipment/cable. After energisation the EPW must be handed over to Sectional

Engineer In-Charge/Sectional Head within the next working day. A sample copy of “EPW”

is given in Annexure-1 (page-10).

c. While issuing more than one EPW for shutdown of a single line/cable/ Equipment, care

must be taken to collect all the EPW’s before line/cable/ Equipment is energized.

d. Each EPW has to have a unique identification number with a duplicate copy. Original

should be issued to the Work In-Charge who will carry out the work. The duplicate copy

shall remain in the booklet. Sheet number and total number of sheets issued shall be

clearly mentioned in the EPW.

e. While arranging for shutdown of any HT (3.3 KV/11KV/33KV) OH line/Feeder/equipment/

cable, preferably two Engineers should be present to avoid any wrong operation. While

energizing, preferably the same two Engineers should be present.

f. NEVER OPERATE ISOLATORS ON LOAD. Switch off the feeder breaker from the breaker

remote control panel and then open the Isolators.

g. For a ring main system, the Engineer Concerned should ensure that the supply to the

portion of the feeder on which work is to be carried out, is totally isolated by switching off

power supply from both ends by opening the breakers and isolators. Similarly for radial

feeders, power supply to the feeder should be made off by switching of the breaker.

h. Always hang a CAUTION board on the breaker panel /isolators which is made off.

i. No attempt should be made to parallel power supply from two different sources in 11 KV/

3.3 KV and 33 KV/3.3 KV interconnections.

j. Wherever the substation incomer is through a Drop out unit, for maintenance of the

substation the dropdown fuses/barrels must be removed from dropout unit. Discharge the

cables connected to the DO Unit with proper rating discharge stick and proper PPE (Safety

shoes, Helmet & Gloves of proper rating) at the work site by the Competent person of

Distribution section in presence of Engineer Concerned of Distribution section and PM/

Installation section.

k. While giving shutdown to OCBs/ACBs, they must be racked out or lowered from the panels

to “Isolated” position & the shutters/spring charging handles must be locked with the

CAUTION board.

l. While giving shutdown to L.T. feeder pillar in the housing area, the Engineer, JE or the

Technician Concerned , should ensure the feeder pillar is completely isolated from the

substations as well as other interconnecting feeder pillars.

m. If any LT feeder is found to be in off position in housing area, no work should be carried out

in that feeder unless an EPW is received from the Engineer concerned who made the

shutdown.


Electrical Engg.

n. In case of any panel, marking of feeder/equipment should be clearly written on both front

and rear side of the panel. The Engineer, JE or the Technician Concerned should ensure

this before giving any shutdown.

o. After opening the circuit breakers/isolators for O/H feeders, the voltage should be checked

in the panel voltmeter & with remote voltage sensing device (for HT) & multimeter or 400

v test lamp having two bulbs in series (for LT) before the same is discharged and earthed.

p. Proper safety gadgets as applicable must be used while working/shuting down (safety

shoes, safety belt, safety helmets, face shields, googles etc.)

q. Proper safety gadgets as applicable like insulated hand gloves, goggles/faces shields,

helmets etc must be used while testing live panels or working on equipments/feeder/

overhead lines For giving panel shutdown, the use of hand gloves is essential.

r. The discharge stick should be of proper rating. Use hand gloves while discharging.

s. During heavy storm and lightning, No work should be carried on O/H line even if there is

emergency.

t. While measuring Insulation Resistance of the OH line, use safety boot, safety belt, safety

gloves and no part of the body should be in contact with the OH line. PT or drop out fuses

of the tapped transformer should be disconnected from the OH line. After each

measurement short the terminals of IR instruments.

1.2 GENERAL SAFETY PRECAUTIONS.

a. While working in hazardous areas, the relevant IS codes, standards, rules, regulations &

OISD guidelines must be followed.

b. No electrical equipment/motor should be meggered and discharged in hazardous areas.

For such equipment/motor, meggering & discharging should be done at the prime source

of supply located in safe area.

c. Tool box meetings shall be conducted in each section by the JE concerned before

commencement of any work explaining the hazards involved and mitigating measures to

be taken. Once in a month Pit level safety meetings are to be conducted by the Installation

manager or the Engineer in charge of a section. In case

d. In every meeting, at least 5 minutes to be devoted at the beginning for general discussions

regarding HSE aspects.

e. All electrical works concerned must comply with the provisions under the Acts, Rules,

Regulations, Codes etc. with all amendments as mentioned below :

i. I.E. rules, 1956 & I.E. Act, 1910.

ii. OMR-1984 & Mines Act 1952

iii. DGMS Circular No. 1 (6) 2001-Genl./3604-of Sept.12, 2001.

iv. I.E.E. Regulations.

v. I.P. Codes & Practices

vi. National Electrical Code, 1985

vii.OISD Standards-105, 118, 137, 146, 147, 148, 149 or any applicable standards.

viii. Departmental Standing Orders.

ix. Provisions under Central Mining Research Institute (CMRI)

x. Provisions under Director General of Mines Safety (DGMS)

xi. Any other regulations/Codes/Practices amended up to date

xii.Safe Operating Procedures.

1.3 SHUTDOWN PROCEDURE FOR L.T. FEEDER /MOTOR STARTER PANEL FROM

PCC/PMCC


Electrical Engg.

a. Identify feeder/starter panel to be attended.

b. Check type of isolation device to be operated.

c. Without opening up the cover, operate isolator handle from ON to OFF position. Similarly

in case of CFS, lower the handle to OFF position.

d. Open the panel covers and check voltage across out going phases of the isolator with

double test lamp/multimeter. In case of CFS, check that all the three fuses with Moving

contacts have come out from the fixed contacts or not).

e. If all the outgoing phases show Zero voltage, then discharge the outgoing phases with

earth using proper discharge stick.

f. Confirm with test lamp/multimeter the presence of any AC/DC control supply voltage. If

present, isolate it at source by removing the fuses.

g. Cautions :

i. Never open the covers of contactors to see whether they are ‘ON’ or not.

ii. Always check the starter by’ isolating’ the load by disconnecting outgoing cables.

iii. Check for the source of control voltage. It may have a different source of supply.

iv. Consider the panel to be ‘LIVE’ unless it is made ‘DEAD’ & TESTED’

v. Always use double test lamp/multimeter to check voltages.

vi. Never use screwdriver/other tools for discharging the panel.

vii.Never rely on the isolator switch position. Ensure by testing the outgoing voltages.

viii. While checking the live incoming side of the switches, tapped from bus bar, use

handgloves,googles/faceshields.

ix. Switch of the PCC/PMCC incomer while working on the incomer side of any switches.

1.4 WORKING PROCEDURES FOR LT OVERHEAD LINES:

a. Shutdown procedure:

i. A shutdown circular has to be circulated among the field sections for information of

the feeder to be shutdown mentioning the area which will be affected.

ii. Identify the feeder to be made shutdown.

iii. Either Concerned Engineer or Authorised Person should Switch off the main switch

iv. Open up the main switch cover and remove all the fuses, neutral link and hang

CAUTION board.

v. Discharge the OH line using suitable discharge stick from the ground with proper

PPE (Safety shoes, Helmet & Gloves of proper rating) at the work site by the Work

In-charge in presence of Engineer Concerned.

vi. Issuance of EPW by the Engineer Concerned to the Work In-charge: Description of

the feeder, date & validity time and time of issuance should be clearly mentioned.

Name, signature, designation of the Engineer Concerned should be legible. Work

In-charge should read the content in the EPW carefully, understand it, if required

clarify, verify and sign the EPW. Work In-charge name, designation, Regd. No should

be legible. After signing of EPW, original of the EPW should be handed over to the

Work In-charge.

vii. Work In-charge shall short all the three conductors of OH line with aerial earth wire

using a shorting conductor of proper size preferably visible and near to the work

site.

b. For energizing:

i. Work In-charge must ensure that work has been completed in all respect and no

one is working on the OH line and all the shorting/earthings has been removed.

Work In-charge shall return the duly signed original of the EPW mentioning the time


Electrical Engg.

and date to the Engineer Concerned.

ii. Engineer concerned/Authorised person should physically check all the shorting/

earthings are removed before energizing the feeder.

iii. Verify the feeder and remove the CAUTION board. Re-install three fuses and neutral

link. Close the main switch and verify load in three phases.

iv. File the EPW.

1.5 SHUTDOWN PROCEDURES FOR L.T. OVERHEAD LINE FOR CARRYING OUT

REPAIR JOBS ON SERVICE LINES:

a. Concerned JE/Technician taking the shut down should possess supervisory certificate of

competency.

b. He should inform his immediate superior / stand by engineer and Electrical enquiry about

the shutdown taken and about the approx.duration.

c. Contact the immediate superior for assistance or clarification, if required.

d. Proceed to Sub-station/ switch room where the concerned feeder is located.

i. Use the required PPEs like helmets, insulated handgloves, googles/faceshields

ii. Identify and confirm the actual feeder to be made shutdown.

iii. Put off the main switch

iv. Open up the main switch cover and remove all fuses and neutral link.

v. Place caution board, “Do Not Close, Men Working on Line”.

vi. Check the non-availability of power at the outgoing terminals of the switch with the

help of a multimeter/400v double test lamp.

vii. The Sub-station/ switch room should be locked and the key should be kept in the

safe custody of the JE taking the shut down.

viii. If the locking facility is not available, keep one team member at the switch room to

avoid accidental switching on by others.

e. Proceed to worksite

i. Verify the non-availability of power by checking at the load end.

ii. Discharge three phases, neutral at the outgoing side with suitable discharge stick.

iii. Short three phase, neutral with earth with the help of discharge stick or proper

shorting wire towards the source of supply.

iv. Carry out the planned repairs on the service connection

v. Remove shorting wires from the overhead line.

vi. Check for any mistake/left out tools etc. while performing the job.

vii. Warn every one present in the site that the line is going to be energized.

f. Proceed to the Sub-station/ switch room.

i. Identify the feeder and remove caution board.

ii. Remove short wires.

iii. Re-install three fuses and neutral link and tighten it.

iv. Close main switch and verify load in three phases.

v. Inform enquiry about the restoration of power.

g. In case of any problem contact the immediate superior.

h. If the JE/Technician taking the shutdown is not carrying out the job himself, the


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above SOP is not applicable and he could contact his immediate superior for your

further advice.

1.6 SHUTDOWN PROCEDURES FOR HT PANEL AT SUB-STATION


i) A shutdown circular has to be circulated among the field sections for information of


ii) Check carefully the number of incoming interconnecting feeders to the HT panel.

iii) Isolate all the incoming interconnecting power to the above HT panel.

iv) Switch off breaker, in case of breaker, lower the breaker up to the ‘Isolated’ position

v) Lock the breaker at lower position and hang ‘Danger Board’ on the breaker/main

switch. Remove PT.

vi) If HT panel is connected to another feeder, proceed to the source of that feeder and

continue operation No. 1.6.a.iv) & v.

vii) Check the presence of any voltage in the incoming feeders on the voltmeter .

viii) Check the presence of any AC/DC control voltage using multimeter. If present, then

isolate at the source and remove fuses.

ix) Open up HT panel doors and discharge each phase of incoming cables with the help

of proper discharge stick with proper PPE (Safety shoes, Helmet & Gloves of proper

rating, face shield) by the Work In-charge in presence of Engineer Concerned.

x) Issuance of EPW by the Engineer Concerned to the Work In-charge: Description of


Name, signature, designation of the Engineer Concerned should be legible. Work In-

charge should read the content in the EPW carefully, understand it, if required clarify,

verify and sign the EPW. Work In-charge name, designation, Regd. No should be

legible. After signing of EPW, original of the EPW should be handed over to the Work

In-charge.

b. For energizing:

i) Work In-charge must ensure that work has been completed in all respect and no

one is working. Warn every one present in the site that the HT panel is going to be

energized. Work In-charge shall return the duly signed original of the EPW mentioning

the time and date to the Engineer Concerned.

ii) Check for any mistake/left out tools etc. while performing the job.

iii) Unlock the breaker, raise it and lock the breaker. Remove the caution board & charge

spring of the breaker if required.

iv) Insert PT.

v) Switch on breaker.

vi) File the original EPW.

1.7 SHUTDOWN PROCEDURES FOR LT PANEL AT SUB-STATION


i) A shutdown circular has to be circulated among the field sections for information of


ii) Check carefully the number of incoming interconnecting feeders to the LT panel.

iii) Isolate all the incoming interconnecting power to the above LT panel.

iv) Switch off CFS, remove fuses and neutral link.

v) Lock the CFS at lower position and hang ‘Danger Board’ on the main switch.

vi) If LT panel is connected to another feeder, proceed to the source of that feeder and

continue operation No. 1.7.a.iv & v.

vii) Check the presence of any voltage in the incoming feeders using Multimeter (Voltage

mode) or test lamp (two lamps in series).


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viii) Issuance of EPW by the Engineer Concerned to the Work In-charge: Description of






In-charge.

b. For energizing:

i) Work In-charge must ensure that work has been completed in all respect and no

one is working. Warn every one present in the site that the LT panel is going to be

energized. Work In-charge shall return the duly signed original of the EPW mentioning

the time and date to the Engineer Concerned.

ii) Check for any mistake/left out tools etc. while performing the job. Remove the caution

board.

iii) Switch on CFS.

iv) File the original EPW.

1.8 SHUTDOWN PROCEDURES FOR FEEDER PILLAR:

a. Shutdown procedures:

i) A shutdown circular has to be circulated among the field sections for information of the

feeder pillar to be shutdown mentioning the area which will be affected.

ii) Check carefully the number of incoming interconnecting feeders to the FP.

iii) Switch off all the incoming interconnecting power to the above FP. Remove all the

fuses and neutral link of the CFS’s and hang a caution board.

iv) Open the FP CFS/Main switch, check the presence of any voltage in the FP CFS

using Multimeter (Voltage mode) or test lamp (two lamps in series).

v) Discharge each phase of incoming cables with the help of proper discharge stick with

proper PPE (Safety shoes, Helmet & Gloves of proper rating) by the Work In-charge in

presence of Engineer Concerned.

vi) Issuance of EPW by the Engineer Concerned to the Work In-charge: Description of

the feeder pillar, date & validity time and time of issuance should be clearly mentioned.





In-charge.

b. For energizing:

i) Work In-charge must ensure that work has been completed in all respect and no one

is working. Warn every one present in the site that the FP is going to be energized.

Work In-charge shall return the duly signed original of the EPW mentioning the time

and date to the Engineer Concerned.

ii) Check for any mistake/left out tools etc. while performing the job.

iii) Remove the caution board, reconnect the fuses and neutral link of the CFS and Switch

ON the CFS.

iv) File the original EPW.


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’


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viii. Discharge the OH line using suitable discharge stick from the ground with properPPE (Safety shoes, Helmet & Gloves of proper rating) at the work site by the Work In-charge in presence of Engineer Concerned.

ix. Issuance of EPW by the Engineer Concerned to the Work In-charge: Descriptionof the feeder, date & validity time and time of issuance should be clearly mentioned.Name, signature, designation of the Engineer Concerned should be legible. Work In-charge should read the content in the EPW carefully, understand it, if required clarify,verify and sign the EPW. Work In-charge name, designation, Regd. No should belegible. After signing of EPW, original of the EPW should be handed over to the WorkIn-charge.

x. Work In-charge shall short all the three conductors of OH line with aerial earth wireusing a shorting conductor of proper size preferably visible and near to the work site.

a. For energizing:i. Work In-charge must ensure that work has been completed in all respect and no one

is working on the OH line and all the shorting/earthings have been removed. Work In-charge shall return the duly signed original of the EPW mentioning the time and date tothe Engineer Concerned.

ii. Engineer concerned should physically check all the shorting/earthings are removedbefore energizing the feeder.

iii. Verify the feeder and remove the CAUTION board from the control panel. Insert the PT.Raise the breaker and lock the breaker lever. Depress the Trip-Healthy button, springcharge the breaker (wherever required) and Switch ON the breaker. Check the voltmeterfor line voltages and verify load in each phases.

iv. File the original EPW.

1.11 Shutdown procedure for HT 3.3/11kV Ring Main Feeder :

a. Shutdown

i. A shutdown circular has to be circulated among the field sections for information of thefeeder to be shutdown mentioning the area which will be affected.

ii. Identify the portion of the feeder to be made shutdown and associated breakers with it.iii. Concerned Engineer should Switch off the breaker in the remote control panel.iv. Check for any voltage in the voltmeter. It should be zero in all phases.v. Unlock the breaker lever and lower the breaker to the “Isolated” position. Hang a CAUTION

board on the control panel door of the breaker.vi. Open the PT on the feeder, if OH line insulation to be measured.vii.Proceed to the other end of the feeder. At other end, check the nameplate written on

the control panel and verify whether it is the same feeder or not.viii.Follow the instructions from (iii) to (vi).ix. Ensure all the interconnected isolators/breakers are open and keep stand-by personnel

wherever isolators exist.x. Discharge the OH line using suitable discharge stick from the ground with proper PPE

(Safety shoes, Helmet & Gloves of proper rating) at the work site by the Work In-charge in presence of Engineer Concerned.

xi. Issuance of EPW by the Engineer Concerned to the Work In-charge: Descriptionof the feeder, date & validity time and time of issuance should be clearly mentioned.Name, signature, designation of the Engineer Concerned should be legible. Work In-charge should read the content in the EPW carefully, understand it, if required clarify,verify and sign the EPW. Work In-charge name, designation, Regd. No should belegible. After signing of EPW, original of the EPW should be handed over to the WorkIn-charge.


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xii.Work In-charge shall short all the three conductors of OH line with aerial earth wireusing a shorting conductor of proper size at both the ends of the RMF preferably visibleand near to the work site.

b. For energizing

i. Work In-charge must ensure that work has been completed in all respect and no oneis working on the OH line and all the shorting/earthings have been removed. Work In-charge shall return the duly signed original of the EPW mentioning the time and date tothe Engineer Concerned.

ii. Engineer concerned person should physically check all the shorting/earthings areremoved before energizing the feeder.

iii. Remove the CAUTION board in the breaker control panel, insert the PT, depress theTrip-Healthy button, spring charge the breaker (wherever required) and Switch ON thebreaker. Check the voltmeter for line voltages in the feeder in all the phases.

iv. Proceed to the other end of the feeder. Follow the instructions from (iii.) & (iv.)v. File the original EPW

1.12 Shutdown procedure for HT 33kV Ring Main Feeder :a. Shutdown procedure:

i. A shutdown circular has to be circulated among the field sections for information of thefeeder to be shutdown mentioning the area which will be affected.

ii. Identify the portion of the feeder to be made shutdown and associated breakers &isolators with it.

iii. Concerned Engineer should Switch OFF the breaker in the remote control panel andhang a caution board.

iv. Check for any voltage in the voltmeter. It should be zero in all phases.v. Check the breaker is in OFF position in the LOCAL panel in the switchyard. Unlock the

isolator (in the switchyard) handle lock and Open the “Feeder Isolator” using properPPE (Safety shoes, Helmet & Gloves of proper rating). Lock the isolator handle andhang a CAUTION board.

vi. Open the PT isolator.vii.Proceed to the other end of the feeder. At other end, check the nameplate written on

the control panel and verify whether it is the same feeder or not.viii.Follow the instructions from (iii.) to (vi.).ix. Discharge the feeder with either ‘Earth Switch’ in the switchyard by the engineer

concerned using proper PPE (Safety shoes, Helmet & Gloves of proper rating) ordischarge the OH line using suitable discharge stick from the ground with proper PPE(Safety shoes, Helmet & Gloves of proper rating) at the work site by the Work In-charge in presence of Engineer Concerned.

x. Issuance of EPW by the Engineer concerned to the Work In-charge: Descriptionof the feeder, date & validity time and time of issuance should be clearly mentioned.Name, signature, designation of the Engineer Concerned should be legible. Work In-charge should read the content in the EPW carefully, understand it, if required clarify,verify and sign the EPW. Work In-charge name, designation, Regd. No should belegible. After signing of EPW, original of the EPW should be handed over to the WorkIn-charge.

xi. Work In-charge shall short all the three conductors of OH line with aerial earth wireusing a shorting conductor of proper size at both the ends of the RMF preferably visibleand near to the work site.

b. For energizing


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i. Work In-charge must ensure that work has been completed in all respect and no oneis working on the OH line and all the shorting/earthings have been removed. Work In-charge shall return the duly signed original of the EPW mentioning the time and date tothe Engineer Concerned.

ii. Engineer concerned person should physically check all the shorting/earthings areremoved before energizing the feeder.

iii. Verify the feeder on one end, unlock and open the ‘Earth’ by opening the ‘EarthingSwitch’ at the switchyard.

iv. Unlock and close the PT isolator (if opened) at switchyard and locked it.v. Unlock, remove the CAUTION board and close the Isolator (Switchyard) and locked it.vi. Remove the caution board in the breaker remote control panel, unlock the TNC switch,

and depress the Trip-Healthy button. Check all the indication for isolator close, springcharge and Switch ON the breaker. Check the voltmeter for line voltages in the feederin all the phases.

vii.Proceed to the other end of the feeder. Follow the instructions from (iii.) to (vi.).viii.File the original EPW.

1.13 Shut down of ASEB Lines/Feeder :a. All shut downs related to ASEB lines/feeders has to be taken from the authorized person

of ASEB. OILs Concerned Engineer/Competent Person will ask in writing for shut down ofASEB line to the ‘Authorized’ person of ASEB, who in turn will give in writing the shutdowndetails. All shorting/earthing & removal of the same after completion of job shall be done byASEB’s personnel. Also, all the jobs on ASEB line to be done & completed in the presenceof the representative of ASEB.

b. After completion of work on ASEB lines, OIL’s Concerned Engineer/Competent Personwill inform the ‘Authorized’ person of ASEB regarding the job completion. Thereby, theremoval of shorting/earthing & energizing the line will be the sole responsibility of ASEB’spersonnel.

c. Remove danger board and energize spring to close the breaker, if required.d. Insert PT/remove earth and close isolator for breaker.e. Close breaker and file the ‘EPW’.

1.14 33KV Power House ASEB Feeder :a. If the ASEB feeder trips at P/H due to O/C or E/F, the same will be energized only after

ASEB’s representative gives in writing that fault is cleared & provides OIL all the IR (InsulationResistance) readings of the feeder to OIL.

b. For any maintenance to be carried out by ASEB on this feeder from P/H, the ASEB’s‘Authorized’ person will ask for shut down in writing from OIL. The same will be energizedonly after the ‘Authorized’ person of ASEB gives in writing regarding the ‘completion ofwork & ready for energization to the OIL’s representative.

c. All energization & de-energization of ASEB feeder at P/H will be done in presence of theauthorized representative of ASEB (i.e. SDO).

d. For carrying out any work in the electrical switch yard at P/H on ASEB feeder (work onbreakers or relays of ASEB feeder). OIL’s representative will telephonically inform ASEB’srepresentative regarding shut down of feeder & the period of shut down. After completionof work, OIL’s representative will inform telephonically to ASEB regarding completion ofwork & energization of feeder.

1.15 Operation/Shutdown/Maintenance procedures for 33 KV Power Station Switchyard.

a. All the gates of the switch yard have to be kept locked and one set of keys has to be keptin power station control room under the custody of shift engineer while the other set of


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keys has been kept in the duplicate key board in electrical office. Only for operation/shutdown/maintenance work of the switchyard, the gate keys can be obtained from power stationshift engineer after recording signature, time and date. Under no circumstances, the gatekeys of the switchyard should be handed over to any person below the rank of AssistantElectrical Engineer.

b. All other keys for isolators etc. are kept in the new 33 KV keyboard at the Power stationcontrol room.

1.16 Operational/shutdown procedures :

a. PM Sectional Engineer In-Charge will be responsible for the normal operation of theswitchyard. Shutdown for all 33 KV feeders originating from power station switchyard willbe given by the Engineers of Distribution section not below the rank of AEE in consultationwith Sectional Engineer In-Charge of PM during normal working hours. After normal workinghours shutdown will be arranged by stand-by Engineer. For all matters, power station shiftengineer will contact sectional engineers of PM & Distribution section during normal workinghours and stand-by Engineer after normal working hours.

Maintenance :b. Sectional Engineer In-Charge of PM & Distribution section is responsible for all repairs/

maintenance connected with the 33 KV switch yard.

1.17 Reclosing of 33KV/11KV feeder breakers following tripping of the breakers atDuliajan Power station.

The procedure to be adopted in case of tripping of feeder breakers on fault in DuliajanPower Station will be as under:

a. During normal working hours, any 11kV outgoing feeder (and not 11kV feeders for auxiliarytransformers and step-up transformers) trips, the shift engineer on duty shall immediatelyinform any sectional engineer or sectional Head of Distribution section/HOD (in case nobodyis available). After normal working hours/holidays/bandh days the shift engineer on dutyshall immediately inform the Stand-by engineers, failing which back-up Stand-by/CEE (F)/HOD (in case nobody is available).

b. After consultation with concerned engineers as per para (a.), reclose the breaker onlyonce if the feeder trips on Earth Fault. In case the feeder trips again, the shift engineer willnot reclose the breaker and he will then inform the concerned engineers as per para (a.)

c. If any feeder trips on Over Current, the shift engineer on duty shall not reclose the breakerand shall immediately inform the concerned engineers as per para (a.), giving detailedinformation (e.g. relay indications, load drop , heavy flicker etc.).

d. In case the feeder trips on Over Current or the feeder did not stand on Earth Fault, patrollingof the faulty feeder(s) will be arranged by sectional engineers or sectional Head of Distributionsection during working hours and after normal working hours the stand-by engineers,either with the help of stand-by gang or in consultation with sectional In-charge of Distributionsection. In case of requirement the distribution engineers or Stand-by engineers/Back upEngineers (as per applicable) should accompany the patrolling gang. After patrolling andclearing of all infringements from the lines, if any, the above field/Stand-by engineer (s) willadvise the shift engineer on duty to reclose the appropriate feeder breaker(s) concernedand the shift engineer will then close the breaker(s) and record the same.

e. In case the above field/stand-by engineer(s) find difficulty to take a decision, he/they willimmediately contact back-up stand-by engineer/CEE (F)/CE (Elect.) and act in consultationwith them.

f. Should the above field/stand-by engineer(s) find that the clearing of fault in the interruptedfeeder will take considerable time and that may lead to interruption of power supply tooperationally critical installations, they will arrange restoration of power supply through


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alternative feeders, if possible.

1.18 SAFETY ASPECTS WHILE PROVIDING OIL’S POWER TO SOCIO-RELIGIOUSFUNCTIONS IN OIL’S PREMISES

a. Company’s representative shall check the load requirement & feasibility of giving powersupply before giving clearance for providing power.

b. Power supply shall be provided only if the pandal is erected away from the overhead line (ifany) as per the safe distance mentioned in I.E. Rules, 1956.

c. If the job is to be done by the contractor, OIL’s representative will give the shutdown of thefeeder from where power is to be tapped.

d. The internal wiring shall be carried out by the customer according to the I.E. Rules by aqualified and holding valid work permit or supervisory certificate of competency issued bythe state Electrical licensing board, Assam & the sole responsibility of leakage/fire due todefective wiring will be that of the customer.

e. An ELCB shall be provided in the circuit as well as all the individual circuits/sub-circuits bythe customer to ensure protection from leakage currents and should ensure the healthinessand the safety of the wiring carried out and the fittings/electrical equipments got installedby him/them in his/their premises.

f. OIL’s representative shall check the work done by the OIL’s Electrical contractor beforegiving power, in this regard, the contractor will ask for clearance in writing for carrying outthe work & will return the same to OIL’s representative after completion of work.

g. The occupant/organising committee should ensure that the total connected load in hispremises for the function shall not be more than sanctioned limit by OIL under anycircumstances. OIL will not be responsible for any short circuit/leakage/fire caused byoverloading or defective workmanship by the customer.

1.19 SAFETY ASPECTS WHILE PROVIDING OIL’S POWER TO SOCIO-RELIGIOUSFUNCTIONS IN OUT SIDE OIL’S PREMISES

h. Guidelines issued by Administration department shall be followed while giving power supplyto parties residing outside OIL’s premises.

i. OIL’s power supply to outside parties shall not be provided unless the owner submits‘NOC’ from ASEB as applicable.

j. OIL shall provide power supply only when the owner submits a load declaration, details oflocation and an undertaking in the prescribed formats (to be provided by OIL).

k. The internal wiring shall be carried out by the customer according to the I.E. Rules by aqualified and holding valid work permit or supervisory certificate of competency issued bythe state Electrical licensing board, Assam & the sole responsibility of leakage/fire due todefective wiring will be that of the customer.

l. An ELCB shall be provided in the circuit as well as all the individual circuits/sub-circuitsm. The occupant/organising committee should ensure that the total connected load in his

premises for the function shall not be more than sanctioned limit by OIL under anycircumstances. OIL will not be responsible for any short circuit/leakage/fire caused byoverloading or defective workmanship by the customer.

n. The occupant/organising committee should carry out the electrical jobs by a competentElectrical supervisor/Electrician and should ensure the healthiness and the safety of thewiring carried out and the fittings/electrical equipments got installed by him/them in his/their premises.

o. Oil will not be responsible for any untoward incidents occurred inside the customer’spremises while using OIL’s power.

p. Only power supply shall be provided to the party at a single point.


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2.0 PART –II ELECTRICAL INSTALLATIONS IN HAZARDOUS AREAS

2.1 GENERAL :

This section deals with electrical installations in hazardous areas only. Electrical installations and

their operation in Oil fields on land are regulated under the Indian electricity Rules 1956 and also

Oil Mines Regulations-1984. A careful study of these documents particularly Chapter-X of IER-

1956 and Chapter-VII of OMR-1984 is recommended. The important safeguards against electrical

hazards are however mentioned below :

In oilfields, there is possibility of accidental release of flammable liquids and natural gas at drilling

and production installations. There is also chance of electrical spark from electrical equipments

installed in such areas which can result in fire and explosion. Hence careful selection, proper

installation and regular maintenance of electrical equipment can prevent such incidents/accidents.

It should however be understood, that ventilation system at the installations are generally good as

most of the installations and well sites are in the open air, Hence the extent of hazardous area in

many cases can be reduced. The number of special electrical equipment can also be reduced by

installing number of equipment in safe areas as far as practicable.

2.2 STATUTORY REQUIREMENTS :

All electrical equipment installed in hazardous areas have to comply with the applicable statutory

requirements. The statutory authorities in India for industrial installations are as follows:

i. Directorate General of Mines Safety (DGMS), Dhanbad.

ii. Chief Controller of Explosives (CCE), Nagpur.

iii. Central Electricity Authority (CEA)

2.3 HAZARDOUS AREA – DEFINITION AND CLASSIFICATION :

DEFINITION

This is an area where during normal operations a hazardous atmosphere is likely to occur in

sufficient quantity to constitute hazard.

A hazardous atmosphere is an atmosphere containing any flammable gas or vapor in a

concentration capable of ignition.

CLASSIFICATION OF HAZARDOUS AREA :

In order to determine the type of electrical installation suitable for use in different conditions of

hazardous atmosphere, the hazardous areas have been classified into three zones viz, Zone-0,

Zone-1 and Zone-2, according to the degree of probability of the presence of hazardous atmosphere.

Refer OIL Mines Regulations No.- 73, 74 & 75 of OMR-1984 including DGMS classified circular

issued time to time.

Zone-0 hazardous area means an area in which hazardous atmosphere is continuously present.

Such a condition exists in the vapor space of separators, storage tanks, the immediate vicinity of

vapor exhaust and discharge end of riser pipes of flare stacks. Since a hazardous atmosphere

exists continuously, any area or spark resulting from failure of electrical apparatus in such an area


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would almost certainly lead to fire or explosion. Therefore, any installed electrical apparatus must

afford an absolute protection.

Zone-1 hazardous area means an area in which hazardous atmosphere is likely to occur only

under normal operating conditions. Such conditions are likely to occur at any time at oil and gas

wells and production installations, which therefore require the fullest practicable electrical protection.

Zone- 2 hazardous area means an area in which hazardous atmosphere is likely to occur only

under abnormal operating conditions which may be caused only by the simultaneous occurrence

of spark resulting from an electrical failure and a hazardous atmosphere arising through failure of

control system.

EXTENT OF HAZARDOUS AREA:

The different operational areas in oilfields are to be classified in different zones, as defined above,

by the Director General of Mines Safety, see Regulations 74 of Oil Mines Regulations 1984, Refer

DGMS Circular No. 1 (6) 2001-Genl./3604-3753 of Sept, 12, 2001 for the extent of hazardous

areas in Drilling Rigs & Production installations (refer Annexure-I in page- 49)

2.4 SELECTION OF ELECTRICAL EQUIPMENT FOR USE IN HAZARDOUS AREAS :

The electrical equipment should be certified by the competent authority for its flameproof ness,

intrinsic safety, increased safety or pressurized protection in respect of gas group-II A (for propane,

butane and other hydrocarbons). Further its use should be approved by the DGMS, Electrical

equipment suitable for use in the three classified zones are mentioned below :

Procedure for selecting Electrical Equipment :

Following factors shall be considered for proper selection of electrical apparatus and equipment

for areas where flammable gas or vapour risks may arise :

i. Area classification (Zone 0, 1, 2 )

ii. Gas group classification i.e. gas group.

iii. The characteristics of the gas or vapor involved in relation to

iv. Ignition current or minimum ignition energy in case of installations of intrinsically safe

apparatus, or

v. Safe gap data in case of installations for flameproof enclosures.

vi. Temperature classification.

vii.Environmental condition in which apparatus is installed.

a. Zone-0 Area

i. Use of electrical equipment including light fitting is prohibited in Zone-0 hazardous area.

b. Zone – 1 Area

i. Motors, transformers and switchgear, refer IS-2148-1968.

ii. Light fitting, flame proof-refer IS-2148- 1968 and IS-22006-1976.

iii. Telephone and communication equipment should be of intrinsically safe type.

c. Zone – 2 Area

i. Motors, transformers and switchgears, flame proof or increased safety or pressurized

equipment-refer IS-2148-1976.


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ii. Light fitting, flame proof-refer IS-6381- 1972

iii. Telephone and communication equipment should be of intrinsically safe type

2.5 FLAMEPROOF ELECTRICAL EQUIPMENT :

The hazard due to electricity in hazardous atmosphere is sought to be contained by the

use of flameproof equipment. It is an equipment that can withstand without damage, any

explosion of the inflammable gas that may occur within it and can prevent the transmission

of flame to ignite the inflammable gas, which may be present in the surrounding atmosphere.

2.6 SAFE PRACTICES FOR MAINTENANCE OF FALMEPROOF ELECTRICAL

EQUIPMENT :

Introduction :

According to IS:13408 (Part-I)-1982 explosion proof electrical equipment as per the following list

should be used in hazardous areas.

Area Type of Explosion proof equipment to be used

Zone-1 Intrinsically safe equipment Ex ib

Flame proof equipment Ex ‘d’.

Pressurized protected equipment Ex ‘p’

Zone-2 Equipment used in Zone-1

Increased safety Ex “e”

Non Sparking Ex “n”

Page 13. Page 14 & page 15 of IS:5572-1994 has detailed the Division of various

hazardous Zone from the source of hazard. The persons doing inspection & mainte

nance should familiarize themselves with the classification.

It should be recognized that even carefully selected electrical equipment installed for safe operationin hazardous area can become a potential source of danger unless its flameproof features areproperly maintained. The recommendations listed below provide guidelines in this respect.

a. The design should not be altered in any-way, the spare parts supplied by the manufacturershould only be used.

b. Flanges should be wiped clean and re-assembled so as to maintain the prescribed air gapin the flange joint. The air gap should not exceed 0.5 mm when the length of the flange pathis 25mm. The gap should be checked with feelers.

c. UI bolts and studs should be in position. Broken studs should be immediately replaced.Shroud around bolts should not be damaged.

d. Terminal boxes, which are dry, should be free from dust and moisture, those with compoundit them should be completely filled with compound.

e. Shaft glands should have the prescribed clearance, which should be checked.

f. Oil immersed apparatus should contain oil up to the prescribed level.


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g. Glass fittings should be intact with retaining rings.

h. Over load and earth leakage relays should have the correct setting.

i. Frequent opening of FLP equipment should be avoided. In the case of opening up of aflameproof enclosure in the hazardous area, the warning inscription to switch “OFF” thesupply elsewhere must be strictly observed. While assembling it must be ensured that nobolts are missing and diametrically clearance between bolt and bolt hole are as per thecertification document. In other words no under size bolt should be used.

j. No corrosion is permitted on the machined surface. The machined surface should not bepainted or to have any solid obstacles which can prevent breathing.

k. Aluminum paint, should not be used for painting. The sealing box used for cable entrymust be filled with compound.

l. FLP well glass fixtures: Wire guard protection must be there in the case of type “B” glasswhich is untoughened and is not impact resistant. For well glass fixtures with type “A”glass external wire guard is not required as it has passed impact test.

m. FLP double compression type cable gland: At least six thread engagements must be therewhen the table gland is connected with external FLP equipment. Internal compressionsealing rubber ring should be replaced whenever found to be worn out. The sealing ringshould also be single piece with uncompressed axial height not less than 25 mm.

n. FLP motor: In case of rewinding or major repairs the motor should be checked for flameproofcharacteristics or explosion test should be done. For air cooled motor of cast iron or MSconstruction fan blade should not be made of light alloy. Similarly motors of light alloyconstruction should not have MS or cast iron fan blades.

o. Increased safety-rotating machines: there must be periodic inspection (at intervals notexceeding 2 years) regarding air gap between stator and rotor and redial clearances. Therubber gaskets provided for the IP 55 protection should be periodically replaced wheneverobserved to be worn out.

p. For increased safety light fittings enclosed break lamp holder should be used.

q. Non-sparking ex ‘n’ Equipment: periodic inspection should be made regarding radial airgap inside the motor. The maintenance as suggested for Ex ‘e’ motors should also befollowed in these cases.

r. Pressurized Enclosure Ex’p’ Equipment : In case of rotating apparatus account should betaken of the cooling arrangement so that adequate over pressure is maintained in all partsof the enclosure where inward leakage could occur. The electrical connection should beindirect the terminal enclosure may be pressurized with the same source of pressurizedgas. Alternatively this may have Ex ‘d’ type protection.

s. Intrinsically safe system: It should be checked that the apparatus has been installed asper the certificate document. Try to avoid replacement of battery in the hazardous area incase of portable instrument.

t. A maintenance schedule should be drawn up for flameproof and other special electricalequipment. The electricians and their helpers should be trained in the correct technique ofmaintenance. A publication of the National Council for Safety in Mines on “ MAINTENANCEOF FALMEPROOF ELECTRICAL EQUIPMENT” provides useful guidance in this respect.


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2.8 PRECAUTIONS DURING MAINTENANCE AND REPAIR WORK IN HAZARDOUS

AREAS.

a. When any maintenance, repair or test work of electrical equipment is required to be

undertaken in any classified hazardous zone, advance information should be given to IM in

case of planned jobs so that he can arrange for the required safety precautions to be

taken. In case of emergency jobs, telephonic information to be given to the IM/the concerned

persons.

b. A written permit for work should be obtained from the IM or the Authorized Person of the

installation. The permit should specify the precautions to be observed and the procedure

to be followed during the work. On completion of the jobs, the permit should be surrendered

to the issuing authority.

c. Work involves excavation of ground, adequate precaution should be taken to ensure that

no oil, gas pipelines, water pipeline and telecommunication cable laid below ground is

damaged during such excavation. It should also be ensured that the excavation does not

cut off access of fire tenders to the work site in case of any emergency.

d. Before undertaking any electrical repairs, it should be ensured that the electric supply line

has been de-energized. Effective steps should be taken to prevent accidental energizing

of electrical supply line.

e. If a megger is to be used to test insulation of the cable from the supply and, it should be

ensured that the covers of the flameproof equipment are kept intact till completion of the

test. Only intrinsically safe megger should be used for the purpose. In the case of electrical

circuits containing solid-state equipment, tests with megger should not be undertaken.

f. If a blowlamp is to be used, it should be ensured that the area is made gas free. For this a

request has to be made to the IM/ IM or the Authorized Person of the installation. Tests with

an approved type of instrument or explosive meter should be made to measure the

concentration of flameproof gas in the atmosphere.

g. A request has to be made to the IM for arranging adequate arrangements for firefighting

should be ensured in consultation with the IM/Fire service dept. It should be ensured that

persons engaged in electrical repair work are conversant with the use of basic fire

extinguishers.


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3.0 PART –III

SAFE WORKING PROCEDURE FOR WORKING ON ELECTRICAL MACHINES/

EQUIPMENT IN AN ELECTRICAL DRILLING RIG.

3.1 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON A DC MOTOR,

(Shut down for electrical maintenance)

a. Inform the Driller-in-charge for (Draw Works & Mud Pumps) & Mechanical JE (for Mud

Pumps) before starting the job.

b. Switch off the isolators in blower & auxiliary motor starters & remove Attach the control

fuses.

c. Attach caution boards on the isolator handles in blower and auxiliary motor starter panels.

d. Switch off the field supply isolator (also put the field AUTO/HAND switch in OFF position).

e. Attach caution boards on the field supply isolator handle.

f. Switch off the heater supply MCB.

g. Remove the control cable plug of the DC motor at motor end.

h. Open the DC motor terminal box & inspection box covers.

i. Check with Multimeter for any voltage between armature, field, other terminals & ground.

j. Discharge all terminals to ground with a discharge stick.

k. Connect both the armature terminals to motor earth point with a standard shorting loop.

l. Carry out the planned job.

m. Remove short from armature terminals & re-fix terminal box cover & inspection covers.

Check tightness of gaskets of the covers.

n. Connect back the control cable plug of the motor at motor end.

o. Replace the control fuses in the starters & switch on the isolators.

p. Switch on the field supply isolator & put the field AUTO/HAND switch in AUTO position.

q. Switch on the heater supply MCB.

r. Remove all the caution boards from isolators.

s. Inform the Driller-in-charge & mechanical JE about the job completion of the job.

t. Record in the logbook & maintenance register. Write a note for next shift-in-charge if the

job could not be completed. JE (Electrical).

3.2 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON THE DRIVE OF

A DC MOTOR.

( Shut down for jobs other than electrical, e.g. for mud pump maintenance etc.)

Concerned departments JE will inform the Driller-in-charge & JE (Electrical) about the job & apply

for Electrical Clearance to Work (ECW) in the approved format available at site (sample format

given below explaining about the modalities).


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Electrical Engg.3.3 MODALITIES FOR ECW PERMIT FOR DRILLING AND WORKOVER WELL SITES :

a. Electrical permit should be requested by the authorized person of the concerned

department to the Shift Engr. (Drilling/Drilling In-charge for taking electrical power shut

down to the particular equipment).

b. Shift Engr. (Drilling)/Drilling in-charge will request J.E. (Electrical)/Electrical In-charge to

obtain Electrical power supply isolation to the said equipment.

c. J.E. (Elect.)/Electrical In-charge/Authorised person does electrical isolation, discharges

the feeder and gives back permit to Shift Engr. (Drilling/Drilling In-charge).

d. Shift engr.(Drilling)/Drilling In-charge hands over the permit to the concerned deptt’s

authorised person for carrying out the specific work.

e. The authorised person of the concerned dept. after completion of work returns the electrical

permit to Shift Engr. (Drilling)/Drilling In-charge.

f. Shift Engineer (Drilling)/Drilling In-charge in turns hands over the same to J.E. (Elect.)/

Electrical In-charge for re-energisation of electrical system/equipment.

g. J.E.(Elect.)/Electrical In-charge energises the equipment or electrical line connected to

the equipment and hands over the electrical permit to the installation Manager for record.

h. Shift Engr.(Drilling)/Drilling In-charge then starts the equipment for operation.

NOTE:

i. The above modalities are to be followed for carrying out job on a non-electrical equipment

such as Draw-works, pumps compressors, mud agitators, desanders & desilters etc.

ii. When more than one group are called upon to work on the same equipment, J.E.(Elect)/

Elect. In-charge should ensure that all the sheets related to the single shutdown/clearance

from different groups are received back prior to recharging of the equipment.

iii. When the equipment has facility to have more than one source of electrical supply, positive

electrical isolation must be ensured and effective earthing of line/equipment for the isolationed

portion must be ensured.

iv. During positive isolation, the control side of power supply/circuit breaker etc. shall be tagged

with caution Board stating “MEN WORKING ON LINE” to caution against anyone attempting

in advertently closing them.

v. While carrying out electrical isolation, the persons connected with the work should use only

approved & tested protective equipment (Rubber gloves, Shoes, mats, other tools/tackles &

instruments).

vi. For a shutdown separate sheets are to be issued to each work-group working on the equipment

& marked sheet no. 1,2,3.

vii.Total no. of sheets issued for a particular shutdown must be indicated clearly. This will also

indicate the total no. of work-groups working on the equipment.

viii.Electrical permit to work is valid till the time & date indicate.

ix. Switching off & discharge of an equipment must be indicated very clearly. Any deviation must

be written clearly & countersigned by the person concerned.

x. Proper safety gadgets must be used while working.

xi. Before switching on the equipment the following points should be ensured.

• All the sheets of the particular permit to work have been collected back.

• Each sheet is complete in all respect.

• Physcal inspection of the equipment is complete.

xii. Electrical JE will do the following while switching off.

a. Switch off the isolators in blower & auxiliary motor starters & remove the control fuses.

b. Attach caution boards on the blower & auxiliary motor starter panel isolator handles.

c. Switch off the field supply isolator & put the field AUTO/HAND switch in OFF position.


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d. Attach caution boards on the field supply isolator handle.

e. Switch off the heater supply MCB.

f. Remove the control supply cable plug of the DC motor at PCR end.

g. Inform the concerned department about the electrical shut down so that they can carry out

other job.

h. After the concerned departmental has carried out the planned job, they will return the duty

filled ECW to the electrical JE accordingly.

i. Electrical JE will do the followingwhile switching on:

a. Connect back the control cable plug of the motor at PCR end.

b. Replace the control fuses in the starters & switch on the isolators.

c. Switch off the field supply isolator & put the field AUTO/HAND switch in AUTO position.

d. Switch on the heater supply MCB.

e. Remove all the caution boards from isolators.

f. Inform the Driller-in-charge and concerned department’s JE that the drive is available

for testing from their end.

g. Electrical JE, will fill-up the last para of EPW & file the same.

3.4 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON AN AC MOTOR.

(Shut down for electrical maintenance)

a. Inform the Driller-in-charge & mechanical JE before starting the job.

b. Switch off the isolator/ MCCB & remove the control fuse of the motor starter.

c. Attach caution board on the isolator/MCCB handle.

d. Remove the plug of the motor cable at PCR end.

e. Open the terminal box cover & test the terminals for any voltage with a Multimeter.

f. Discharge all the terminals to ground with a discharge stick.

g. After completing the job, re-fix the terminal box cover & connect the motor cable plug at

PCR end.

h. Replaced the control fuse in the starter & switch on the isolator/MCCB.

i. Remove the caution board.

j. Inform the Driller-in-charge & mechanical JE about job completion.

k. Record in the log-book & maintenance register. Write a note for next shift-in-charge if the

job could not be completed.

3.5 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON THE DRIVE OF

AN AC MOTOR.

(Shut down for jobs other than electrical, e.g. for pump maintenance of a mud mixer).

Concerned department’s JE will inform the Driller-in-charge & JE (electrical) about the job & apply

for Electrical Clearance to Work (ECW) in the approved format available at site.

Electrical JE will do the following while switching off:

a. Switch off the isolator/MCCB & remove the control fuse of the motor starter.

b. Attach caution board on the isolator/MCCB handle.

c. Remove the plug of the motor cable at PCR end.

d. Inform the concerned department about the electrical shut down so that they can carry out

their job.

e. After the concerned department has carried out the planned job, they will return the duly

filled ECW to the electrical JE according.


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Electrical JE will do the following while switching on:

f. Replace the control fuse in the starter & switch on the isolator/MCCB.

g. Connect back the motor supply cable at the PCR end.

h. Remove the caution board.

i. Inform the Driller-in-charge and concerned department’s JE that the drive is available and

can be tested from their end.

j. Electrical JE will fill-up the last para of EPW & file the same.

3.6 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON A STARTER

PANEL IN ACPCR.


b. Switch off the isolator/MCCB, Remove control & power fuses in the starter. Short the

outgoing terminal of MCCB to ground with a shorting loop.

c. Disconnect & insulate the control circuit wires that are interconnected to DC-PCR in case

of blowers, MP auxiliary motors & super charger starter.

d. Check all naked terminals for any voltage with a test lamp (400V,double lamp) and then

with a Multimeter.

e. Discharge all terminals to ground with a discharge stick.

f. Carry out the planned job.

g. Remove all shorting loops after completion of the job.

h. Reconnect all control circuit wires as mentioned in point 3 above.

i. Re-fix power & control fuses.

j. Switch on isolator/MCCB

k. Inform the Driller-in-charge & mechanical JE about the job completion.

l. Record in the log-book & maintenance register. Write a note for next shift-in-charge if the

job could not be completed.

3.7 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON A GENERATOR

PANEL:


b. Switch off and rack out the generator breaker & stop the engine.

c. 120V DC power will always be available from bus PT in voltmeter selector switch even if

engine is made off. Remove bus PT fuses while working on this switch.

d. 12V DC power from battery is always available on ECS. Switch off battery supply while

working on this switch.

e. Insulate wires to AC module pin nos. 537 through 543 while replacing AC module.

f. Take complete shut down of 600V bus in case of any job on the backside of breaker

cradle.

g. Stop all the running engines.

h. Check for residual voltage in the bus and naked metal plate.

i. Discharge the bus and all exposed metal parts to ground.

3.8 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON AN SCR PANEL:

a. For replacement of DC module, control transformers etc.

i. Inform the Driller-in-charge about the shut down and unavailability of the SCR. Exercise

extreme care while working in SCR panel due to presence of un-insulated high voltage

parts & buses.

ii. Remove DC safety (control) fuses & switch off ACB before working on DC modules,

control transformers & cards.


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iii. Insulate wires to terminal nos. 114, 117, 122, 125 & 133 while replacing DC module.

b. For replacement of SCRs or assignment contactors :

i. Inform the Driller-in-charge about the shut down and unavailability of the SCR. Exercise


parts & buses.

ii. Take complete shut down of 600V bus while replacing assignment contactor or SCRs. In

case any of the generator is to be kept running off the bus (because of engine problem

etc.) rack out the breaker of the running generator.

iii. Checked for residual voltage in the bus and naked metal parts.

iv. Discharge the bus and all exposed metal parts to ground.

v. Short all the three phases of 600V AC bus to ground in the SCR panel under repir.

vi. During contactor or SCR replacement, place cardboard pieces over blower openings to

prevent any hardware, tools from falling into blower assembly. While replacing SCR blower,

switch off and rack the ACB out of chassis and remove associated fuses.

3.9 OBSERVE FOLLOWING SAFETY MEASURES FOR WORKING ON A FIELD

PANEL:

a. Inform the Driller-in-charge about the shut down and unavailability of the SCR. Exercise


parts & buses.

b. Switch off the field supply isolator of the field circuit under repair.

c. Cover the heat sinks of other energized field supply, In case they are below the working

area, with an insulating sheet to prevent short circuit due to accidental fall of tools.

d. Take shut down of the other energized field supply in case the live heat sink is close to the

working area.

3.10 STANDARD SAFETY TOOLS DEVICES :

a. 400 V(double bulb) test lamp,

b. Multimeter

c. Discharge stick

d. Rubber hand gloves (Rated 11KV for standard use)

Notes :

i) While working in panels such as SCR panel or generator cubicles, tie the tools to the wrist

with a short length of cotton/plastic rope so that it will not fall inside the panel components/

compartments. Alternatively, the tools can be tied to the top cover of the panels.

ii) While replacing AC module/DC module, unscrew the terminals one by one and check for

voltage. Stick a piece of PVC tape over the terminal and mark the wire (if ferrules are not

present). Control voltage may be present in some terminals.

3.11 EARTHING OF EQUIPMENT IN DRILLING RIGS

a. For safety of operating staff and equipment itself, earthing or grounding of electrical equipment

in a drilling rig is very important. In addition to the electrical equipment, all enclosure,

mounting structures, skids etc. (for example, ACPCR and DCPCR body, HSD and LDO

tanks, mud tanks, cable trays, ghoomties, crew huts, C G I sheet covered sheds) Should

be earthed.

b. The scheme of rig electrical earthing is based on IS:3043 and IE Rules, 1956.

c. All electrical equipment, enclosures, mounting structures, skids etc. are solidly earthed by

two independent earth conductors which, in turn, are earthed at various places by earth

electrodes. These earth electrodes are of Galvanized iron pipes and are suitable for driving

into the ground by hammering, after the earth has been softened by watering. Use of large

number of electrodes ensures good earthing, i.e. low earthing resistance, thus providing


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maximum safety. All the earth electrodes are again interconnected with a G.I. strap.

3.12 NEUTRAL EARTHING

In the ACSCR system, the alternator neutrals are not earthed, as they are feeding SCR

bridges. Therefore in order to ensure safety on the AC system, the secondary star points

of the 600 KVA transformers are grounded solidly or with NGR.

PROCEDURE :

a. Drive the earth electrodes into the ground by hammering with a sledgehammer. Also,

earth pits may be dug in the ground if the soil is not enough for hammering of electrodes.

Bury the earth electrodes in the pits. Decide the tentative positions for earth electrodes for

transformer # 1 & # 2, power packs # 1, 2, 3, air compressor utility house, fuel pump,

water booster, mud mix motors ; super charge and mud pump motors; desander, desilter,

shale shaker, degasser motors. Draw Works motors, mud agitator motors. BOP motor,

recycling motor, ghoomties/crew hut as per the requirement and lay out drawing.

b. Measure earth resistance of each electrode. Earth resistance measurement procedure is

described in ANNEXURE-II (NOTE : resistance should be less than 2.0 Ohm. If not, take

steps to lower the resistance).

c. Connect all electrodes with the main loop. Measure the combined earth resistance of the

loop. This should be less than 0.5 ohm.

d. Earth the motors by two separate and distinct earth conductors. Earth all PBSs.

e. Earth ACPCR and DCPCR body, HSD and LDO tanks, mud tanks, cable trays, Bunk

houses/crew huts, CGI sheet.

f. Enter the test results in a proper register, kept exclusively for that purpose. The records

should be signed by the sectional Supervisor/Engineer.

NOTE :

i) G.I. stranded wires should be terminated with solder type lugs for good electrical

conductivity.

ii) Earth resistance values should conform to requirement of IS : 3043 & relevant OISD

standards.

iii) Cross sectional area of earth conductor should not be less than 14 mm² or half of the

cross sectional area of main conductor, whichever is the maximum.

3.13 MATERIALS /TOOLS REQUIRED

a. Earth electrodes – as per the requirement and lay out drawing.

b. Main earth loop- 5/8” G.I. wire or 2” x ¼” G.I. strip

c. Earth conductor for motors-8 SWG G.I. wires for small (1/1.5 HP) motors, 1” x ¼” G.I. strip

for 75 HP mud agitator motors.

d. U clips-5/8” x ½”.

e. Nut/Bolts with washer -3/8” x 1.5”

f. Aluminium paint

g. Wire brush

h. Paint Brush

i. Slide Wrench (12”)-02 no.

j. COMBINATION PLIERS -01 NO.

k. Cutting pliers -01 no.

l. Earth augur.

m. Pointed solid iron rod (Chabol)

n. Earth tester.

o. Sledge hammer.


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4.0 PART-IV: SAFE OPERATING PROCEDURE IN OCSS & GCSS:

4.1 EMERGENCY SHUTDOWN SYSTEM IN GCS S WHERE ELECTRICAL DRIVEN GASCOMPRESSORS ARE INSTALLED.

An emergency shutdown system is available in all the GCSs where an Electrical operatedswitch is located near the gate of the installation. This disconnects electrical power supplyto the installation. The ESD system shall be used by the installation-in-charge afterassessing the requirement of the station to be electrically disconnected. The ESD switchis protected against accidental activation & identified clearly.

a. Objectives of Electrical Safety system in Production Installation :i) To prevent undesirable events that could lead to a release of spark due to Electrical short

circuits.ii) Shut down the affected part to stop the release of sparks.iii) Prevent shocks due electrical hazards like current leakages.iv) Isolate Power to the Electrical apparatus in case of fire.

b. Emergency Conditions:i) Electrical short circuits, sparking and shocks.ii) Fire in Production installation.iii) Gas leakages in excess of 20% of LEL.iv) Leakage of gas line.

c. Testing of ESD :Once in every six months, the ESD should be tested by the installation-in-charge to ensureproper functioning of the system.

4.2 ARTIFICIAL LIFTING OF OIL BY ELECTRICAL SUBMERSIBLE PUMP (ESP):In this system, pump intake & driving motor with connecting cable are lowered in a well ortubing. The subsurface cable is connected through pigtails & mini mandrel of the wellheadto the surface cable & then brought to the switchboard. The installation is generallyunmanned. The hazards in this method of lift are due to electricity and fire. The followingprecautions are recommended :

While lowering the ESP into the well, it should be ensured that :

a. The rig mast should be perfectly centered for carrying out running in & pulling out operationof ESP.

b. The connection of cable to motor are made as specified by vendors.c. The couplings in between the sections of the complete assembly are properly fitted.d. The speed of lowering is not more than 1.5 mtr per min. (one stand /10-12 minutes).e. The cable is clamped to the tubing at every 12-15 ft.f. Rotary slips and tubing tongs are not engaged to the cable.g. The cable is suitably guided from the drum so that it unwinds uniformly without over lap &

is not stretched by the movement of the elevator during running in & pulling out operation.h. It is to be ensured that no foreign material particularly, the cut piece of cable clamps do not

fall into the well, otherwise this well lead to stuck up during pulling out operation.i. When connecting and disconnecting tubing’s, the electric cable should be safely held by a

metallic hook connected to the derrick/mast.

4.3 SAFE PRACTICES IN PRODUCTION INSTALLATIONS :a. Before taking up any electrical work, the permission from the installation-in-charge/

workpermit should be obtained.b. Cold work permit should be obtained from installation-in-charge for laying of cable in


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production installation in the format designed in OISD-105 & duly signed.c. Earthing of all electrical equipment & apparatus , pressure vessels, manifolds, etc should

be checked once in every year & the earth resistance readings should be recorded,Earthing pits should be clearly marked for inspection. The values of earth resistance shouldcomply to IE Rules-1956, IS-3043 & OISD-149. Earthing of equipment is elaborated inpart-III of this sop.

d. The preventive maintenance of all electrical equipment should be carried out periodically& the records of such maintenance shall be kept in the department.

e. All electrical equipment shall be installed as per classification of hazardous area as perDGMS circular no. 1 (6) 2001-Genl/3604-3753 of Sept. 12.2001.

f. All electrical panels should have rubber mats of suitable voltage rating for the safety of theworking personnel.

g. All the electrical protective devices, like relays, shall be tested once in two years to ascertainthe healthiness of the protective system. The manufacturer’s catalogues & recommendationshall be followed for testing of the protective relays.

h. All the electrical apparatus/equipment shall be installed as per the guidelines provided,taking into account the hazardous area classification in that installation & the type ofequipment requirement for such areas. DGMS Circular & the relevant IS Codes 8240 &5571 should be followed for guidelines.

i. Every production installation should be protected against lighting by suitable lightingarresters which should be installed as per guide lines in IS-4850-1968. Lighting arrestersshould not be installed directly on the storage tanks.

j. While loading & unloading oil in tankers/ bowsers, its engine should be stopped & batteryisolated from the electric circuit. The engine should not be re-started & the battery shouldnot be connected to the electric unit until all tanks & valves are securely closed.

k. At the load area, all oil pipelines, filling & delivery hoses, metallic loading area, swiveljoints, tank & chassis of tank vehicle should be electrically continuous & efficiently earthed.

l. Electrical control room, switchgear room, computer room etc. should be maintained ingood condition.

m. There should be rubber mats in electrical control room & switchgear room & cables shouldbe properly laid in trenches, which should be filled with sand. Lighting fixtures should bepermanent & no hanging wires or naked bulbs are permitted. There should not be anyleakage of water from the ceiling in electrical control room, switchgear room, starter panelsof all equipment should be closed when equipments are in operation.

n. Use of electrical equipment including light fittings is prohibited in Zone-0 hazardous area.Flameproof and intrinsically safe light fittings/equipments should be used in Zone- 1 &Zone-2 hazardous areas as per Is-2148-1981 & IS-8289-1976 & IS- 2206-1976.

o. All electrical equipments & fittings should be maintained properly.p. The electrical equipment shall not be painted by Aluminium paint.q. All electrical fittings/equipment shall have “danger” boards placed on them cautioning the

people of the presence of voltage.r. The following important BIS Standards should be followed for electrical equipment in

hazardous areas.

i) IS-2148:FLP Enclosures of electrical apparatus.ii) IS-9570 : Classification of flammable gases.iii) IS-8280 : Guidelines for electrical equipment in hazardous atmosphere.iv) IS-5571 : Guidelines for selection of electrical equipment in hazardous areas.v) IS-7389 (Part-I ) : Pressurized enclosure.vi) IS-8224 : Electrical light fittings for division- 2.vii) IS-5780 : Intrinsically safe electrical apparatus & circuits.viii) IS-8289 : Electrical equipment with protection ‘e’/ ‘n’ix) IS-6381 : Increased safety equipments.x) IS-8985 : Electrical instruments for hazardous areas.


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xi) IS-2206 (Part I & II) : Specification for FLP light fittingsxii) IS-5572 (Part-I) : Classification of hazardous areas.xiii) IS-3682 : FLP A.C. Motors.xiv) IS-4051 : Installation & maintenance of electrical equipment in mines.xv) IS-4691/2147 : Degree of protection of enclosures.xvi) IS-9628 : 3 phase induction Motors with protection ‘n’.xvii) IS-7693 : Oil immersed electrical apparatus for hazardous atmosphere.xviii) IS-7724 : Sand filled protection for electrical equipment in hazardous atmosphere.xix) IS-58241 : Marking for identification of electrical equipment in hazardous atmosphere.?xx) IS-11333 : Dry type transformers for hazardous atmosphere.

s. The following OISD standards shall be referred for use of electrical apparatus in hazardousareas.

i) OISD-105 : Hot/Cold Work Permit System.ii) OISD -110 : Recommended practices on static Electricity.iii) OISD-137 : Inspection of Electrical equipment.iv) OISD-147 : Inspection & safe practices during Electrical installations.v) OISD-149 : Design aspects for safety in Electrical System.vi) OISD-118 : Layouts for Oil & Gas installations.vii) OISD-146 : Preservation of idle Electrical equipment.viii) OISD-148 : Inspection & safe practices during overhauling of Electrical equipment.

t. The following IE Rule shall be referred for use of electrical apparatus in hazardous areas.i) The voltage limited of electrical equipment in hazardous area shall be as per clause 118

of IE Rules, 1956.ii) The additional precautions to be adopted in Oil-fields shall be followed as per the guidelines

in chapter-X of I.E. Rules, 1956.iii) The supply of energy to every electrical installation other than low voltage installation

below 5KW shall be controlled by an earth leakage protective device so as to disconnectinstantly on the occurrence of earth fault or leakage current as per the provision of clause61-A of I.E. Rules, 1956.

iv) For use of electricity at high voltage (up to 6600 volts) the guidelines provided in clause64 of I.E. Rules, 1956 shall be followed.

u. The Oil Mines Regulations (OMR)-1984 shall be followed while working in an Oil mine.

4.4 SAFE PROCEDURE TO WORK ON L.T. MOTORS/LIGHTING FEEDERS/STARTERPANELS/OVER HEAD LINES

a. Concerned JE/Technician taking the shut down should possess supervisory certificate ofcompetency

b. He should inform the in-charge /IM of the installation about the shutdown taken and aboutthe approx. duration.

c. Contact the immediate superior for assistance or clarification, if required.d. Get the permission/permit from in-charge/IM of the installatione. Proceed to Sub-station/ switch room where the concerned feeder is located.

i) Use the required PPEs like helmets, insulated hand gloves, goggles /face shieldsii) Identify and confirm the actual feeder to be made shutdown.iii) Put off the main switchiv) Open up the main switch cover and remove all fuses and neutral link.v) Place caution board, “Do Not Close, Men Working on Line”.vi) Check the non-availability of power at the outgoing terminals of the switch with the help

of a multimeter/400v double test lamp.


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vii) The Sub-station/ switch room should be locked and the key should be kept in the safecustody of the JE taking the shut down.

viii) If the locking facility is not available, keep one team member at the switch room to avoidaccidental switching on by others

ix) If the testing of power is to be done at the incoming of switches, tapped from busbar directly using brought strips, extreme caution to be taken so that inadvertentcontact of the brought strips with body of the panel shall not take place.

x) For working on the above switches, immediate superior is to be contacted andincomer of the panel should be switched off.

xi) The substation should be locked and the key should be kept in the safe custody of theJE/Technician taking the shut down.

f. Proceed to worksite

i) Verify the non-availability of power by checking at the load endii) Discharge three phases, neutral at the outgoing side with suitable discharge stick.iii) Short three phase, neutral with earth with the help of discharge stick or proper shorting

wire towards the source of supply.iv) Carry out the planned repairsv) Remove shorting wires from the overhead line.vi) Check for any mistake/left out tools etc. while performing the job.vii) Warn every one present in the site that the line is going to be energized.

g. Proceed to the Sub-station/ switch room.

i) Identify the feeder and remove caution board.ii) Remove short wires.iii) Re-install three fuses and neutral link and tighten it.iv) Close main switch and verify load in three phases.v) Inform in-charge /IM of the installation about the restoration of power.

h. In case of any problem contact the immediate superior.

i. If the JE/Technician taking the shutdown is not carrying out the job himself, theabove SOP is not applicable and he could contact his immediate superior for yourfurther advice.

4.5 SAFE WORKING PROCEDURE FOR CARRYING OUT MAINTENANCE JOB ON 3.3KV COMPRESSOR MOTORS IN GAS COMPRESSOR STATION:

a. Report to the installation & take permission slip (FORM-A) duly signed.b. Inform operator in thee GCS before starting electrical maintenance job on the 3.3 KV

compressor motor and its auxiliary motors in GCS.c. Completely lower the 3.3 KV OCB of the said motor inside the Electrical sub station.

Close panel door & hang danger board.d. Open the back-side cover of the 3.3 KV motor OCB panel for discharging motor cable

terminals.e. Put 11 KV insulated rubber hand gloves & discharge the motor cable terminals to ground

with a discharge stick.f. Put OFF the main switch in LT switchgear room which supplies power to the auxiliary

motors of the 3.3 KV motor & take-out the main control fuses. Hang a caution board onmain switch.

g. Open the cable terminal box of 3.3 KV motor & inspect the terminals. Check & inspectother parts of the 3.3 KV motor.

h. Check & inspect auxiliary motors, starters, etc. of 3.3 KV motor.i. The 3.3 KV motor & its auxiliary motors should not be meggered in compressor station as


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they fall in hazardous area.j. Meggering of 3.3 KV motor should be done on the cable terminals of the motor at the

3.3KV panel inside the sub-station. Ensure no person is working on the motor whenmeggering is done.

k. The 440V auxiliary motors should be checked by a multimeter inside the compressormotor.

l. After meggering the 3.3 KV motor, discharge the cable terminals of the motor to the groundwith a discharge stick.

m. Close the back-side cover of the 3.3 KV panel which was opened.n. Remove the caution boards.o. Raise OCB of motor in 3.3 KV panel.p. Put ON the main switch of auxiliary motors in LT switchgear room.q. Inform the operator of Gas Compressor Station about completion of the job.r. Return the permission slip (FORM-A) to the installation-in-charge.s. Record in the log-book & maintenance register.

4.6 SAFE WORKING PROCEDURE WHILE DOING MAINTENANCE ON 3.3 KV CRUDEOIL DESPATCH MOTOR (CODP) IN OCS :

a. Report to the installation & take permission slip (FORM-A) duly signed.b. Inform operator in the OCS before starting electrical maintenance job on the 3.3 KV CODP

motor.c. Put OFF the CODP feeder OCB in the 3.3 KV panel in the Sub-station & down the OCB

upto isolate position.d. Close the panel door & attach the caution board on the door.e. Isolate the in-coming Oil-switches in starter panel from both the sides & rack-out the oil-

switches & cover the H.T. connecting bushing with protective cover.f. Open the back cover of the panel & discharge all terminals to the ground with discharge

stick. Then open the 3.3 KV motor terminal box & discharge all three terminals to ground.g. Carry-out the planned job. As the panel is FLP, care should be taken that not a single bolt

is missing. Also, the bolts should be tightened properly so that air-gap is as per ISspecifications. As the motor & the starter panel falls in hazardous area, they should not bemeggered at site from CODP shed.

h. Remove the caution board.i. Raise the OCB upto service position & close the OCB.j. Rack the oil-switches in position & put them ON.k. Inform the operator of OCS about completion of the job.l. Return the permission slip (FORM-A) to the installation-in-charge.m. Record in the log-book & maintenance register.

5.0 PART-V :

EQUIPMENT EARTHING :

5.1 Objective :

Equipment earthing or grounding relates to the manner which non-electrical conductive material,which either encloses energized conductors or adjacent thereto is to be interconnected andgrounded. The basic objective being sought are the following :

a. To ensure freedom from dangerous electric shock voltage exposure to persons in thearea.

b. To provide current carrying capability, both in magnitude and duration, adequate to acceptthe earth fault current permitted by the protection system without creating a fire or explosivehazard.

c. To contribute to superior performance of the electric system by isolating the defective


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equipment from the system.

5.2 Terminology :

a. Bond : To connect together electrically two or more parts.b. Dead : Dead means at or about earth potential and disconnect from any live systems.c. Earthed : An equipment is said to be earthed when it is electrically connected to an earth

electrode.?d. Earth electrode : A metal piece, pipe or other conductor connected to the general mass

of the earth.e. Earthing lead : The conductor by which the connection to the earth electrode is made.f. Potential gradient: The potential difference per unit length measured in the direction in

which it is maximum.g. Resistance area of an earth electrode: The area within which practically the whole of

the potential difference between the electrode and the general mass of the earth occurswhen it is carrying fault current.

h. Step potential: The maximum value of the potential difference possible of being shuntedby human body between two accessible points on the ground separated by a distance ofone pace may be assumed as one meter.

i. Touch potential: The maximum value of the ground and a point on an object likely tocarry fault current such that the points can be touched.

5.3 Earthing and IE Rules (for details please refer Indian Electricity Rules)

a. Rule 33: In case of medium, high and extra H.T installations, a consumer has to providehis own earthing system over and above the earthing terminal provided by the supplier.

b. Rule 51: All metal work associated with the installation other than that designed to serveas conductor, be connected to earth.

c. Rule 61 (2): All metallic parts pertaining to apparatus and equipments shall be earthed bythe owner by two separate and distinct connections with earth.

d. Rule 61 (4): Before supply is made “ON” all earthing systems shall be tested to ensureefficient earthing.

e. Rule 61(5): All earthing system shall be tested for resistance on dry day during dry seasonno less than once in every two years.

f. Rule 61(6): A record of every earth test made and the result thereof shall be kept.g. Rule 66(5): Whenever conductors are enclosed in metal sheathing, the metal sheathing

should be earthed.h. Rule 88(2): Whenever guard wires are provided, these guard wires should be connected

with earth.i. Rule 92(2): The earthing lead for any lighting arresters shall not pass through any iron or

steel pipe but shall be taken as directly as possible from the lightning arresters to a separateearth electrodes subject to the avoidance of bends whenever applicable.

5.4 GENERAL

In addition to the above I.E. rules, the following must be followed :a. Earth pit locations must be identified by permanent marker and its surrounding must be

kept neat and clean and must be accessible i.e., it should be in easy approach for inspection.For the earth pits inside the installation IM should ensure this.

b. Area around the earth pit should be kept clean and no debris should be dumped near by it.For the earth pits inside the installation IM should ensure this.

c. All earth electrodes must be tested for earth resistance by means off standard earth testmegger.

d. Earth resistance of the grid or mat should be maintained sufficient low and should meet ISrequirements.

e. Electrodes must have a clean surface not covered by paints, enamels, grease or other


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materials of poor conductivity. All earth electrodes are so located avoiding interface withroad, building foundation column etc.

f. Individual earth electrodes are provided for each lighting arresters as per I.E. rules 92 (2).g. Disconnect facility should be provided for the individual earth pits to check their earthing

resistance periodically.h. All the electrical equipments are doubly earthed by connecting two-points on equipment to

the main earthing grid/bus. The earthing ring should be connected via links to severalearth electrodes. The cable armour shall be earthed through cable glands for LT cables.For H.T. cables the armour shall be brought out and connected to the earth bus.

i. In all hazardous areas, all major process equipment shall be connected to the earthinggrid by means of welding or nut/bolt connection, using spring and back washers. All pipesare bonded and earthed on entering the battery limit of the process area.

j. All earthing connections for equipment are taken from the earthing plate mounted abovethe ground whenever possible.

k. Anchor bolt or fixing bolt is used for earthing connections.l. All hardware used for earthing installations are hot dip galvanized or zinc passivated. Also

spring washers are used for all earthing connections of equipment.m. Lighting fixtures and other LT equipment are earthed through the extra core provided in

the cable for this purpose.n. Equipment earthing and system earthing (neutral earthing) are done with separate earth

pits.

5.5 EARTHING MATERAL.

a. The grounding material must have the following characteristics:b. High conductivity.c. Low rate of corrosion.d. Low rate of corrosion due to galvanic action.

The following materials are fulfilling the above characteristics:a. Copper.b. Steel and galvanized steel.c. Aluminium to some extent.

5.6 SIZE OF EARTH CONDUCTOR :

a. Main Earthing Lead:The main earthing lead (e.g. earth bus to earth pit electrode) shall notbe less than 8 SWG of copper or GI wire, 20mm x 3mm copper strip or 25mm x 4mm GIstrip.

b. Loop Earthing :The minimum size of loop earthing (e.g. from DB to switches) shall be 14SWG GI/4 sq.mm. Aluminium.

c. Size of earth Bus for Generation Station

SL Capasity of Transformer Size

1. Up to300 KVA 20 x 4 mm G.I. Strip

2. Above 300 KVA 32 x 5 mm or 40 x 4 mm G.I. Srip

3. Above 500 KVA But not exceeding 800 KVA 40 x 6.3 mm or 50 x 5 mm G.I. Strip

4. Above 800 KVA but not exceeding 1000 KVA 50 x 6.3 mm or 2 nos 40 x 4 mm G.I. Strip


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6.3 Running of Gas Turbine

During running of the turbine with load, apart from the above points the following parametersare also strictly being monitored

a. Combustor Inlet and Turbine exhaust temperaturesb. Turbine speedc. MW and MVAR loads of generator and system pf, voltages/ currents etc.d. Fuel gas pressuree. Bearing vibration values and lube oil drain temperaturesf. Lube oil supply Temperatures and Pressuresg. Any Alarm conditionsh. Testing the operation of emergency lamps dailyi. Testing the operation of Black Start Diesel Engine (BSD) weeklyj. Cleaning of insect screen regularly

6.4 Shutdown of Gas Turbine

a. Normal Shutdown

For a safe shutdown operation of turbine following steps are carried out

i) Ensure that the main breaker and the filed breaker is offii) Initiate the shutdown by operating “Normal Stop” push button once. Turbine will stop

after completion of 15 min (approx) Cool Down Cycle. (Note: Shutdown can becancelled by pressing “Normal Stop” push button once again within 15 minutes of CoolDown Cycle.)

iii) Note the speed at which RTS (Ready To Start) / TG(Turning Gear) and Clutch Airestablished indication comes

iv) Note the turbine rundown timev) Check the TG operation physicallyvi) Close the main gas Valvevii) After one and half hour put the turbine on 1st spinviii) After two hours of 1st spin, put the turbine on 2nd spinix) After two hours of 2nd spin, put the turbine on 3rd spinx) After 72 hours of shut down the TG will automatically go off. (See appropriate

procedure)

b. Emergency shutdown

When it is required to stop the turbine immediately due to emergency conditions like fire etc.emergency shutdown can be activated from the following locations.

i) By operating emergency push button switch at LCR control panelii) By operating emergency push button switch at CCR control paneliii) By operating over speed trip valve mechanism located at auxiliary gear boxiv) By operating push button at PS & G panel

After emergency shutdown of the Unit, follow the “Normal Stop” procedures mentionedabove.

c. Post stop checks

After the Gas Turbine has been stopped check the following

i) Operation of TGii) Lube oil circulationiii) Gas Valve closed


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6.5 Activities during tripping of Gas Turbine:

a. When there is a total black out, emergency lights (from battery bank) should turn on

automatically. After a few seconds Black Start Diesel (BSD) engine starts automatically (If

not, start manually) to supply emergency power to the turbine auxiliaries as well as to the

turbine hall. Then emergency lights (from battery) should go off automatically. If BSD power

is available, following steps are carried out for safe restoration of normal power.

i. Check the TG operation of the tripped turbine

ii. Check the operation of the battery chargers

iii. Check the Black Start Diesel (BSD) generator operation and fuel level in tank

iv. Open all the 11 kV and 33 kV feeder breakers, both 11 & 33 kV side breakers of 10 MVA

Transformers except 500 kVA GT Station Transformer breakers and 11 kV GT Bus Coupler

breakers

v. Carry out the pre start check for starting the stand by turbine

b. If the BSD (Black Start Diesel) at the GT fails in supplying emergency powers due to some

problem, then emergency power is brought from the WHRP (Waste Hear Recovery Plant)

BSD. Following steps to be carried out to import emergency power from WHRP BSD to

GT LT (normal) bus

i. Switch off the incomer 1 and 2 to LT bus of GT station Transformers at LT (GT) switch

gear room

ii. Check breaker D at WHRP MCC panel, should open automatically. If not, open manually.

iii. Check breaker E at WHRP MCC panel, should closed automatically. If not, close manually

iv. Close GT – WHRP LT inter connector at WHRP MCC panel

v. Close GT – WHRP LT inter connector at GT switchgear room

vi. Transfer the “Robonic” switch to normal

c. If only the Circuit Breaker trips and not the turbine, then following steps to be carried out for

safe restoration of normal power

i. Restore the emergency power following the relevant steps as described above

ii. Check if breaker can be closed, if not, start the standby turbine.

iii. Initiate normal shutdown of turbine, if breaker could not be closed.

6.6 Safety practices specific to the power station

a. Cold work permit: (CWP):

CWP is issued to a section/ contractor for works in different locations. It is ensured that

the following are adhered to (Whichever is applicable):

i. Inspection of equipment.

ii. Area is cleared, checked, and covered.

iii. Electrical switches/ substation are locked out

iv. Running water hose/ portable extinguishers provided

v. Equipment blinded/ disconnected

vi. Equipment drained/ depressurized

vii. Equipment water flushed, purged

viii. Proper lighting and ventilation provided


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ix. Gas test done

x. Checks against alarms, toxic/ hazardous chemicals, and fire.

b. Use of PPEs

===== Use of safety helmet, gloves, goggles, safety shoes, boiler suits, welding suits, dust

respiration, face shield, fresh air mask, apron, life line, safety belt etc. as and where

applicable.

===== For details refer the section on HSE management (SOP)

c. Fire fighting:

===== Fire Contingency Plan of the station is followed

===== Fire extinguishers are provided in the gas plant, turbine hall, control rooms, corridors,

switch gears, battery room, BSD room and near stores rooms

===== The extinguishers are checked periodically and maintained in healthy condition

===== Fire hydrant exists around the plant with adequate no. of hydrant points.

===== For details, section on Fire services activities (SOP) to be followed

d. Hot work/ vessel entry/ vessel box up permit:

(Refer SOP on HSE management)

The above permit is issued to competent person for safe working. The following conditions

are checked before issuing the permit (Whichever is applicable):

===== Inspection of equipment/ work area.

===== Checking/ cleaning of surrounding area.

===== Sewers, manholes, CBD (Continuous Blow Down) and nearby hot surfaces covered.

===== Considered hazard from other routine/ non-routine operation and concerned person

attended.

===== Equipment electrically isolated and tagged.

===== Fire water horse/ portable extinguisher provided.

===== Fire water system checked for readiness.

===== Equipment blinded/ discounted/ closed/ isolated/ wedged open.

===== Equipment properly drained/ depressurizes.

===== Equipment properly purged.

===== Equipment water flushed.

===== Provided shield against spark.

===== Proper ventilation and lighting provided.

===== Precautionary board/ tags provided.

===== Portable equipment/ nozzles properly grounded.

===== Stand-by personnel provided for vessel entry.

===== Welding machine checked for safe location.

===== Check for earthing / return connection to the equipment welded.

===== Oxygen/acetylene cylinder kept outside the vessel/ tank.

e. Gas testing:

===== Natural gas, which is highly inflammable in nature, is used as fuel in Gas Turbine for

generation of power in Duliajan Power Station. Gas testing is done to detect any leakage of

gas in the vicinity of gas supply line and gas plant before any hot work is taken up in and

around the plant.


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f. Level of Sound & Use of ear protector:

===== The sound level in and around the plant is monitored every month. The personnel working

in the vicinity of the Gas Turbine must use ear protectors.

===== The working personnel must undergo health checkups in the company hospital on regularbasis to ensure proper health.

g. Electrical shutdown, discharging and isolation works:

===== Before working on any electrical equipment, the following are done by a competent person.

o. Disconnect the equipment. o. Complete isolation o. Discharging by earth sticks and Lock out

===== Work permit is issued to a competent person to work on electrical equipment, clearlymentioning the date and time up to which it is valid.

===== Rubber gloves, floor mats are used while working on electrical equipment.

6.7 Safety precaution while working on overhead EOT crane:

===== Load test of the crane is carried out six monthly

===== Safe Working Load (SWL) to be inscribed on the body of EOT crane.

===== Through check up of overhead crane (Electrical/ mechanical) is done annually.

===== While working power supply is made off and fuses are taken out.

===== Greasing of ropes and measurement of rope diameter done every month.

===== D- Shakels, Sling should be inspected before lifting any weight.

===== Use of appropriate PPE is mandatory.


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CIRCULAR REGARDING CLASSIFICATION OF HAZARDOUS AREA

Bharat Sarkar/ Govt. of India

Shram Mantralaya/ Ministry of Labour

Khan Suraksha Maha Nideshalaya

Directorate-General of Mines Safety

No. 1 (6) 2001 – Genl. /3604-3753 Dhanbad, dated the 12th Sept.,2001.

To

Owners, Agents and Managers of all Oil Mines of M/S Oil India ltd.

Sub : Classification of hazardous area in Oil Mines under regulation 74 of the Oil Mines

Regulation, 1984.

1. By the virtue of the power conferred on me under Regulation 74 of the Oil Mines Regulation,

1984, in supersession of all earlier classification, classify the areas in all your Oil mines into

different zones according to the degree of probability of the presence of hazardous

atmosphere, as given below:

A. Drilling and work-over operation :

(1) Well-head area :

(a) When the derrick is not enclosed and the substructures is open to ventilation, the area in all

direction from the base of rotary table extending upto 3.0 m shall be zone 2 hazardous area.

Any cellars, trenches or pit and below the ground level, shall be zone I hazardous area ; the

area lying upto 3.0 m in horizontal direction form the edge of any cellars, trenches or pit and

0.5m vertically above the cellars, trenches or pit shall be zone 2 hazardous area.

(b) When the derrick floor and substructures are enclosed, the enclosed substructure below

the derrick floor, including cellars, pits or sumps below the ground level, shall be zone I

hazardous area.; the enclosed area above the derrick floor shall be zone 2 hazardous.

(2) Mud Tank and channel :

The free-space above the level of mud in tank and channel shall be zone I hazardous

area., the area in a radius of 3.0 m in all direction from the edge of mud tank and channel

shall be zone 2 hazardous area.

(3) Shale shaker :

i. The area within a radius of 1.5 in all direction from the shale shaker in open air shall be zone

1 hazardous area. The area beyond 1.5 m upto 3 m in all direction from the shale shaker

shall be zone 2 hazardous area.

ANNEXURE-I


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ii. When the shale shaker is located in an enclosure, the enclosed area shall be zone 1

hazardous area to the extent of the enclosure. The area out side the shale shaker and upto

1.5 m in all direction from the shale shaker shall be zone 2 hazardous area.

(4) Degasser :

The area within a radius of 1.5 from the open end of the vent extending in all direction shall

be zone 1 ; the beyond 1.5 m and upto 3 m in all directions from the open end of vent shall be

zone 2 hazardous area.

(5) Desander and Desilter :

The area within a radius of 1.5 m in all direction from the desander and desilter located in

open air shall be zone 2 hazardous area.

(6) Effluent Pit and Open sump :

The free space above the level of flammable liquid within the effluent pit or sump shall be

zone 1 hazardous area ; the free space lying upto 3.0 m in horizontal direction from the edge

of any effluent pit or sump and 0.5 m vertically above the effluent pit or open somp shall be

zone 2 hazardous area.

B. Oil Wells :

(1) Flowing well :

An area below the ground level shall be zone 1 hazardous area; the area lying upto 3.0 m in

horizontal direction from the edge cellars, trenches or pit and 0.5 m vertically above the

cellars, trenches or sump shall be 2 hazardous area.

(2) Artificial lifted well :

(a) The area in wells equipped with sucker-rod pump upto 3 m above the ground level and upto

3 m horizontally in all direction from the well –head shall be zone 2 hazardous area. In case

of cellar, an area below the ground level shall be zone 1 hazardous area ; the area lying upto

3.0 m in horizontal direction from the edge of any cellars and 0.5 m vertically above the

cellars shall be zone 2 hazardous area.

(b) The area in wells equipped with submersible electric motor-driven pump or hydraulic sub-

surface pump or gas lift well shall be specified in clause B(1) when the well is provided with

cellar or sump.

(3) Well under production test :

The area within a radius of 8 m from an open discharge of petroleum bearing fluid from a

well under production test, shall be zone 1 hazardous area. The area beyond zone 1 hazardous

area for a further distance of 8 m in all direction shall be ‘zone 2’ hazardous area.


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(4) Well servicing operation :

The area within a radius of 10 m in all direction from a well-pulling and other such well

servicing shall be ‘zone 2’ hazardous area.

Provided that where cellar or sump is present ; the area within the cellar or sump shall be

zone 1 hazardous area and the area lying upto 3.0 m in horizontal direction from the edge of

any cellars or sumps and 0.5 m vertically above the cellars or sump be zone 2 hazardous

area.

(5) Gas Vent :

The area within a radius of 1.5 m from open end of the vent extending in all directions shall

be ‘zone 1’ hazardous area and area lying within a radius beyond zone 1 hazardous area

upto 3 m of the vent shall be ‘ zone 2’ hazardous area.

C. Oil and gas processing and storage equipment :

(1) Oil-gas separation vessels, fired vessels, Dehydrator, stabilizer, hydrocarbon recovery

(a) The area within a radius of 3 m from any oil-gas separation vessel, fired vessel, dehydrator,

stabilizer and hydrocarbon recovery unit shall be zone 2 hazardous area.

(b) Any trench or pit below the ground level shall be zone 1 hazardous area and the area lying

upto 3.0 m in horizontal direction from the edge of any trench or pit and 0.5 m vertically

above the trench of pit shall be ‘zone 2’ hazardous area.

(2) Gas Vent :

The area within a radius of 1.5 m from open end of the vent extending in all directions shall

be ‘Zone-1’ hazardous area and area lying within a radius beyond Zone-1 hazardous area

upto 3m of the vent shall be ‘Zone-2’ hazardous area.

(3) Relief Valve :

The area within a radius of not less than 3.0 m from discharge of a relief valve, extending in

all directions shall be ‘Zone-2’ hazardous area subject to the conditions that ‘ there shall be

electrical equipment in direct path of discharge from relief valve.

(4) Pig Trap :

The area within a radius of 1.5 m of pig launching/receiving trap extending in all directions

shall be ‘Zone-1’ hazardous area. The area lying beyond Zone-1 hazardous area and upto a

radius of 3m in all directions from pig lunching/receiving trap shall be Zone-2 hazardous

area.

(5) Pump or Gas Compressor :

a) Where a pump handling flammable liquid or a gas compressor is isolated in open air or

under well ventilated shed without walls. The area lying upto 3 m in all directions from the

pump or compressor shall be zone-2 hazardous area.


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b) Where a pump or compressor is located in an adequately ventilated building, the entire

interior of such building including an area within 1.5m of the vent shall be Zone-2 hazardous

area.

c) Pits, sumps, trenches below the ground level shall be zone-1 hazardous area and the area

lying up to 3.0 m in horizontal direction from the edge of any trench or pit and 0.5 m vertically

above the pits, sumps or trenches shall be zone-2 hazardous area.

(6) Storage Tanks :

a) In case of floating roof tank, the space above the floating roof and inside the enclosures upto

top level of the enclosure wall shall be ‘Zone-1’ hazardous area; the areas beyond Zone-1

hazardous area and upto a radius of 4.5 m in all directions from tank shell & sheel to shall be

zone-2 hazardous area. In case of a dyke, zone-2 hazardous area shall extend vertically

upto the height of the dyke & horizontally upto the physically boundary of the dyke.

b) In case of fixed roof tank, the area inside the tank and within a radius of 1.5 m from all

openings including breather valve, dip hatch, thief hatch and safety valve, shall be Zone-1

hazardous area; the area beyond Zone-1 hazardous area upto a radius of 3 m in all directions

from shell and roof of the tank shall be zone-2 hazardous area. In case of a dyke, the sump

in the dyke shall be Zone-1 hazardous area and an area extending vertically upto the height

of the dyke & horizontally upto the physically boundary of the dyke shall be Zone-2 hazardous

area.

D. General

Where ever sampling cock or belled off valve is fitted. The area upto 1.5 m in all

directions from the release point shall be Zone-2 hazardous area.

A.K. Rudra

Director General of Mines Safety

Dhanbad


Fire Service

OIL INDIA LIMITED


Volume - II

Section - 3

FIRE SERVICE

ACTIVITIES


Fire Service


FIRE SERVICE ACTIVITIES

CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1. Introduction ...................................................................................................... 1

2. What is fire & its classification and principle of extinguishment ..................... 2

3. Fire fighting equipment and its safe operating and maintenance Procedures. 5

4. Action plan/fire fighting procedures in case of fire emergency .......................16

5. Mock Fire Drill ..................................................................................................17

6. Important telephone nos. .................................................................................18

7. Proforma for mock Drill (Annexure - I) ............................................................19


Fire Service

INTRODUCTION

The purpose of presenting this ‘SOP’ is to make all our employees conversant with the

fire fighting procedures so that they can safely and efficiently operate appropriate fire fighting

equipment in case of any fire emergency in our industry.

Risk of fire hazard in every stages of operation in oil field area is enormous. To overcome

this fire risk a systematic planning of fire protection and prevention arrangement for each

and every installation is a must, besides regular fire fighting training to all the employees

working in the oil field areas.

In this manual we have discussed in brief various fire fighting equipment and its safe

operating and maintenance procedures. However it is also very much important to know

how fire caused and what are the various types/classes of fires and its extinguishment

procedures.

Hope, this information will go a long way to make aware our employees towards fire

safety and thus will help to minimise losses due to fire incident in our industry.


Fire Service

2.0 : WHAT IS FIRE ?

Fire is an exothermic chemical reaction, where in rapid oxidation process takes place with

evolution of heat and light of varying intensity.

Fire occurs due to the combination of three elements - fuel, oxygen and heat in right

proportion. When any substance is heated to its critical temperature in presence of oxygen it

starts burning (the temperature at which burning starts is called critical/ignition temperature of

that material).

The three elements required for occurrence of any fire can be more easily understandable

with the help of “FIRE TRIANGLE”, where in each arm of the triangle represents particular element.

To form any triangle all the three arms are needed, similarly for occurrence of fire all the three

elements are also essential.

2.1 : Classification of fire

Fire is classified in four classes depending upon the materials involved in the fire as given in

Table - 1. To select proper extinguishing media for extinguishing any fire; it is very much important

to know what class of fire is involved.

Class ‘A’ Fire - These fires involves ordinary combustible materials such as wood, paper,

cloth etc.

Class ‘B’ Fire - These fires involve flammable liquids such as condensate, petrol, diesel,

crude oil, paints, etc.

Class ‘C’ Fire - These are gas fires such as LPG, Methane, Propane etc.

Class ‘D’ Fire - These fires involves combustible metals such Magnesium, Aluminium,

Potassium, etc.

It is to be noted that when fire involves in any electrical equipment, if the electrical equipment

is de-energized then fire became Class-A or Class-B fire. However, when electrical equipments

energized and if fire occurs, then extinguishing media should be of electrically non-conductive

type such as Dry Chemical Powder or Carbon di-oxide.

FIRE - EASY TO LIGHT, HARD TO FIGHT


Fire Service

2.2.0: Principles of fire extinguishment

We know that occurrence of fire depends upon the presence of three elements-fuel,

heat & oxygen. Principles of fire extinguishment depends on elimination of any of the above three

elements. Fire can be extinguished by the following three procedures -

i) Elimination of heat i.e., source of ignition by cooling method

ii) Elimination of oxygen by smothering method.

iii) Elimination of fuel i.e. starvation.

2.2.1 : Cooling :

In the cooling method, heat is removed from the burning material by applying water so

that its temperature reduces below its ignition temperature. Water absorbs the heat from the

burning substance, thus the fire gets completely extinguished.

Generally, Class-A (ordinary combustible material) fires are extinguished by this method.

2.2.2 : Smothering :

In this method oxygen supply is eliminated or diluted so that it can not support the fire to

continue. By blanketing or diluting the oxygen percentage in the fire area, with the help of inert gas

or non-combustible powder any fire can be extinguished.

Generally, Class-B liquid fuel fires are extinguished by this method.

2.2.3 : Starvation :

In this method fuel is salvaged/removed, thus fire is extinguished. In case of any gas fire,

if we can stop the flow by shutting the valve or any other means, the fire will automatically extinguish.

This method can also be applied in case of storage tank fire where liquid can be shifted to other

place if proper drainage facilities are provided with the tank, thus fire can be minimised.

FIRE HAZARDS ARE OUR GREATEST ENEMY

- PREVENT THEM


Fire Service

TABLE - 1

SUITABILITY OF DIFFERENT TYPES OF PORTABLE FIRE

EXTINGUISHERS FOR DIFFERENT CLASS OF FIRES

CLASS OF FIRE

Class ‘A’

Class ‘B’

Class ‘C’

Class ‘D’

MATERIALS INVOLVED SUITABLE PORTABLE

FIRE EXTINGUISHER

Fires invloving ordinary combusitble

material such as wood, cloth, paper

etc.

W ater type fire extinguisher

(Water CO2 gas cartridge type

fire extinguisher).

Fires involving flammable or

combustible liquids - period, diesel and

similar materials which are lighter than

water

Fire Extinguisher discharging

Foam, Carbon di-oxide or Dry

Chemical Powder.

Fires involving gaseous substances

such as LPG, Natural Gas, Methane,

Propane etc.

Fire extinguishers discharging

Dry Chemical Powder or

carbon dioxide.

Fires involving certain combustible

metals such as Magnesium, Titanium,

Sodium, Potassium, etc.

Fire extinguishers discharging

Special Dry Chemical Powder,

(Eutectic Chloride or Special

powders for matel Fires).


Fire Service

3.0: FIRE FIGHTING EQUIPMENTS AND ITS SAFE

OPERATING AND MAINTENANCE PROCEDURES

In our installations a number of fire fighting equipment are placed/installed according to

the hazard involved to combat any fire emergencies. These equipment are mainly -

(1) First-Aid Fire Fighting Equipment

(2) Fixed Fire Fighting System.

In this chapter, we will discuss about the above two categories of fire fighting equipment,

its safe operating and maintenance procedures.

3.1. 0 : FIRST AID FIRE FIGHTING EQUIPMENT

These are portable fire fighting equipment. All fire extinguishers of various capacities, fire

bucket, fire blanket etc. fall under this category. Depending upon the nature of fire hazard involved,

suitable fire extinguishers are placed / installed in the particular area. Depending upon the type of

portable extinguishers used in our oil fields, identifiable marks are inscribed on the body of the

extinguisher as A,B,C & D. (Refer Table - II) These extinguishers and their safe operating procedures

are given below -

3.1.1 : Water/CO2

gas cartridge type fire extinguisher

This is 9 lits. capacity water type fire extinguisher, useful for Class - A fire (ordinary fire)

i.e. fire in paper, wood etc. This extinguisher is cylindrical in shape. It has 9 lits. water and a CO2

gas cartridge inside the cylinder. The cap of the extinguisher having a sliding type plunger to

puncture the seal of CO2 gas cartridge. It has one meter long discharge hose with nozzle (in

some extinguisher nozzle is directly connected to the body without any hose). These extinguishers

are marked with letter ‘A’ for better identification.

Operation Procedure

I. Remove the extinguisher from its bracket and take it near to the fire.

II. Keep the extinguisher straight and strike the plunger knob hard.

III. Hold the extinguisher handle by left hand and hold the hose nozzle by right hand. (If

nozzle is directly connected to body, lift the extinguisher by both hands)

IV. Direct the water jet on to the seat of fire and advance towards the fire for better

coverage and ensure that fire is completely extinguished.

ENSURE FIRE SAFETY, SAVE LIFE SAVE PROPERTY.


Fire Service

3.1.2 Foam type fire extinguisher :

There are two types of foam extinguisher -

(i) Chemical foam extinguisher &

(ii) Mechanical foam extinguisher.

Since chemical foam extinguisher is withdrawn by the statutory body (ISI), here we will

discuss only mechanical foam extinguisher.

3.1.3 : Mechanical foam extinguisher

Mechanical foam extinguishers are useful to extinguish Class ‘B’ fire, i.e. flammable liquid

fire (fire involving in crude oil, petrol, diesel, PVC materials etc.). These extinguishers are commonly

available in 9 lits. and 45 lits. capacity And higher capacity mechanical foam extinguishers are

also available, mounted on wheels/trolley for easy movement.

Mostly, we use 9 lits. capacity mechanical foam extinguisher. These extinguishers are of

cylindrical in shape. It has 9 lits. water mixed with 500 ml. AFFF foam concentrate inside the

cylinder. Inside the cap a gas cartridge is fitted. Cap of the extinguisher is having a sliding type

plunger to puncture the CO2 Gas cartridge’s seal. One meter long PVC discharge hose with a

special type discharge horn having air intake facility is fitted to the extinguisher’s body. These

extinguishers are marked with letter’B’for better identification.

Operating Procedure

(i) Remove the extinguisher from its bracket and take it near to the fire.

(ii) Keep the extinguisher straight and strike the plunger knob hard.

(iii) Hold the extinguisher handle by left hand and hold the discharge nozzle by right

hand.

(iv) Direct the foam jet on to the fire in such a manner so that foam slide to the top of

the liquid fire to give a blanketing effect and ensure fire is completely extinguished.

FIRE IS A GOOD SERVENT, BUT A BAD MASTER


Fire Service

3.1.4: Dry Chemical Powder (D.C.P) type fire extinguisher :

These fire extinguishers are commonly known as DCP fire extinguisher. These

extinguishers are available in different sizes (1 Kg, 2 Kg, 5 Kg, 10 Kg, 25 Kg, 50 Kg, 75 Kg, etc.)

There are two types of DCP extinguishers -

(i) Cartridge operated type &

(ii) Stored pressure type.

We mostly use cartridge operated type, however at some places 5 Kg. capacity stored

pressure types are also kept. 10 Kg. capacity DCP. extinguishers are most commonly used in our

organization. Few trolley mounted higher capacity extinguishers (25Kg., 50Kg. & 75 Kg.) are also

installed at some vital installation.

The shape of the 1 0 Kg. DCP extinguisher is of cylindrical type. Dry chemical powder of

1 0 Kg. weight is charged in the outer container. One small C02, gas cartridge (propellant gas) is

threaded into a puncture valve which is a part of cap assembly and placed in an inner container,

which leads to the bottom of DCP container. The DCP is discharged through a hose attached to

upper portion of the outer container. This portion is fitted with a siphon tube inside the outer container.

Discharge of DCP is controlled by a squeeze grip nozzle at the end of the hose.

DCP extinguisher is highly effective for class ‘B’ hydrocarbon fires, class ‘C’ fires, live

electrical equipment and certain ‘A’ class fires. Some special type of DCP is highly effective for

class ‘D’ metal fires. Mostly used Dry Chemical Powder contains 97% Sodium Bicarbonate powder

and other additives in small quantities. Some special types of DCP are also used for high risk

area, these are Mono-Ammonium Phosphate base, Potassium Bi-Carbonate base, Potassium

Chloride base, Urea-Potassium Bi-Carbonate base etc. These extinguishers are marked with

letter ‘C’for better identification.

OPERATING PROCEDURE (10 Kg. capacity)

1. Remove the extinguisher from its bracket and take it near to the fire.

2. Remove safety clip from plunger knob.

3. Hold the squeeze grip nozzle by pressing in one hand and strike the plunger to

puncture the gas cartridge.

PREVENTION IS BETTER THAN CURE


Fire Service

4. Direct the powder at the base of the flame with sweeping motion and advance

towards the fire by holding the extinguisher by other hand.

5. While operating, the operator should stand at up stream of wind direction so that

powder should not come towards his body.

OPERATING PROCEDURE (25 Kg. and above capacity)

1. Place the extinguisher near to the fire by pushing the trolley.

2. Unwind the hose from the bracket and check the nozzle gun is properly functioning.

3. Remove the safety clip of CO2 cylinder valve and slowly open the valve to its full position.

4. Open the nozzle gun and hold it firmly.

5. Direct dry powder at the base of the flame with sweeping motion and advance towards

the fire.

3.1.5 : Carbon-dioxide (CO2) extinguisher -

This is a compressed gas fire extinguisher. CO2

gas is compressed at a very high

pressure (64 Kg/cm2 to 70 Kg / cm2 at or below 31O C temp.) and stored in liquid state. Best use

of this type of extinguisher is on electrical fire. It is also useful for class ‘B’ and class ‘C’ fires.

CO2 type extinguisher are available in varied sizes i.e. 2 Kg, 3 kg, 4.5 Kg, 6.5 Kg, etc.

CO2 extinguisher are cylindrical in shape, high pressure seamless type. It has high pressure

discharge tube with discharge horn and a gas releasing valve assembly. 6.5 Kg. and higher capacity

CO2 extinguishers are mounted on trolley. Carbon-dioxide extinguisher is very effective in closed

areas. Care should be taken while using such extinguisher inside a room as it may create suffocation

& poor visibility to identify the escape route.

These extinguishers are marked with letter ‘D’ for better identification.

OPERATING PROCEDURE -

1. Remove the extinguisher from it’s bracket/location and take it near to the fire by keeping

a safe distance of about 1.5 to 2 mtrs.

2. Remove valve wheel’s locking pin.

3. Rotate the valve wheel in anticlock wise to discharge the CO2 gas.

4. Hold the extinguisher handle or trolley by left hand and the insulated handle of the

discharge horn by right hand.

5. Direct carbon-dioxide on the base of the flame by sweeping action and gradually

progress forward as the flame is extinguished.


Fire Service

TABLE - II

MARKING ON EXTINGUISHER AS PER OUR PRACTICE

FOR BETTER INDENTIFICATION

MARK TYPE OF EXTINGUISHER APPEARANCE OF EXTINGUISHER

A

B

C

D

WATER CO2 GAS CARTRIDGE

TYPE EXTINGUISHER

(9 LITER CAPACITY)

MECHANICAL FOAM TYPE

EXTINGUISHER

(9 LITER CAPACITY)

DRY CHEMICAL POWDER

TYPE EXTINGUISHER

(10 KG CAPACITY)

CARBON DIOXIDE TYPE

EXTINGUISHER

(2 TO 4.5 KG CAPACITY)


Fire Service

3.2: MAINTENANCE OF FIRE EXTINGUISHER -

All types of fire extinguishers should be quarterly inspected and maintained for its better

performance. Since, some extinguishers are of pressurised type and some generate pressure

inside the extinguisher during operation, utmost care should be taken during maintenance. Water

type, DCP & foam extinguisher’s cap are having few nos. small holes/pores in its threaded portion

for releasing pressure while unscrewing the cap. The developed pressure inside the extinguisher

will be released through these pores, hence these pores should be kept clean to avoid accidents

during maintenance due to pressure development inside the extinguisher. Hydraulic pressure

testing should be carried out for each extinguisher once in every three years. During handling of

bulk quantities of DCP, necessary dust mask should be used.

While using any gas cartridge refills for any extinguisher comparability of cartridge with

the extinguisher should be ensured. Any over weight or under weight gas cartridge should be

avoided Extinguisher’s siphon tube, discharge tube & nozzle should be free from any obstruction

for safe operation.

Total number of Fire extinguishers required for a particular installation shall depend on

the hazard potential and risk involvement in the said area. This should also confirm to relevant

OISD standards such as STD-189.

SMALL FIRES GROWS RAPIDLY

WISDOM LIES IN FIRE PROTECTION


Fire Service

3.3 : FIXED FIRE FIGHTING SYSTEMS

As a major fire protection arrangement, all our vital installations are having a number of

fixed fire fighting systems, these includes fire hydrant, fixed water/foam monitor, water drenching/

spraying system and semi automatic foam pouring system for crude oil tank protection. Fire

fighting water ring main at OCS, CTF, GCS etc. are non pressurised type (only in LPG recovery

and bottling plant water ring main is pressurised type). In OCS, CTF etc. to pressurised the fire

water ring main, we have fire pumps (drenching pumps) which will have to be operated manually

to pressurised the ring main. In every OCS we have 2 Nos. 160 KL fire water storage tanks and

two nos. fire pumps (drenching pump) by which ring main can be pressurised to required pressure

to operate the various fixed fire fighting system. In some OCSs, fire water storage capacity has

been enhanced to 650 KL.

3.3.1 : FIRE HYDRANT -

Fire Hydrants are installed on the firewater ring mains throughout the installation. Mostly

in our installation single headed hydrant of 63 mm outlet are installed.

OPERATING PROCEDURE OF ANY HYDRANT -

(a) Pressurise the water ring main by operating fire pump unit.

(b) Open the main control valve (4" gate valve) of the hydrant to the fullest

extent.

(c) Connect the hose to the hydrant outlet and lay the hose up to the site of

fire.

(d) Open the landing/hydrant valve slowly as sudden opening may result in

bursting of the hose.

(e) In case of any leakage or wastage of water, shut-off the hydrant’s main

control valve.

3.3.2 : FIXED MONITOR

Fixed monitor are of two types. Water Monitor and Water cum Foam Monitor. Depending

upon the hazards involved monitors are installed at some selected points on the fire water mains

of any installation. In OCS monitors are fitted around the tank farm and separator area. Once the

monitor is properly set, it can be locked in the operating position and can be left unattended. Main

puropose of installing monitor is to cover large area under cooling, thus to restrict spreading of

fire.

ADOPT FIRE PRECAUTIONS - PREVENT DESTRUCTION


Fire Service

MONITOR OPERATING PROCEDURE

(a) Open the main control valve to the fullest extent.

(b) Adjust the monitor in the proper angle and lock the vertical movement locking lever.

(c) If large area is to be continuously cooled, then direction of the water jet should be

changed by moving the handle of the monitor to all direction.

3.3.3 : WATER DRENCHING/SPRAY SYSTEM

All the crude oil storage tanks in OCS & CTF area are protected with water spray /

drenching system. Some places this drenching ring are open hole type and at some places it is

fitted with spray nozzles. In this system water sprayed in fine form on the tank’s outer surface to

protect it from conductant and radiant heat.

OPERATING PROCEDURE OF DRENCHING SYSTEM

(a) Fire fighting ring main has to be pressurised to appropriate pressure by operating

drenching pump unit.

(b) Main valves of the drenching system has to be open slowly.

(c) Spray system will start immediately. Cheek the water spray for effective/uniform

pattern all around the tank.

(d) After use, close the main valves and ensure that water is fully drained out from the

system.

3.3.4 : SEMI AUTOMATIC FIXED FOAM SYSTEM

All the storage tanks (floating roof & fixed roof) at OCS & CTF area are protected with fixed foam

system. Our system is semi automatic type. It consists of foam line, inline inductor, foam

concentrate tank and foam maker cum vapour seal chamber. In this system no fire tender is

needed. Operating staff of the installation can operate the system easily before the fire service

reach at site and thus can save the installation.


Fire Service

OPERATING PROCEDURE OF FOAM SYSTEM

(a) Pressurised the fire water ring main to the required pressure (7 Kg/cm2) by operating

drenching pump units.

(b) Open the foam system’s manifold valves and ensure the manifold is pressurised

to 7 Kg/cm2.

(c) Open the inline inductor’s inlet valve of a particular tank’s (where you want to apply

foam) foam line. Water will immediately go to the foam maker area at the tank top

and will break the vapour seal glass (in case of fixed roof tank).

(d) Simultaneously open the foam concentrate tank’s valve to allow foam compound

to enter into the inline inductor.

(e) Foam solution will start going to the tank top’s foam maker area where aeration will

take place and final foam will form and will enter into the tank’s inside surface

through the foam pourer outlet.

(f) Constant monitoring is required during operation to ensure that no back flow of

water take place in the foam concentrate tank, otherwise it will damage the quality

of the foam compound.

(g) Once the foam application is over, foam line should be flushed by pumping fresh

water for few minutes and after the operation entire water from the foam system

should be drained through drain cock.

3.4 : MAINTENANCE OF FIXED FIRE FIGHTING SYSTEM

Routine inspection & maintenance is utmost important for smooth and effective operation

of any fire fighting system.

It will help the installation personnel to operate the system safely & easily during any fire

emergency. Various fire fighting system should be inspected & maintained as per the following

procedures -

3.4.1 : FIRE WATER LINES

(a) Hydraulic pressure testing of the fire water ring main & all other lines should be

carried out with test pressure at least annually. During this test actual flow pressure,

leakage/ damage etc. of any portion should be recorded. Test pressure should be

1.5 times of maximum allowable working pressure.

(b) All isolation valves should be tested once in a month by opening/cleaning and it

should be well greased.

(c) Entire lines should be flushed thoroughly at least once in six months.


Fire Service

3.4.2 : FIRE WATER HYDRANTS

(a) All hydrants should be flushed at least once in six month. Any leakage from flanges

or from the connection of the coupling should be attended to on priority.

(b) Hydrant valves should be lubricated for easy operation.

(c) Ensure easy operation of female coupling lugs.

(d) Checking whether wheel is in position and free to operate.

(e) Check the coupling for washer, if missing or damage, replace with new one.

(f) All hydrants should be painted for protection from external corrosion.

(g) Ensure approach to the hydrant is free from any obstruction.

3.4.3 : WATER MONITOR

(a) All monitor should be flushed at least once in six month. Any leakage from flanges,

lock, nut, nozzle joints etc. should be attended to on priority.

(b) All the swivel joints should be lubricated for easy vertical & horizontal movement.

(c) All the locks, handle should be checked for any defect/damage.

(d) Monitor should be painted for protection from corrosion.

(e) Monitor nozzle should be left pointing downwards to protect collection of rain water

which may damage the nozzle.

(f) Ensure approach to the monitor is free from any obstruction.

3.4.4 : WATER DRENCHING / SPRAY SYSTEM

(a) Entire drenching / spray system should be thoroughly checked at least once in six

month. Any defect should be attended.

(b) Drenching ring of the tank’s top should be inspected for any blockage of holes/

spray nozzles, which is to be cleaned.

(c) Drenching’s main valve should be checked and greased for free movement.

3.4.5 : FIRE WATER STORAGE TANK

1) Tank dip should be taken daily to ensure availability of water storage.

2) Tank leakage (Visual Check) should be done daily.

NEVER TAMPER WITH ELECTRICAL EQUIPMENT.


Fire Service

3.4.6 : SEMI AUTO M ATIC FIXED FOAM SYSTEM

(a) Entire foam system should be thoroughly inspected and tested once in every six

month. Any corrosion of metal can be determined by visual inspection.

(b) Foam maker cum vapour seal chamber should be examined for any leakage of

vapour, clogging of air inlet area by any foreign particle/bird nesting etc.

(c) Foam line connection should be checked for any excessive rusting, cracks or open

breaks.

(d) Any leakage in inline inductor’s flange area should be checked. Proper foam suction

at inline inductor is to be ensured. Any blockage in ventury on foam suction line

should be removed.

(e) All foam lines should be thoroughly checked for any leakage or damage.

(f) While carrying out any functional testing of fixed roof tank’s foam system, vapour

seal glass should be removed and the area should be blocked to stop entry of

foam/water inside the tank and the top cover of the chamber should be opened to

discharge the foam outside the tank.

(g) Floating roof tank’s foam pourer’s discharge outlet should be checked and any

blockage due to bird nesting should be removed.

(h) Foam concentrate storage tank should be thoroughly inspected to identify any

damage due to corrosion.

(i) Proper function of non return valve in the foam suction line should be ensured.

(j) Painting of foam tank and removing of any sedimentation has to be carried out if

needed.

Note : Fire protection arrangement for Drilling / Workover Rigs, GCS & EPS etc. should be as

per OISD standards, respective rules and regulations following best industrial safe

practices.

DON’T OBSTRUCT ACCESS TO FIRE EXTINGUSHER.


Fire Service

4.0 : ACTION PLAN IN CASE OF ANY FIRE EMERGENCY

4.1 : OPERATION STAFF AT SITE

(i) Shout ‘Fire’ ‘Fire’.

(ii) Immediately sound fire alarm to alert the other operating staff in the installation.

(iii) Inform Fire Station by dialing Fire Call No. 7333 (For Duliajan).

(iv) While informing Fire Station operator caller should give exact site/place, installation’s

name, telephone No. etc.

(v) Try to extinguish/control the fire with available fire extinguishers.

(vi) Try to isolate the affected area from the other equipment/materials.

(vii) Start the drenching pump unit to pressurised the ring main and use the drenching/

cooling system and foam system etc. if needed (in case of OCS/GCS, CTF & LPG

area).

(viii) Call ambulance by dialing 6361 (For Duliajan) if required.

(ix) Simultaneously render first aid to the person (s) injured with available first aid

materials.

4.2 : FIRE FIGHTING STAFF

(i) On receiving fire call message, immediately first turnout with necessary fire fighting

staff should start from fire station towards the site of fire. First turnout should leave

fire station within 30 sec. after receiving the fire call.

(ii) Keep stand-by personnel and other fire tender/equipment in readiness.

(iii) Control room operator will inform Chief Engr. (S&E - Fire Service) / Dy. Chief Engr.

(Fire Service) and Sr. Engineers (Fire Service) and if required he will inform others

as per telephone priority list.

(iv) Chief Engr. (S&E - Fire Service) will rush to fire station and will take the charge of

control room.

(v) Fire officer concerned will rush to the site of fire.

(vi) On arrival at site first turn out will immediately start fire fighting.

(vii) Fire officer will assess the fire situation and will direct fire fighting operation at site.

(viii) Fire officer at site will be in touch with Chief Engr. (S&E - Fire Service) and will call

2nd or 3rd turn out or outside help in consultation with Chief Engr. (S&E - Fire

Service) depending upon the fire situation.

(ix) If required Chief Engr. (S&E - Fire Service) will proceed to the site to guide the fire

fighting operation.


Fire Service

5.0 : MOCK FIRE DRILL

Mock fire drill should be conducted once in every month in all installation (OCS, GCS,

Drilling & Work-Over Rig, etc.) with their own resources and manpower to make the operating

personnel habitual with the fire fighting procedure and the various fire fighting systems installed in

the installation. However, once in a year Fire Service, Ambulance and other service section will

also take part in the mock fire drill in the installation. A report of the mock fire drill should be

prepared by the installation manager as per the proforma attached in annexure - 1.

MAINTAIN SAFE DISTANCE OF FLAMABLE LIQUIDS FROM

SOURCE OF IGNITION


Fire Service

6.0 : IMPORTANT TELEPHONE NUMBERS

Fire Call : Duliajan - 7333

Moran - 333

Manabhum - 311

Digboi (IOC - AOD) - 222

Fire Station Control Room : Duliaian - 7332

Moran - 239

Manabhum - 311


Ambulance Call : Duliajan - 6361

Moran - 312

Manabhum - 305


Production (Gas) Control Room : 6412 (Duliajan)

Telephone Enquiry : 7396/7389 (Duliajan)

245 (Moran)

Water Supply : 8326 (Duliajan)

Disaster Control Room

(S&E Dept. - 2nd Floor) : 8888/7294

Established during 0374-2804888

on-site/off-site emergency (Fax & Land line)

0374-2801795

Note :For Important Telephone Numbers of Key Persons / Co-ordinators, Please

refer On-Site / Off-Site Disaster Management Plan.


Fire Service

ANNEXURE - 1

MONTHLY MOCK FIRE DRILL PROFORMA

Ref. No.: .......................................... Date : ................................

TO,

G.M. (Concerned Department)/Head of the Department

1. Name of the Installation :

2. Type and Place of fire :

3. Date and Time of Fire Call :

4. a. Name of the persons :

attended the mock drill

b. Personnel reported late :

(After 2 Minutes), Record reasons

5. Action taken by the installation personnel :

a. Name of the person initiated :

the fire alarm

b. Name of the persons :

used the fire extinguisher

and Type of the fire extinguisher

c. Name of the person isolated the :

valves / seat of fire

d. Name of the person informed :

to the fire service & time

e. Name of the person informed :

to the Ambulance and time

f. Name of the person who started the :

drenching system or trailer fire pump

and time

g. Name of the person who operated :

the fire alarm regarding completion

of fire drill and time

Contd..........2


Fire Service

Page... 2

6. a. Reporting time of fire tender and :

actions taken by fire service personnel

b. Name of the fire service personnel :

attended the mock fire drill

7. Reporting time of the ambulance at site :

8. Adequacy of fire extinguisher as per OISD STD 189 :

9. Fire hydrant/monitor nozzle pressure :

10. Last inspection/checking date of foam pouring

system :

11. Last participation date of fire service and

ambulance service in the drill at site :

12. Observation/deficiency :

(i)

(ii)

(iii)

Copy : Head - S & E

: CE (S&E - Fire Service)

: File

Signature

(INSTALLATION MANAGER)


Field Engg.

OIL INDIA LIMITED


Volume - II

Section - 4

FIELD ENGG. ACTIVITIES


Field Engg.


FIELD ENGG. ACTIVITIES

CONTENTS


1.0 4 MGD Water Treatment Plant........................................................................ 1

2.0 Safety measures to be taken during emergency............................................ 12

3.0 SOP for General Workshop............................................................................ 14

4.0 Maintenance procedures for floating Roof Crude Oil storage tank................. 18

5.0 COCP (Crude Oil Conditioning Plant) ............................................................19

6.0 Boiler .............................................................................................................. 25

7.0 Welding Operation ......................................................................................... 26

8.0 ICE Shop ........................................................................................................ 27


Field Engg.

4 MGD WATER TREATMENT PLANT AT TIPLING

List of Machineries & valves in 4-MGD W/T Plant

(A) Inlet Chamber :

1) Drain valve - 100 mm (4”) dia — 2 nos.

2) Inlet valve of Inlet Chamber - 600 mm (24”) —1 no.

3) By-pass vertical gate (pressed plate) with H.S. & spindle - 1000×1000 mm — 1 no.

4) Outlet gate (pressed plate) with H.S. & spindle - 800 × 800 mm — 1 no.

(B) Presettler :

1) Moving bridge driven by electric motor (1 HP) — 1 no.

2) Drain valve - 200 mm (8”) — 2 nos.

(C) Leading Channel :

1) Flow meter with calibration from 0 to 10000 M3/Hr — 1 no.

2) Vertical gate 1000 × 1000 mm — 1 no.

3) Outlet gate (PP) with HS & spindle 800 × 800 mm — 2 nos.

(D) Clariflocculators : 2 nos.

1) Moving bridge driven by electric motor (1 HP) — 2 nos.

2) Flocculator motor (2 HP) — 4 nos.

3) Drain valves 200 mm (8”) — 4 nos.

4) Sludge bleeding valve 200 mm (8”) — 2 nos.

(E) Settle Water Channel :

1) Vertical Gate 1000 × 1000 mm — 2 nos.

2) By-pass Gate (PP) with HS & spindle 800 × 800 mm — 1 no.

3) Filter Inlet Gate (PP) 600 × 600 mm with HS & spindle — 4 nos.

(F) Filter House :

1) Wash water outlet Gate (PP) 600 × 600 mm — 4 nos.

2) Backwash valves - 350 mm (14”) — 8 nos.

3) Air Inlet valve 100 mm (4”) with HS & spindle — 8 nos.

4) Air Bleeding valve - 12 mm (1/2”) — 8 nos.

5) Filter outlet valve - 200 mm (8”) with HS & Spindle — 8 nos.

6) Rate Settler— 4 nos.

7) Outlet Indicator (Filter) —— calibration 0 to 300 mm3/hr — 4 nos.

(G) BACK WASH TANK :

1) Electric motor (12.5 HP) with pumps — 2 nos.

2) Sluice valve 150 mm with wheel — 4 nos.

3) Non-return valve 150 mm dia — 1 no.

4) Press plate Gate 800 × 800 mm with HS & Spindle — 1 no.

5) Level Indicator — 1 no.

6) Sluice valve 100 mm with wheel — 1 no.


Field Engg.

(H) AIR COMPRESSOR :

1) Electric motor 30 HP with Air Compressor — 2 nos.

2) Non-return valve 100 mm dia — 1 no.

3) Sluice valve 100 mm with key — 2 nos.

(I) Chemical House :

1) Alum stirrer with electric motor — 2 nos.

2) Lime stirrer with cyclo gear driven by 2 HP motor — 2 nos.

3) Reciprocating type metering pump with electric motor — 2 nos.

4) Chlorinator — 2 nos.

5) Electric motor with 2 HP pump along with fittings — 2 nos.

(J) Pure water pump :

1) Pressed plate gate 800 × 800 mm with HS & Spindle — 2 nos.

2) Vertical gate (Sluice gate) 1500 × 1500 with HS & Spindle — 2 nos.

(K) Pump House :

1) Electric motor with pump (380 HP) — 4 nos.

2) Sluice valve of 150 mm dia — 4 nos.

3) Non-return valve of 150 mm dia — 4 nos.

4) Vacuum pump with electric motor (0.5 HP) — 2 nos.

5) Sluice valve with 350 mm dia wheel — 1 no.

(L) Pontoon :

1) Pump with electric motor of 100 HP — 3 nos.


3) Sluice valve with 300 mm dia wheel — 3 nos.




7) Sluice valve with 600 mm dia wheel — 1 no.

(M) Raw water pump :

1) Pump with electric motor of 100 HP — 2 nos.

2) Sluice valve with 100 mm dia — 3 nos.



5) Sluice valve with 200 mm dia — 1 no.


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l Preamble: Field Engg Department looks after the operation, distribution and maintenance

of water supply system of Oil India Limited. Water is required mainly for two purposes, Potable

purpose to the company’s housing area as well as other nearby set-ups and Industrial purpose to

the various installations and locations for company’s different activities.

W e are having two water supply Stations at Tipling. The design capacity of one is 4 Million

Gallons per day (New water supply station) and the other is 1.5 MGD (Old water supply station).

However, due to ageing the capacity of old water supply station has come down to around 1.0

MGD. Presently, due to increased new housing area and other new installations/set-ups of the

company, the New water supply station has to run on around 6 MGD i.e. on an overload of 1.5

times than its design capacity (which has been established by installing flow meter). Still the

quantity of water being supplied is found to be not sufficient.

The raw water from the river Dehing is treated in the 4-MGD water treatment in the following

stages:

1.1 l Pontoon: There are two Pontoons in the river Dehing. 1) Big Pontoon- having 3 raw

water pumps of capacity 720 Kls/Hr. each. 2) Small Pontoon- having 2 raw water pumps of capacity

500 Kls/Hr. each. There is also one engine driven pump of capacity 500 Kls/Hr. for emergency

purpose. The operating procedure of the Pontoon pumps is given below:

(Refer fig.- 1)

1) Close Air valve V 7 on rising main, Drain Valve V

0 and raw water delivery valve V

2

2) Open Raw water suction valve V1.

3) Open Raw water delivery valve V6 on rising main.

4) Close water drain valve V5 from Vacuum chamber.

5) Open Air suction valves V3 on vacuum line.

6) Start the Vacuum pump (P6 or P

7) till water comes out through glass tube.

7) Close Air suction valve V3 on vacuum line

8) Stop the Vacuum pump.

9) Start the Raw water pump (P1, P

2, P

3) to be started

10) Open the Delivery valve V2 slowly and maintain the require current.

11) Open the drain valve V 5 of the vacuum chamber.

1.2 l Inlet Chamber : The procedures for smooth and safe operation of the Inlet Chamber

are:

(Refer fig.- 2)

1) Open Inlet valve l1 of Inlet chamber.

2) If necessary open the sluice valve I2 for old water supply

3) Close the By-pass sluice gate SG1.

4) Open the outlet of Inlet chamber i.e. press plate PS1.

4) Open drain valves V1 & V2 for 10 minutes at least two time in a day.

Inlet Chamber (fig. - 2)


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The procedures for smooth and safe operation of the Presettler are: (Refer fig.- 3)

1) Open the outlet and inlet press plate gate (PSI) of the Inlet Chamber and Presettler

respectively.

2) Start the moving bridge for one hour after the rest of 3 hours in plant running time.

3) Open the drain valve (D1) for 5 to 10 min. when the bridge completes one rotation.

4) Close the drain valve DI

1.4 l Chemical House : The following chemicals are added to the raw water as coagulant

to help in formation of flock. These are added in the leading channel that carries the water to the

Clariflocculator tanks

(Refer fig. - 4)

1.3 l Presettler : The Presettler is a circular tank having two sections in concentric circles.

W ater from the Inlet chamber enters into the inner section from the bottom. A bridge moving

continuously in slow circular motion on the pivoted channel around the tank helps the suspended

solids to be settled down at the bottom of the tank (as shown in the fig. -3). After initial settling in

the tank it goes to the outlet chamber from the top and finally to the leading channel (siphon action)

that leads the water to Clariflocculator tank.


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1.5.1 Ü Alum : The chemical composition of Alum is Al2(S0

4)

3, 18 H

20. This coagulant is

effective to the water having PH value in between 6.5 to 8.5. Alum reacts with the bicarbonate

alkalinity (temporary hardness) present in the raw water. The reaction is as follows:

Al2(S0

4)3, 18 H

2O + 3 Ca(HCO

3)

2 = 2 AI(OH

3) + 3 CaSO

4 + 18 H

20 + 6 CO

2

Aluminum Hydroxide, A1 (OH3) thus formed is insoluble in water and behaves like flock. Dosing

rate of Alum varies according to the turbidity, colour and taste, PH value, temperature etc. of water.

Normally dosing rate varies from 5 to 30 mg per litre, the usual being 14 mg per litre.

1.5.2 Ü Sodium Aluminates : The chemical composition of Sodium Aluminates is Na2A1

2O

4.

This coagulant is used to remove carbonate or temporary hardness and non-carbonate or

permanent hardness of raw water. This coagulant is costly and therefore used together with Alum

when flock by Alum alone is not easily formed. When it is dissolved and mix with water reacts with

salts of calcium and magnesium to remove temporary and permanent hardness of water. Reactions

are: With carbonate salt (To remove temporary hardness):

Na2AI

2C

4 + Ca(HCO

3)

2 = CaAI

2O

4 + Na

2CO

3 + CO

2 + H

2O

W ith non-carbonate salt (To remove permanent hardness):

Na2A1

2O

4+ CaCI

2 = CaAI

2O

4 + 2NaCI

Na2AI

2O

4+ CaSO

4 = CaAI

2O

4 + Na

2SO

4

1.5.3 Ü Lime : The chemical formula of lime is Ca(OH)2. Lime is added to raw water if water

possesses a little or no alkalinity. The reaction is as follows:

A12(SO

4)

3, 18H

2O + 3Ca(OH)

2 = 2AI(OH

3) + 3CaSO

4 + 18H

2O.

1.5.3 Ü Bleaching Powder (as pre-chlorination) : The bleaching powder is added to the raw

water as pre-chlorination.

The dosing rate of the above chemicals depends according to the flow-rate of the raw

water, which is being continuously measured by a flow meter installed in the leading channel. A

row of baffle plates in the leading channel helps these chemicals to mix up properly before entering

into the Clariflocculator tanks.

1.6 Ü Clariflocculator : The leading channel then carries this chemical-mixed raw water

into two numbers of Clariflocculator tanks, which are situated in parallel. This tank is also a

combination of two concentric circular chambers. The inner chamber is Flocculator and the outer

chamber is Clarifier.

Clariflocculators (fig. - 5)


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W ater from the leading channel enters into the flocculator chamber from the bottom (as shown in

the fig.- 5). A bridge moving continuously in slow circular motion on the pivoted channel around the

tank does the flocculating effect. Water from the Flocculator, enters into the outer Clarifier chamber

by symphonic action so that only the clean water comes into the clarifier tank leaving the flock in

the flocculator chamber which is being drained intermittently.

The procedures for smooth and safe operation of the Clariflocculators are given below: (Refer fig

5)

1. Close the bye pass gate i.e. sluice gate (SG2) of leading channel.

2. Open the Inlet i.e. press plate gate (PS2 & PS3) of clariflocculators.

3. Start the moving bridge for one hour after the rest of 3 hours in plant running time.

4. Open the drain valves (D2, D3 & D4, D5) for 5 to 10 minutes respectively where

bridge, completes one rotation.

5. Close the valves (D2, D3 & D4, D5)

6. In the heavy rainy season open the sludge bleeding valves (SB1 & SB2) continuously

7. Open the SG2 & close the PS2/PS3 and also SG3/SG4)

1.7 Ü Water Filter : Water from the clarifier of the clariflocculator goes to the four numbers of

rapid gravity type parallel water filters through the leading channel. The capacity of each water

filter is 200 Kls/hour (1.0 MGD). The filter bed consists of six layers of sand/pebbles (as shown

in the fig.-6). The filtered water goes out from the bottom of the filters to the underground water

reservoir through the filtered water channel. The procedures for smooth and safe operation of

filters are given below

(refer fig 7)

Rapid Gravity Filters (fig. - 7)


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1. Close the press plate gate bye pass valve B. of the settled water channel.

2. Close the drain valve V,, air inlet valves V1 & V5, backwash water valves V2 & V6.

3. Open the inlet water valve Vi (press plate gate type) from the clariflocculators to filters.

4. Close the filter rate controller V4.

5. Open slowly the filter outlet valve V3

6. Open slowly the filter rate controller V4.

The above procedure has been given individually for one filter only. It will be same for the all the

other three filters also.

The detail procedures for backwash of the filters are given in the fig.- 6.

1.8 Ü Water Reservoir : The size of the reservoir is 48 M length, 31 M width and 3 M height.

The capacity of the underground water reservoir tank is approximately 4500 Kls. The tank is

divided into two chambers by a partition wall so that the tank can be cleaned part by part whenever

required without shutting down the plant. Water enters into both the parts separately as shown in

the following sketch (fig.- 8) from where filtered water pumps take the suction.

1.9 Ü Pump House : There are four filtered water pumps and two vacuum pumps (for priming

the filtered water pumps) in the Pump house (as shown in fig. - 9). The filtered water pumps take

the suction from the underground filtered water reservoir.

WATER RESERVOIR (fig. - 8)


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PUMP HOUSE (fig. - 9)


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1.11 The procedures for safe and smooth operation of the vacuum (for priming) and

filtered water pumps

The procedures are given for pump no. 1. It will be same for the other pumps also.

1.11.1. Confirm that the inlet valves on the pumping main at the overhead tank are open.

1.11.2. Close the delivery valves SV1.

1.11.3. Open the delivery sluice valve SV5 on the pumping main.

1.11.4. Open the Inlet gates i.e. sluice gates of suction pit.

1.11.5. Close the drain valve D of the vacuum tank.

1.11.6. Open the air suction valve 1, near filtered water pump no. 1

1.11.7. Open the inlet valve 15 of the vacuum pump.

1.11.8. Start the vacuum pump (VP1) and observe the glass tube unless until water comes

through it.

1.11.9. Stop the vacuum pump VP1

1.11.10. Start the filtered water pump no. - 1

1.11.11. Open the delivery valve SV1 of filtered water pump no. -1 and maintain the current

maximum up to 60 amps.

2.0 SAFETY MEASURES TO BE TAKEN DURING EMERGENCY

2.1 lllll IN CASE OF POWER FAILURE IN PONTOON AND WATER SUPPLY:

2.1.1. CLOSE THE DELIVERY VALVE OF THE RUNNING PUMPS.

2.1.2. INFORM ELECTRICAL ENQUIRY ABOUT THE POWER FAILURE OVER TELEPHONE

NO: 7396 AND 7389.

2.1.3. INFORM MAIN OVER HEAD TANK AT TEL. NO.- 7222 FOR NECESSARY

CONTROLLING OF THE VALVES.

2.1.4. INFORM THE CONCERNED ENGINEER.

2.2 lllll IN CASE OF CHLORINE GAS LEAKAGE.

2.2.1. IF THE CHLORINE GAS LEAKAGE IS FOUND IN THE CHLORINATOR OR IN THE GAS

SUPPLY LINE, IMMEDIATELY CLOSE HANDLE-FITTED VALVE IN THE CHLORINATOR

i.e. IN THE CHLORINE CYLINDER.

2.2.2. OPEN ALL THE DOORS AND WINDOWS OF THE CHLORINATOR ROOM.

2.2.3. IF THE LEAKAGE IS IN THE CHLORINATOR ROOM, IMMEDIATELY OPEN THE VALVE

OF THE WATER SPRAYING SYSTEM FITTED IN THE ROOF OF THE ROOM.

2.2.4. INFORM THE FIRE SERVICE SECTION AT 7333

2.2.5. INFORM THE CONCERNED ENGINEER.

2.1.6. ALWAYS REFER MSDS (MATERIAL SAFETY DATA SHEET)

2.3 lllll IN CASE OF FIRE:

2.3.1. INFORM FIRE SERVICE IMMEDIATELY AT TELEPHONE NO.- 7333

2.3.2. FOLLOW THE FIRE CONTINGENCY PLANT WRITTEN IN THE BOARD IN THE WATER

TREATMENT PLANT.

2.3.3. INFORM THE CONCERNED PEOPLE IMMEDIATELY.


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2.4 lllll GENERAL SAFETY PRECAUTIONS :

2.4.1. USE OF PPE WHILE WORKING IN WATER SUPPLY STATION.

2.4.2. SAFE OPERATING PROCEDURE FOR HANDLING ALUM, BLEACHING POWDER,

AL. HYDROXIDE.

2.4.3. USE OF WORK PERMIT SYSTEM WHILE CARRYING MAINTENANCE OF MOTORS /

ELECTRICAL EQUIPMENT.

2.4.4. GENERAL DO’S & DON’TS ON THE HSE PRACTICES SHOULD BE FOLLOWED.

Short - cut : you may feel brave,

Same way lead you to your Grave.


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3.0 SAFE OPERATING PROCEDURES FOR THE WORKSHOP

3.1 Fire Precautions :

a) All jute/waste contaminated with oil/grease should be removed from the shop, before starting

the work everyday.

b) Cleaning oil like petrol, paraffin, condensate should not be allowed to drain out haphazardly.

c) Acid should not be stored in any building other than specified place.

3.2 Electrical Precautions :

a) Electrical fire : In case of electrical fire, supply should be cut off at the main switch. The fire

fighting should be done by dry chemical powder or CO2 extinguishers only.

b) Damp condition : Damp conditions are often liable to leakage of current. All operators should

work on a wooden platform and all the machines to be earthen properly and checked

periodically.

c) Defects : All electrical equipment particularly flexible wires, extension cables, plugs etc,

should be examined regularly for defects. A routine check-up by Electrical Department to be

carried out.

d) E.O.T crane : The overhead supply line to be checked frequently for its isolation from main

structure. All the contacts to be checked frequently.

e) There must be rubber mat in front of the main switch/panel board.

f) Carbon Brush : All brush gear should be checked periodically for carbon deposition which

may lead to fire occurrence.

g) Fuse : All fuses in case of “blown” to be replaced by Electrical Department only.

h) For any work on E.O.T. crane, the shut down procedure as laid by the company should be

followed strictly. After removal of main fuses, the switch box to be locked and key to be kept

with responsible person only.

i) Over heating : If any electrical equipment shows sign of over heating, immediately it should

be shut down and electrical department to be informed for rectifying the defect. Air cooled

motors should have a free flow of air and should not have any obstacle.

3.3 Accident Precautions :

a) Working at a height : When working at a height any ladder/platform used should be firmly

fixed and tools placed in such a manner that there is no possibility of toppling. Person

working at a height must wear safety belt. While using ladder one person should firmly hold

the ladder to avoid skidding.

b) Pressure risks : When operating hydraulic press, a constant observation should be kept to

avoid over pressure that may lead to an accident.

c) Bench work : Heavy coil springs should not be compressed in a bench vice. Hardened steel

headed hammer should not be struck on any hardened steel like drills, files etc. as there is

a danger of injury from steel splinters.


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d) Goggles : Goggles should be worn by personnel engaged in all types of works within the

shop floor premises to prevent abrasives or pieces of metal injuring the eyes.

e) Cleanliness : Precautions should be taken with regard to cleanliness of personnel handling

lead, paints, mineral oils, dope and cellulose enamel, acid etc. The hands should be washed

immediately in running water and food should not be eaten or placed near any of these

materials.

3.4 Machine shop safety precautions :

1. Suitable guards are to be fitted around electrical motors/pulley systems gears/flywheels/

couplings etc.

2. Guards must be used in instances where main drive or counter shafts beltine approaches

with in 2.1 meters of the ground level in a fare way.

3. Any shafting or counter shafting that is erected at a height of less than 2.1 meter from the

floor level to be enclosed or screened by fencing.

4. Planning and shaping machine are to be installed in such a position that the table or ram at

each end of the maximum travel positions are not less than 18 inches from any fixtures that

is not a part of the machine.

5. Line shafting and counter shafting must not be lubricated or cleaned whilst in motion.

6. Lathe face plates, driving plates, chucks etc. are to be mounted or removed with the mandrel

at rest. These fitting must not be stopped by hand in order to bring the mandrel to rest after

switching it off.

7. No loose fitting clothing should be allowed in the shop.

8. No running job should be inspected by finger while the machine is in motion irrespective of

the speed of rotation.

9. The shop floor should be maintained in good condition, non slippery and kept free from

loose materials.

10. Adequate lighting should be provided, but no light ray should fall on operators eyes directly.

11. No person should touch chips with free hand, proper chip disposal system should be made

so that chances of accidental injury to hands chips is eliminated.

12. While using grinding machine plane goggles must be used.

13. All person in the shop floor should wear safety boots.

14. Operator assigned to a machine should have general experiences and sufficient knowledge

of that particular type of machine.

15. Guard or fences should not be removed or carelessly positioned.

16. An operator should not use their hands too close to cutters.

17. No machine to be put in operations for which it is not designed or over loaded.

18. An operator should not attempt to work with defective or improperly adjusted tool/cutter.

19. No running machine should be left unattended.


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3.5 Black smithy shop :

1. Care should be taken while firing furnace as there may be an accumulation of natural gas

that may cause an explosion.

2. Work that has been heated and thrown to floor for cooling should be marked “black hot”.

3. During hardening, some poisonous gases are generally released and that should not be

inhaled use Gas mask.

4. Hammer heads should be checked regularly to ensure that they are secure on the shafts.

5. All persons working in the shop should wear personal safety gears like safety boots, apron

hand gloves and goggles etc.

3.6 Fitting shop :

1. No chain should be subjected to shock loads or hammered. Chain should not be dragged

on the floor or thrown down from a height as it is liable to failure due to crystallization of link

material.

2. Safe working load for chain/sling : Always care should be taken while lifting by chain/sling,

so that load is equally distributed. All the knots should be perfect and over loading is strictly

avoided SWL should be marked on the sling and the chain sling.

3. While in the shop, all personnel should wear/use personnel safety gear like safety boots,

gloves and goggles etc.

4. Proper house keeping should be maintained.

5. Special care to be taken while heating bearings/housing etc. for shrink fitting.

3.7 Welding Shop :

1. The generator body should be earthed properly to avoid shocks in damp weather.

2. The rays of electric arc is injurious to human body, specially to the eyes, causing severe

pain and temporary weakness of eye sight and in some cases it may be serious. To protect

the eyes the welder should look at the arc through light filters of the hand shield or glass

attached to the helmet.

3. Welder should wear leather gloves to protect hands and should wear leather or tarpaulin

apron / leg guard to protect his body and clothes.

4. The welding place should be shielded to avoid the arc from injury other people.

5. While chipping and cleaning the welds, welder must wear goggles with plain glass to protect

his eyes from fragments of slag.

6. Welder should take care, so that he does not inhale fumes generated during welding cutting

operation special mask for welder should be worn.

7. Welder should wear safety boots and other personnel safety gears.

8. Leakages of oxygen or acetylene should be located and remedied immediately.

9. Connections for cylinders which do not fit easily should not be forced and all connection

should be free from dirt and oil

10. The blow pipes should not be used unless the operator is wearing goggles of the approved

quality and design, if the glasses of the goggles are badly pitted they should be replaced.


Field Engg.

11. Oxygen valves must be opened very slowly, otherwise the pressure reducing valve may

fracture and cause accident.

12. When lighting, if back fire occurs from jet there is a possibility of a leakage along the acetylene

feed tube at a joint or a weak point; the tube therefore should be inspected and replaced if

necessary. Defective tube ends should be cut-off in case of any signs of deterioration.

3.8 General Safety :

1. All the employees should undergo Mines Vocational Training course.

2. Maximum Nos. of employees should have First Aid training and First Aid trained personnel

should be made available in all the shifts.

3. At least two Nos. of First Aid box should be available on the shop along with other accessories

like stretcher etc.

4. All personnel should have adequate knowledge of their respective machine operations.

5. Regular pit level safety meeting should be organized. (frequency-once in a month)

6. Smoking should be strictly prohibited within the workshop premises.

7. A routine on preventive and scheduled maintenance for all the machine should be prepared

and to be followed.

8. House keeping and illumination should be proper.

9. All the nuts and bolts of the structure of E.O.T. crane should be checked regularly.

10. Load testing for lifting equipment to be carried out on regular internal.

11. Adequate fire extinguishers should be kept in vulnerable places and these are to he checked

by fire service personnel regularly.

12. Fire contingency plan should be displayed in various places.

13. Primary fire fighting training should be provided to the shop personnel.

14. A plant lay out drawing & installation Manager’s name designation and Phone No. should be

displayed.

15. Safety boundary line should be marked on the floor with yellow colour paint.

16. A list mentioning the names of First Aid personnel should be displaced.

17. All statutory records should be maintained and kept as per SOP on HSE Management.

18. All electrical equipment should have proper earthing connection and the same should be

checked as per SOP on Electrical Engg. activities.


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4.0 SAFE MAINTENANCE PROCEDURE FOR FLOATING ROOF

CRUDE OIL TANKS :

The following jobs are to be carried out for overhauling of the tank :

1. The residual crude oil from the tank is to be pumped out with a separate Engine driven

pump set down to the level of 15 cm to 20 cm. Thereafter the Manhole covers and Agitator

cover are to be dismantled.

2. After removing wax, sludge etc. from the tank, the inside of the tank is to be thoroughly

cleaned manually. All the inside structures are to be throughly scrapped using Diesel, sand

etc. so that no trace of crude oil is left out and the inside of tank is made gas free.

3. The tubes of old heating coils are to be cut into pieces with hacksaw and taken out of the

tank.

4. New tubes [114.3mm (4.5") OD Seamless Line pipe of wall thickness 7.14mm (0.281"),

and bends (made in General Workshop) for heating coils are to be taken inside the tank and

aligned.

5. Gas testing to be carried out inside the tank using gas tester. After obtaining requisite Hot

Permit from the Installation Manager, the above. tubes and bends are to be welded for the

fabrication of two sets of heating coils.

6. 30 nos. of welded joints from the above are to be radio graphically tested.

7. Both the new heating coils are to be hydraulically tested up to 20 Kg’sq cm. and the pressure

to be recorded for 24 hours using a circular recorder.

8. The thickness of bottom plates and shell plates are to be measured with ultrasonic thickness

gauge.

9. All the pontoon chambers of the Double Deck Roof of the tank are to be physically checked

for any trace of crude oil in any of these chambers. Thickness of bottom plates of these

chambers are to be measured with ultrasonic thickness gauge.

10. The Rim seal assembly of the tank is to be replaced with a new one.

11. The manhole covers and the agitator assembly are to be boxed up and the tank is to be

hydraulically tested by filling water in the tank up to a level of 3 meters.

12. OISD STD - 129 should be followed.

13. Tank bottom sludge should not be permanently dumped within the CTF area / inside the

Tank Bund enclosure.


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5.0 C.O. C. PLANT

SAFE OPERATING PROCEDURE

5.1 PLANT COMMISSIONING IN WINTER :

i) First of all air compressor is to be started.

ii) The oil - circuit should be purged by introducing natural gas and the system pressure to be

maintained at around 10 PSI initially.

iii) Booster Pump (Main Line) to be started after proper priming.

iv) By opening the valve in the internal circulation line, 75% of both the crude conditioning vessels

(T2A/T2B) to be filled up.

v) Main line booster pump to be stopped.

vi) Filling and dropout valves of Tr. No. 1:1 and 1:2 to be kept open.

vii) Then Pump P-1 to be started after proper priming.

viii) Balance Tank level control valve to be commissioned.

ix) Level of balance tank T.1 to be observed carefully and when balance tank T-1 is half filled

then immediately Pump- P-2 is to be started after priming and the crude oil flow to be

maintained at around 250 Kls/Hr. initially.

x) Thereafter gas-controller should be commissioned to maintain die pressure of crude oil

circuit at 1.2 Kg/cm2.

xi) The plant will be under internal circulation and dosing pumps are to be operated till the

treatment of all the crude oil available at the conditioning tank. Then flow improver injection

should be stopped.

xii) As soon as PS-1 starts drawing of crude oil from C.O.C. PLANT, the booster pump will have

to be started and internal circulation valve is to be closed totally.

xiii) Throughput to be adjusted by operating the delivery valve of pump- P-2 as per PS-1’s

requirement and accordingly flow-unprover dosing to be started.

5.2 NORMAL SHUT-DOWN PROCEDURE (FOR SUMMER OVERHEAUL)

I) Flow-improver injection to be stopped.

II) Main line Booster Pump to be stopped.

III) Pump- P-1. to be stopped.

IV) Allow pump-P-2 to run with a low delivery till it loses suction.

V) Pump- P-2 to be stopped.

VI) PS-1 is allowed to draw crude-oil until it loses suction.

VIl) Then the valves (outlet) at the end of C.C.V (T2NT2B) to be closed.

VIll) Gas control valve to be closed.

IX) System pressure to be released.

X) Air-Compressor to be stopped.


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5.3 Restarting of C.O.C. Plant (in case of Power failure) :

I) As soon as power comes, Air compressor to be started.

II) Pump - P-2 & P-1 to be started simultaneously by opening internal circulation valve.

III) Booster pump to be started and PS-1 to be informed to draw oil.

IV) After closing internal circulation valve, Flow-improver chemical dosing to be started.

5.4 General Safety Precautions :

1. Only non-sparking tools should be used in maintenance within the COC Plant area.

2. Personal protective equipment should be used in all operations.

3. Safety belt should be used while working on elevated areas.

4. Materials handling equipment should be checked before being put to use. Ensure that it

does not have any broken wire ropes on slipped locking strips and worn out gear teeth on it.

5. No welding cutting job should be allowed inside the plant until it has been made adequately

gas free.

5.5 FOR OPERATING BOOSTER PUMP SET

9.0 Emergency Shut-Down

iii)

i)

ii)


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iv)

v)

5.6 FOR OPERATING HEAT EXCHANGER


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9.0 Emergency Shut-Down

i)

ii)


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5.7 FLOW IMPROVER CHEMICAL HANDLING SET-UP


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5.8 FOR OPERATING CHEMICAL DOZING PUMP SET


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6.0 : SAFE OPERATING PROCEDURE FOR BOILERS

6.1. A boiler (nor flame arrested) should be installed at least 90 mtrs. away from any well head,

crude oil tank or any hazardous areas.

6.2. The boiler operators must have a valid I.B.R. certificate to run the boilers. The operators

holding 1st Class certificate are eligible for operating a boiler whose heating surface is 7500

sq. ft. The operators holding 2nd Class certificate holder are eligible for operating a boiler

whose heating surface is 1500 sqft.

6.3. To start a boiler

The operator should ensure that -

a) There is sufficient water in the boiler. The water level should be 3/4 full in the gauge

glass tube.

b) Blow down valve should be closed fully.

c) There should not be any leakage from any part of the boiler.

d) The pressure gauge pointer should read ‘0’.

e) The feed water pumps or injectors should be in order.

f) Air vent valve should be in open condition.

g) There should be sufficient water in the storage tank. The tank outlet valve should be

perfectly opened.

The gas valve should not be opened before the masal or lighter placed in front of the burner. The

fireman should stand on one side of the burner and under no circumstances should any one

stand direct in front of the boiler.

The water fed in the boiler should be treated chemically to save the boiler parts and tubes from

corrosion, scale formation etc.

6.4 Maintenance Safety

6.4.1 All the mountings, accessories, pipe fittings steam pipes used related to boilers should be

of I.B.R. quality and must be certified by the competent authority recognised by CIB, Assam.

6.4.2 After continuous running of the boiler for a month the boiler should be taken for descaling,

cleaning etc.

6.4.3 During carry out above jobs proper safety appliances should be used such as hand gloves,

goggles etc. The boiler should be isolated with a blank flange from the other boilers which

are not in operation.

6.4.4 The worn out fittings mountings should be immediately replaced before putting the boiler in

operation. Boilers should never run with broken gauge glasses or pressure gauges. For

welding boiler related items, the welder must be a boiler certificate holder.

6.4.5 Before repairing any boiler, a prior written or verbal permission should be taken from local

IBR authority The hydraulic test of the boiler must be done in presence of local IBR authority.

6.4.6 The fusible plugs must be renewed once in a year at the time of annual inspection of the

boiler. All the tools used in the maintenance jobs must be in good condition.


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7.0 SAFE PRACTICES TO BE FOLLOWED DURING WELDING OPERATION ATPRODUCTION INSTALLATIONS:

7.1. Obtaining work permit (Hot/Cold) from the Installation Manager prior to welding operation.

7.2. Carrying out “gas testing” in the area where welding operation is to be carried out.

7.3. Deploy a competent person to surpervise / oversee the welding operation.

7.4. Arrange fire fighting equipment as may be reqd. (Fire tender, extinguishers etc). with

competent operating personnel.

7.5. Clean the area of debris/inflammable material prior to commencement of welding operation

be always stress on proper housekeeping.

7.6. Ensure that the welder/helpers are wearing the necessary safety gears viz: helmet, goggles,

shoes, gloves, etc.

7.7. Ensure that the welding set is in good/safe operating condition.

7.8. Ensure that acetylene/oxygen cylinders are properly stacked on a trolley.

“Field observations and frank discussions with operating personnel

are the best ways to learn how to avoid unsafe acts and unsafe

practice. A few minutes of thought before starting the job may save

lives and million of rupees”


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8.0 ICE SHOP

1. Description

The procedure describes general requirements for personnel protection and safety in the

ICE-Shop.

2. Purpose

The purpose of this procedure is to provide industry-accepted requirements for protecting

personnel from known diesel and gas engine repairing shop hazards. This procedure is

intended for use by the personnel who are engaged in the shop to carry-out repairing, servicing

and overhauling of Gas and Diesel engines.

3. Referenced Documents

The following documents are considered part of this procedure by reference.

i) Oil Mines Regulations, 1984

ii) OISD guide lines/STDs/RPs

iii) Product Maker’s safety informations

iv) General First Aid Guidelines

v) Emergency Spillage Procedures

vi) Government Environmental Protection Regulations

vii) Emergency Contingency Plan

viii) Posted Emergency Phone Numbers

ix) Crisis Management Guidelines

x) Materials Safety Data Sheets (MSDS)

4. Equipment and Material Requiremtnts

Safety Equipment and facilities

i) Approved Fire Extinguishers with ABC rating

ii) Industrial First Aid Equipment such as first aid box, first aid kit. stretcher etc.

iii) Safety reliev valves for air/gas vessels.

iv) List of first aid trained personnel.

v) Readilly available all files like Form A, J, H etc.

vi) Readily available all files like list of MVT trained personnel, fire extinguishers re-

filling dates, other training list etc.

vii) Hazardous materials storage and disposal container.

viii) Readily available files of current MSDS.

Safety Clothing

To prevent injury, personnel should use. The following items appropriate to their job function or

task.

i) Cotton, rubber, leather, neoprene or vinyl gloves

ii) Cotton, leather, or neoprene apron


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iii) Rubber, leather or neoprene boots

iv) Coveralls

v) Steel-toed shoes (safety boots)

vi) Eye protection; such as goggles, face shields etc.

Personal safety equipment

To prevent injury, personnel should be use the following items appropriate to the workplace

conditions and the assigned task :

i) Safety glasses or goggles

ii) Face shield

iii) Earplugs

iv) Safety belts

v) Welding helmet

vi) Welding jacket/bib

vii) Hand gloves

5. Personnel Safety

Safety Training : Periodic training in all of the following areas should be conducted for all

personnel.

i) Mines Vocational Training (MVT)

ii) First Aid Training

iii) First Aid Fire Fighting Training

iv) Emergency procedure

v) Evacuation Plan

vi) Shop safety

vii) Spillage cleanup procedure

viii) Emergency phone numbers

ix) Equipment / power Tool operation

x) Product use

Shop Safety : To avoid injury to themselves and others, shop personnel should follow these

precautions :

i) Tie back or tuck in long hair

ii) Do not wear jewelry such as chain etc.

iii) Keep stains, walkways, etc. clean and clear

iv) Return tools and products to their proper storage location

v) Clean up spills immediately

vi) Make sure the work area has recommended illumination & ventilation.


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vii) Wear clothing and use personal safety equipment appropriate to work being performed.

viii) Do not use electrical equipment in wet areas.

ix) Get help before lifting heavy objects.

x) Use care when climbing to avoid falls.

xi) Maintain support under objects being raised.

xii) Follow product and equipment maker’s safety recommendation.

xiii) Clean waste generated like jute, scrap spares etc. and discharge in waste bin only.

xiv) Do not smoke inside the shop.

xv) Use safety belt as & when required.

Tool safety : To avoid injury when using hand & power tools, shop personal should follow these

safety precautions :

i) Use proper tools for the job.

ii) Do not use any tool you have not been trained to use.

iii) Do not use any tool that is not working properly.

iv) Do not keep sharp tools in your pockets.

v) Make sure safety guards are in place before using power tools.

vi) Do not exceed any tool maker’s speed, pressure, or power restrictions.

vii) Disconnect power tools before cleaning, cleaning, adjusting or oiling.

viii) Turn off equipment when it is not in use.

ix) Follow equipment maker’s safety recommendations.

x) Before servicing any electrical equipment, lock the power circuit in the OFF position

and tag the switch to show the equipment or circuit is being worked on.

Grinder Safety : To avoid injury when working with grinders, shop personal should follow these

safety precautions :

l Ensure that no combustible or flammable materials are nearby that could be ignited

by sparks from the grinder wheel.

l Ensure that a guard covers at least 270 degrees of the grinding wheel on bench-

mounted machines.

l Place the grinder tool rest 1/8 inch from the wheel and slightly above the centre line.

l Allow the grinder to reach full speed before stepping into the grinding position. Faulty

wheels usually break at the start of an operation.

l Unless otherwise designed, grind on the face of the wheel.

l Use vise-grip pliers or clamp to hold small pieces.

l Slowly move work pieces across the face of whell in a uniform manner. This will keep

the wheel sound.

l Do not grind non-ferrous mateials.


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l Periodically check grinder wheels for soundness. Suspend the wheel on a string and

tap it. If the wheel rigns, it is probably sound.

l Replace wheels that are badly worn or cracked.

l Never use a wheel that has been dropped or received a heavy blow, even if there is no

apparent damage.

l Before using a new wheel, let it a run a few seconds at full speed to make sure it is

balanced.

Welding and Cutting Safety : Welding and cutting are two forms of hot work that require special

safety considerations. Unless they are done in a designated shop area, welding and cutting are

strictly prohibited without proper authorization. Before conducting welding or cutting operations,

inspect your equipment for the following.

l Welding cables must be completely insulated and in good condition.

l Cutting tools must be leak-free and equipped with proper fittings, gauges, regulators,

and flashback devices.

l Oxygen and acetylene tanks must be secured in a safe place.

In addition, follow thses guidelines for most welding and cutting procedures :

l Conduct welding and cutting operations in a designated area free from flammable

materials. When welding or cutting is necessary in an undesignated or hazardous

area, have someone nearby act as a fire attendant.

l Periodically check welding and cutting areas for combustible atmospheres.

l Take care to prevent sparks from starting a fire.

l Remove unused gas cylinders from the welding and cutting area.

l Keep hoses out of doorways and away from others people. A flattened hose can

cause a flashback.

l Mark hot metal with a sign or other warning when welding or cutting operations are

complete.

Fuel Safety : To avoid injury when working around or with fuel, shop personnel should follow

these safety precautions :

i) Keep fuel, fuel tanks, and fuel containers away from any sparks or flame.

ii) Do not turn ignition switch ON or crank the engine with a fuel line disconnected.

iii) Have the proper fire extinguishers available.

iv) Always relive fuel pressure before performing any engine repairs.

v) Store fuel only in a approved container.

vi) Do not fill containers completely with liquid, fuel, leave about 25 mm (one inch) for

expansion.

vii) If filled containers must be transported, make sure they are secured to prevent tipping.

viii) Do not store a partially filled container for a long time.

ix) Never leave containers open after filling or pouring from the container.


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x) Before welding, grinding or cutting on a gas engine, turn off the gas supply and run the

engine until it stops and disconnect the battery.

Battery safety : To avoid injury when handing or servicing lead-acid storage batteries, shop

personnel should follow these safety precautions.

i) Wear appropriate eye and skin protection.

ii) Do not smoke, or allow open flames or sparks near a battery.

iii) Take care when adding water to batteries.

iv) Do not remove vent caps from maintenance free batteries.

v) Make sure that the charger is OFF before connecting or disconnecting it to a battery.

vi) Always use markings on the battery to determine the polarities of the terminals.

vii) Follow the equipment the equipment maker’s recommendations for using the charger.

To avoid injury when removing or installing a battery :

i) Follow the engine maker’s recommendations.

ii) Ensure that all electrical loads are OFF before disconnecting or reconnecting the

terminals.

iii) Disconnect and isolate the negative (ground) cable first, reconnect it last.

Hazardous Materials safety : Personnel should know how to protect themselves from corrosive

chemical vapors.

To avoid injury from corrosives :

i) Wear neoprene or rubber golves, boots & apron.

ii) Wear safety glasses with splash shields.

iii) Do not allow material to splash when pouring.

iv) Use peoper containers for storing and handling.

v) Keep containers closed at all the times.

vi) Clean up spills immediately.

To avoid injury from chemical vapors :

i) W ear a vapor respirator.

ii) Properly vent the vapors.

iii) Always follow the safety recommendations on the product MSDS.

Engine Safety : To avoid injury when working on an engine, shop personnel should follow these

safety precautions.

Inspection and testing of engines

Periodic safety inspections should be performed to ensure that the following items currently meer

all statutory health and safety requirements.

Safety inspection

i) Medical supplies


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6. Shop Orientation checklist : The following points shoul.d be discussed/explained/

shown to any new entrant in the shop for working/training purpose

i) Emergency procedure

ii) Shop orientation and Training Procedure

iii) Major shop Hazards

iv) Proper Dress

v) Personal protective Equipment

vi) Organization

vii) Cleanliness

viii) Access

ix) Facilities

x) Parking

xi) Shop Equipment

xii) W aste disposal

xiii) Flammables

xiv) Hot work permit/Cold work permit

xv) Engines on repairing

xvi) Pain/Fumes/Dust

xvii) Electrical

xviii) Disciplinary Action

7. Maintenance Procedure : The recommended maintenance procedure includes : - a.

Inspection, b. Routine attention, c. Running repairs of General overhaul.

NOTE : For maintenance of engines, the given below points to be followed in addition to OEM’s

and OISD recommended inspection procedure.

Inspection inspect the following :-

i) check loss of compression

ii) check valve clearance

iii) check bad valve settings

iv) check valve springs

v) check sticky valve steam

ii) Safety equipment

iii) Equipment safety features

iv) Hazard communication program (including MSDS collection, product leveling, written

plan, employees training)

v) Expiration dates


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vi) check bearing knock

vii) check faulty fuel injection/timing

viii) check lube oil pressure

ix) check lube oil temperature

x) check water temperature

Routine attention

Check the followings :-

i) oil sump level

ii) water pump

iii) bearing lubrication

iv) all ball or pin joints lubrications

v) oil filters

vi) valve system

vii) fuel injection system

viii) fuel timing

ix) fuel pipe lines

x) fuel filter

xi) belt tension


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OIL INDIA LIMITED


Volume - II

Section - 5

TRANSPORT ENGG.

ACTIVITIES


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TRANSPORT ENGG. ACTIVITIES

CONTENTS


SEC-1 M O TOR VEHICLE OPERATION ..................................................................... 1

SEC-2 CRANE OPERATION....................................................................................... 4

SEC-3 M ATERIAL HANDLING OPERATION .............................................................. 8


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SECTION -1

MOTOR VEHICLE OPERATION

GENERAL

In oil field operations, large number of vehicles is deployed for carrying passengers and

cargo. Safe operation of these vehicles is vital for efficient conduct of work and minimization

loss due to incidents / injuries. Driving of vehicles, particularly heavy vehicles like trucks and

trailers, calls for exceptional skill and alertness on the part of drivers.

Motor vehicle operations are particularly hazardous in adverse weather condition, bad roads,

cross-country drives and also during night. In such situations if the driver is not really

competent and well prepared for any emergency, it may lead to accidents.

Apart from following Traffic Rules and laws of the land, the recommendations listed below

provide guidance in this respect.

It is also necessary that drivers attend refresher training courses on safe driving practices

at regular interval

1.0 DRIVER

Selection, medical fitness and training of drivers should receive due attention and the following

steps should be taken:

1.0.1 Every driver should undergo a driving test to ensure that he is capable of handling the

type of vehicle assigned to him.

1.0.2 Every driver should undergo thorough medical examination once in every two year

with special reference to vision, night and colour blindness.

1.1 SAFE PRACTICE FOR DRIVER

1.1.1 Consumption of alcoholic beverages while driving motor vehicle is illegal and expressly

prohibited. No driver should be under the influence of alcohol when he is required to

operate a motor vehicle.

1.1.2 It is unsafe for a driver to drive a vehicle when he is heavily fatigued and physically ill.

1.1.3 Safe driving implies that the driver should be prepared to compensate for unsafe acts

of other drivers on the road.

1.1.4 Drivers should be fully familiar with the traffic laws of the area and in case of doubt; he

should seek guidance from his superior official.

1.1.5 The speed limit admissible under the law should be adhered to, subject to conditions

of road, weather and traffic.

1.1.6 It is dangerous to follows the vehicle ahead of the driver too closely. The driver should

always judge/ maintain the distance as per the safe breaking distance limit of his

vehicle. It is essential to maintain this distance so that the driver can safely stop his

vehicle if the vehicle ahead stops suddenly.


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1.1.7 Overtaking of vehicles can be extremely dangerous unless the situation is carefully

judged. The driver should overtake only when he is assured of safe and clear passage

in the direction.

1.2 MAINTENANCE OF VEHICLES

While every vehicle should undergo thorough maintenance as per approved schedule, it is

the driver to check the condition of his vehicle before taking it out on the road. The daily

check should include the following items:

1.2.1 Steering wheel - no excessive play should be allowed.

1.2.2 Brakes - brake should be fully efficient.

1.2.3 Tyres - adequate air pressure and good tread surfaces, worn out tyres affect braking

efficiency.

1.2.4 Battery condition - good terminal contacts, top-up with distilled water.

1.2.5 Fuel, Oil and water should be adequate.

1.2.6 Horn - test for correct operation

1.2.7 Lights - cheek high and low beams.

1.2.8 Wipers - check smooth operation.

1.2.9 To cheek / tightening of all wheel bolts and nuts

In case of any defect, the matter should be immediately attended to or reported to the

competent person for remedial action.

1.3 DRIVING ON WET ROADS

While driving on wet roads, the main hazard is skidding of the vehicle. The following

precautions are recommended:

1.3.1 Slow down when going round the bend.

1.3.2 Keep speed at safe level.

1.3.3 Avoid sudden braking.

1.3.4 Check brakes properly and push the brake paddles after the vehicle is driven through

water logged area two or more times (if required) to dry the brake lining/disc before

increasing the speed of the vehicle.

1.3.5 In case of skidding, proper safeguard is to drive/steer the vehicle towards the direction

of the movement of the skidding vehicle.

1.4 DRIVING AT NIGHT

1.4.1 It should be ensured that all the lights are in good working order.

1.4.2 Keep the windscreen clean.

1.4.3 Avoid glare of headlights to approaching vehicle and keep to your left. Use Dipper at

night.


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1.5 DRIVING IN DESERT

1.5.1 Drive along known or familiar tracks, as any deviation could be treacherous.

1.5.2 If you get lost, stop and look around without going any further, if possible back-track

until you know, where you are.

1.5.3 If the vehicle is stuck, dig sand slowly in the direction of travel from both front and rear

wheels to allow room for rocking the vehicle, some air can be let out of the tyres to

provide friction.

1.5.4 In no case leave your vehicle, since it is easier to spot a vehicle than an individual

either from the ground or from the air. Headlights and mirrors of vehicles can be used

for signaling.

1.6. REVERSING OF VEHICLE

While reversing a vehicle, the driver should ensure that he has clear view of the track on

which the vehicle is being reversed. In case of heavy vehicles, the drivers should be assisted

by a signalman while reversing. Audiovisual alarm should be available in working condition

particularly in the heavy vehicles.

1.7 TRANSPORTATION OF OVERSIZE LOADS

1.7.1 The load should be uniformly placed on the trailer/truck and secured to its body with

chain, clamps and side support.

1.7.2 Sufficient number of chain should be used for tubular goods for lashing.

1.7.3 Loads extending over the rear of the truck/trailer should be flagged during day with a

piece of red flag, a red light should be displayed at night.

1.7.4 When a cargo after being loaded on the vehicle stands more than 4 (four) meters

above ground level, the vehicle should be accompanied by a pilot vehicle carrying a

Supervisor. The Supervisor should ensure that there is adequate clearance ahead for

the loaded vehicle to pass safely, particular attention should be paid for adequate

clearance under electric transmission lines.

1.7.5 Overhead clearance :

• The minimum permissible overhead clearance for LT power line is 18 feet from

ground.

• The minimum permissible overhead clearance for HT power line is 22 feet from

ground.

• Safe height of the Cargo on truck or trailer should not be more than the height of

the Cabin in all normal cases.

Only in exceptional like PCR, Power Pack etc. Maximum permissible height is 4

meter (12 feet) from ground.

1.8 TRANSPORTATION OF DANGEROUS HAZARDOUS GOODS

When transporting dangerous goods by road like gas cylinders, carboys of acid, chemicals

and toxic substances, the following precautions should be taken:


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1.8.1 All dangerous goods to be transported should be securely packed to prevent spillage

or damage.

1.8.2 The goods should be clearly labeled to indicate contents like - INFLAMMABLE GAS,

OXIDIZING AGENT and ACID etc.

1.8.3 Oxidizing substances should not be loaded along with other dangerous goods.

In this regard, the stipulated guidelines and rules of statutory/advisory bodies for

transportation of dangerous/hazardous goods are to be followed. It is also important

to refer “Material Safety Data Sheet” to have knowledge on the type of dangerous

goods being transported, its safely Precautions and emergency Preparedness.

1.8.4 TREM card to be filled up & kept in the vehicle for hazardous goods.

1.8.5 Parking Guidelines :

i) Vehicle should not be parked in crowded area.

ii) While parking, vehicle should be parked on leveled ground with reverse gear in

engaged position and Parking Brake On.

iii) Vehicle should not be parked on down hil or on slope.

iv) Wedge should be put against the wheels.

v) In case of parking on road side in night, parking light to be kept on.

vi) Statutory Warning Signals in bright coloured painting to be written on back and

both sides of the tank/cabin with appropriate symbols for easy attraction of passers

by.


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SECTION - 2

CRANE OPERATION

2.0 GENERAL

The safe practices given here relate to cranes used for out door lifting and handling heavy

equipment and tubular goods.

2.1 CRANE OPERATOR

Operators of cranes should be experienced and should meet the following requirements:

2.1.1 Be able to read and understand operating instructions.

2.1.2 Be able to understand the load chart.

2.1.3 Be able to understand about the functioning of the safety devices.

2.1.4 Be able to understand hand signal code used.

2.1.5 Have eyesight and hearing that are normal and have no known physical deficiency

such as epilepsy or heart condition that would be detrimental to safe operation of

cranes.

2.1.6 Have proper muscular co-ordination, depth perception and reaction time.

2.2 INITIAL INSPECTION AND TESTING

All new or substantially repaired or altered cranes should be inspected by competent person(s)

and tested to ensure that they comply with manufacturers load rating and are operationally

satisfactory. The crane should be put to use only when the test results are satisfactory.

The results of every such inspection and test should be recorded by the person(s) making

the test.

2.3 SAFE WORKING LOAD

Load on the crane at any operating configuration (operating radius, height of lift, etc.) should

be not more than 90% of the test load, but in no case it should exceeded the rated capacity

load.

The safe working load of the crane should be legibly marked on it. A weight indicator should

be available which can be used to determine weight of unknown load to be lifted. Load

Moment Indicator with audio visual display of the operational parameters should be available

in working condition.

2.4 SAFETY FEATURES

2.4.1 Every crane should be provided with a ready means of escape from its operating cab.

2.4.2 The crane should be equipped with audible warning system.

2.4.3 A dry chemical power type fire extinguisher should be provided within easy reach of

the operator.

2.4.4 First Aid box with medicines / accessories should be available in the operators cabin.


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2.4.5 Lights should be provided on the crane boom/support structure.

2.4.6 Safety limit switches must be available in working condition in all the cranes and all

controls shall be operative.

2.4.7 Couplings and gears shall be provided with adequate guards.

2.4.8 Spark arrester is to be fitted in the exhaust silencer wherever applicable.

2.4.9 Slings, which are to be used for lifting should be checked and inspected for any

damage, torn or twist.

2.4.10 Wooden logs/planks used for jacking up should be pre-selected to withstand load.

2.5 DAILY INSPECTION

The following items of crane should be visually inspected daily or before its use if not used

everyday, to ensure that the crane is in safe working order.

2.5.1 All controlled mechanism for mal-adjustment interfering with proper operation.

2.5.2 All safety devices inspected for mal-function.

2.5.3 Leakage in air or hydraulic system.

2.5.4 Crane hooks for deformation or cracks.

2.5.5 Electrical apparatus for mal-function.

2.5.6 Crane booms and running ropes to make sure they have not been accidentally

damaged.

2.5.7 W ire ropes and rope slings for excessive wear, broken wires and kinks.

In case any defect or damage is noticed, it should be immediately brought to the notice of

the superior officer and appropriate remedial action be taken.

2.6 PLANNING TO EXECUTE CRANE OPERATION

Most accidents can be avoided by careful job planning. Person lncharge, must have a clear

understanding of the work to be done, consider all danger at the job site, develop a plan to

do the job safely and then explain the plan to all concerned.

The following points are to be taken care of while planning to execute crane operation.

2.6.1 What is the weight of the load to be lifted, the lift radius, boom angle and the rated

capacity of the crane?

2.6.2 How will the signalman communicate with the operator?

2.6.3 Are there gas lines, power lines or structures, which must be moved or avoided?

2.6.4 Is the surface strong enough to support the machine and load?

2.6.5 How can the crane be positioned to use the shortest boom and radius possible?

2.7 OPERATION PRECAUTIONS

2.7.1 Operator must be alert, physically fit, free from influence of alcohol or medications

that affect his eyesight, hearing or reactions. Always avoid over loading of cranes.

Over loading would result by:


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a) Lifting of load more than rated capacity at the particular radius.

b) Derricking down and increasing load radius.

2.7.2 Crane should be placed on jacks/ outriggers with proper wooden planks.

2.7.3 While doing pick and carry operation keep the load as low to the ground as possible.

2.7.4 Ensure that enough room is available for rotation of the cranes.

2.7.5 Ensure that load being lifted is not stuck frozen or attached to something else, which

may cause accident.

2.8 OPERATION

2.8.1 The code of hand signals adopted for use should be understood and observed by the

crane operator and his signalman.

2.8.2 The crane should be properly jacked on a firm foundation and secured before lifting

heavy load.

2.8.3 The crane operator should sound the audible warning before lifting any load.

2.8.4 Suitable hooks or rope slings attached to the load should only be used for lifting loads.

2.8.5 Crane should not be used for dragging load on ground.

2.8.6 The operator should ensure that during lifting of load, persons remain at a safe distance.

2.8.7 The crane operator must not allow any person to ride on suspended load or remain

under a suspended load.

2.8.8 There should be at least two wraps of cable on the drum at all times, while operating

the crane to obviate the line load being applied to the fastening clamp.

2.8.9 • Safe distance to be maintained while working near Power Lines –

- up to 125 KV = 10 feet

- up to 125 to 250 KV = 15 feet

- over 250 = 20 feet

2.8.10 When not in use, the hook of the crane should be firmly secured to the boom.

2.9 MONTHLY INSPECTION

A complete inspection of each crane, its foundation and drive track should be made every

month and the results recorded in a register. The manufacturer’s recommendation should

be kept in view. The following items should be carefully looked for:

2.9.1 Deformation cracked or corroded members in the crane structure, foundation and

boom.

2.9.2 Loose bolts or rivets.

2.9.3 Cracked or worn sheaves and drums.

2.9.4 Worn, cracked or distorted parts such as pins, bearings, shafts etc.


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2.9.5 Excessive wear on brake and clutch system.

2.9.6 Load hooks for deformation and cracks.

2.9.7 Excessive wear of chain drive sprockets and excessive chain stretch.

2.9.8 All ropes for compliance with manufacturers’ specifications, reduction in diameter

due to corrosion or wear.

2.10 CAPACITY OF THE CRANE

Capacity of the crane is to be displayed in bold letters on the boom and super structure on

both sides and front and rear of the crane.

2.11 TRAINING

2.11.1 Training should be imparted about the crane operation and maintenance for crane

operators and technicians and supervisors at field site every year for safety

awareness.

2.11.2 The lifting capacity of the cranes should be periodicity to be mentioned.

• Inspect mobile crances every 400 to 600 hrs or every three months, whichever

comes first.

• Inspection to be carried out be experienced staff and record to be kept in the form

of a standard checklist duly approved by Competent Person.

2.11.3 Periodical human physical ability test may be conducted for the driver and the crane

operator through reputed institute e.g. National Labour Institute or any other institute.

2.11.4 • Place the crane on hard, level ground.

• Extend all outriggers fully.

• Jack up the crane and balance the same on four outrigger jack.

• Turn the crane to Over Rear.

• Raise the boom to an angle that conforms to the Load Chart or LMI reading.

• Take measurement of the book length from LMI and also the maximum permissible

gross load.

• Attach a load as per above reading and hang it freely from the hook.

• Take initial reading of ground clearance of the load.

• Hang the load for 30 minutes.

• Take final reading of the ground clearance of the load.

• If both readings are identical, crane is holding the load perfectly.

• If final reading is less than the initial reading, there might be internal leakage of the

lifting cylinder of the crane. Check for leakage in the boses or mal-function of the

check valves, oil seal etc.


Transport Engg.

2.11.5 Physical checking of lifting tackles –

• Wire Rope –

• Check for loose or broken wire strand

• Check for Any elongation or rupture

• Check for ‘Bird Caging’ symptom

• Check for ‘Kink’

• Check for Rust and stiffness

• Chain sling –

• Check for Corrosion of the chain links

• Check for Crack on chain links

• Check for Excessive opening of the hook mouth

• Check for crack on the hook

• D-shackle

• Check for corrosion

• Check for reduction of diameter of the pin

• Check for any crack on the shackle – bow or pin

Procedure for load testing of crances.

Physical checking of lifting tackles.


Transport Engg.

SECTION -3

MATERIAL HANDLING OPERATION

3.0 GENERAL

Material handling is one of the important activities in any industry. Progress of various activities

largely depends on timely input of materials required for various operations. This is best

achieved by safe material handling practices.

3.1 HAZARDS

Different materials involve different hazards in handling. Some of the major and important

hazards are mentioned herein for safety awareness:

l Lifting and handling of heavy loads may cause accidents, pain or back injuries. Incorrect

kinetic techniques cause injury to the spinal column.

l Use of unsafe wire rope type or slinging belt type.

l Improper use of flexible steel wire ropes leading to kinks damage.

l Careless and incorrect use of lifting equipment (cranes, forklift trucks, over head crane

etc.) including over loading.

l Distraction of drivers/workers due to improper visibility, steam/vapours, slippery areas.

l Improper preservation of materials.

l Careless handling of chemicals like acids etc.

l Improper stacking and movement of tubulars and heavy structures.

l Unsuitable overhead clearance in lifting or movement.

3.2 SAFEGUARDS

Some of the measures in this regard are given below for guidance:

3.3 MANUAL HANDLING

Manual handling of goods and materials is one of the greatest single causes of accident at

work. Safe lifting depends on the skillful use of the correct muscles and not on brute force.

The correct method in manual lifting involves the following basic points:

a) In all acts of lifting, the back must be kept straight. If bending is required, do so from

hips and knees, keeping the back straight.

b) Keeping the load as close to the body as possible, when lifting or carrying.

c) Ideally the feet should be about the same width apart as the hips with one foot forward

in the direction of travel. Strains occur if feet are too close together or too far apart.

Never jerk load.

d) Arms and elbows should be as close to the body as possible while lifting or carrying.

e) The load should be in a firm grip (palm grip) with the edges or corners well into the

root of the fingers.


Transport Engg.

f) If a load is to be shifted from an awkward position to a more favourable position for

lifting, use your own body weight to initiate movement in the desired direction.

g) When a load is too heavy or bulky for one man to lift, then help of one or more persons

should always be taken. In such multiple men-lifts, synchronies movements of all to

lift load smoothly.

h) Normal working clothes suitable for such work should be used.

i) Before lifting or moving any load, size-up job to determine the best method of lifting.

j) There is in general no upper limit for lifting by a person; normally 25 kg may be the

optimum beyond which help of other persons should be taken.

3.4 SAFE SLINGING

Safe slinging practice involves the following :

a) Do not exceed safe working load.

b) Select multi-leg slings and hook the slings wherever necessary.

c) Use correct pins in shackles.

d) Ensure that load is stable.

e) Ensure there are no sharp bends/kinks in wires .

f) Plumb crane over the load .

g) Use proper signals and never pass a load over another person’s head.

h) Do not ride on the load being lifted.

i) Unload the load on safe foundation/ground.

3.5 WIRE ROPES

General precautions / safeguards in wire rope use are given below:

a) In case of flexible steel wire rope watch for stretching, breaks, flats or bird caging

which are regarded as failure signs of such ropes.

b) A wire rope should not be used if more than 5% of visible wires are broken.

c) Do not jerk load the wire rope

d) A damaged or overstrained rope may break and cause accidents

3.6 HOOK, SHACKLES, EYEBOLTS AND CHAINS

a) Use crane hooks with sling within an angle of 90 degree.

b) Use a ‘D’ shackle to connect slings, thimbles etc.

c) Check that the angle of the slings is correct before lifting .

d) Fit a shackle between lifting hook and eye bolts to reduce strain on the hook .

e) Always tighten eyebolts to the correct position.


Transport Engg.

3.7 LIFTING EQUIPMENT (CRANES/FORK LIFTS etc.)

a) Consult and observe manufacturer’s safe opening procedures for equipment in use

Trucks.

b) Cheek lifting equipment before use every day.

c) Take stock of unladen weight, capacity, load, center distance and maximum lift height,

before operating lifting equipment.

d) Never add to counter weight.

e) Never run over cables as flexible pipes etc.

f) Do not allow persons to walk under loads.

g) Travel slowly and carefully down slopes.

h) Do not leave it on gradients unattended.

i) Never use it as a working platform.

j) Maintain the backward till of the mast of Fork Lifts.

k) Keep the forks low (4 to 6 inches from the ground) and backward tilt, to aid stability of

Fork Lifts when laden.

l) Look in the direction of travel - for obstructions etc.

m) Avoid sudden starts, stop and turns.

n) Cheek for weak floors, soft ground, potholes and skid patches like oil, loose sand,

gravel etc.

o) Use extra care on high stacks and watch for unstable loads.

p) Park cranes/ Fork Lifts with hand brakes on, control forks flat on ground, ignition/

power switched off and key removed.

q) While parking it should not obstruct access to roads, working areas etc.

Prevention is not only better than cure

but is also cheaper.


Civil Engg.

OIL INDIA LIMITED


Volume - II

Section - 6

CIVIL ENGG.

ACTIVITIES


Civil Engg.

PREAMBLE

Many construction activities of the civil engineering works pose safety hazards to the workmen

and technicians which can be minimised by following safe operating procedures. SAFETY

FIRST should thus be the foremost aim of the construction operations. Many accidents can

be eliminated by adopting safe construction techniques, without sacrificing quality or progress.

Bureau of Indian Standards has published a number of safety codes for various types of

work which must be followed. A list of safety codes relevant to the type of work usually

required to be handled by the Civil Engineering Department of OIL is given in Appendix A.

1.0: Basic Safety Precautions

(a) Proper training on Safety hazards and job knowledge shall be imparted to the company

employee as well as the contractor personnel to conduct his work in a safe manner.

(b) No employee shall be given a new assignment of work unfamiliar to him without proper

introduction as to the hazards both to himself and his fellow employees.

(c) Under no circumstances should an employee hurry or take unnecessary chances

when working under hazardous conditions.

(d) Employees shall not leave naked fires unattended. Smoking should not be permitted

in hazardous areas and adequate fire fighting equipment should be provided at strategic

locations.

(e) Employees under the influence of any intoxicating beverage, even to the slightest

degree, must not be permitted to remain at work.

(f) There must be a suitable arrangement at every worksite for rendering prompt first aid

to the injured under the guidance of a Medical Officer.

(g) The staircases and passage ways shall be adequately lighted and kept clean.

(h) Employees working around moving machinery shall not be permitted to wear loose

garments. Safety shoes are recommended when working in shops or places where

materials or tools are likely to fall. Only experienced workers will be permitted to go

behind guard rails or to clean around any energized or moving equipment.

(i) The employees shall use proper PPEs as per the requirement of job.

j) No employee below the age of 14 years shall be employed for carry out any job.

2.0: Fire Hazards, Fire Extinguishers and Fire Escapes

2.1 General

Safety from fire and similar emergencies for buildings are dealt with in Part IV of National

Building Code of India 1983. It specifies the demarcation of fire zone, restrictions on

construction of building in each fire zone, classification of buildings based on occupancy,

types of building construction according to fire resistance of structural components and

other restrictions and requirements necessary to minimise danger to life from fire and other

eventualities. The planning of a new colony or construction of a new building etc. should be

done as per the requirement of various codes, standard, rules, acts, regulations and other

sound engineering practices. A specialist organisation/consultancy firm should be referred

where ever required as felt by Head-Civil Engg. The type of exits, arrangement of exits and

capacity of exits should conform to the codes.


Civil Engg.

4.0 Safety Measures for Storage of Inflammable Materials

In addition to the requirements as laid down in earlier paragraphs, the following provisions

also apply:

(a) Outdoor storage of drums requires extra care to avoid entry of moisture and dirt in

hydraulic brakes, transmission fluid, gasoline, or lubricants. The storage area should

be free of accumulated spilled products, debris and other hazards.

(b) Compressed gases and petroleum products are not stored in the same building or

close to each other.

(c) In cases when the spoil is not utilised and has to be disposed of as waste, then

disposal by burning should not be done. The spoil should be dozed or transported and

dumped into low lying areas and covered with earth.

5.0 Electrical fire & Shock Hazards

5.1 Measures to deal with Electrical Fires/Electric Shock

Refer “SOP on Electrical Engg activities” in addition to the following precautions to

deal with electrical fire/Shock hazard.

(a) Safety measures for electrical work are contained in IS: 5216 “Guide for Safety

procedures and practices in electrical work” and should be followed.

(b) Electrical fires emanating from electrical installations must be dealt with by fire

extinguishers which have a special quenching medium. Carbon dioxide extinguishers

are commonly used for extinguishing electric fires. These are particularly suited for

fighting electrical fires even when the current has not been switched off. Use of water

and foam should be avoided in fighting electric fires except after the current has been

cut off. If oil is involved, water must not be used even after current has been switched

off.

(c) As per sub-rule (1) of Indian Electricity Rule 43, fire buckets filled with clean dry sand

and suitable fire extinguishers for extinguishing electric fires should be marked

conspicuously and kept in convenient spots in generating stations, sub-stations and

enclosed switch rooms.

(d) In case of fire in factory blocks, offices, canteens, stores, or residential premises,

station staff should immediately contact the concerned electrical staff and cut off the

supply to the place near the fire. This will avoid any accident due to the fire-fighting

staff inadvertently directing the water hose on live lines and equipment.

(e) To break the victim’s contact with live electrical parts, dry clothing, dry rope, dry board

or any other dry non-conductor should be used.

(f) While rescuing a victim from contact with live electrical equipment, the following must

be kept in mind:

(i) If the victim is aloft, measures must be taken to prevent him from falling, failing

which his fall must be made safe.


Civil Engg.

6.4 Fire Control measures

The outbreak of any gas fire should not be extinguished until the gas supply is cut off at the

source. If the fire is extinguished immediately, there can be a grave danger of an explosion

from the re-ignition of the gas cloud. Gas fire has to be controlled by water jet spray and by

means of dry powder. Fire Services should be contacted immediately.

7.0 Safety of Timber and Timber Spoils

Where storage of timber is considerable and handling of timber is a regular feature, ‘log

ponds’ may be constructed. ’Log ponds’ are ponds filled with water with necessary chemicals

added to prevent organic growth in water. The size of the pond and related particulars must

be designed in accordance with standard practices of forestry. Timber spoils are hazardous

to store; and if, for any reason, they have to be stored in large quantities, a pond for the

same may be considered. If such a measure is not adopted, any part of the spoil should not

be closer than 5 m from any naked live electric wire. No kerosene lamp or stove should be

used closer, than 5 m from the nearest part of the spoil. The spoils should generally be

stored inside a building and not in the open. Smoking must not be allowed inside the premises

where the, spoil is stacked/stored. Where possible, sprinklers may be arranged to keep the

spoil wet.

8.0 Safe Storage, Stacking and Handling of Construction Materials

8.1 General

Materials should be stored, stacked and handled in such a manner as to prevent deterioration

and ensure preservation of their quality and suitability for the work. Materials should be

stacked on well drained, firm and unyielding surface in a manner so as not to constitute a

hazard to passersby. Stairways, passage ways and gang ways should not be obstructed by

storage of building materials, tools or accumulated rubbish.

8.2 Protection of Stores against Fire

Timber, coal, paint and similar materials can lead to fire hazards. Where possible, these

materials should be segregated from each other so as to minimise spread of fire. Inflammable

liquids such as petrol, thinner, etc. should be stored in conformity with safety regulations.

Explosives like detonators, gun powder etc. should be stored in special explosive stores

and safety instructions followed.

8.3 Plastic and Rubber Sheets

Plastic and rubber sheets should be stored in accordance with the manufacturer’s

instructions. The coolest store room available should be utilized for the storage of the sheets.

The storage rooms should be well ventilated and kept as dark as possible. Direct light

should not be allowed to fall on them. The sheets should be stored away from electric

generators, electric meters, switchgears and other such electrical equipment as they produce

harmful gases which can damage the sheets.

8.4 Paints, Varnishes and Thinners

(a) Paints, varnishes, lacquers, thinners and other inflammable materials should be kept

in properly sealed or in closed containers. The containers should be kept in a well-

ventilated location, free from excessive heat, smoke, sparks or flame. The floor of the

paint stores should be made up of 10 cm. thick loose sand.


Civil Engg.

(g) All torches, regulators, cylinders and other such equipments should be of an approved

design, regularly inspected and kept in good condition. Defective apparatus and

equipment should be removed from service, replaced or repaired and reinspected

before being placed again in service. Repairs should be made only by persons

thoroughly familiar with such apparatus.

(h) Welders and helpers should wear suitable eye protective devices during welding and

cutting operations. Eyes exposed to welding or flashes should be washed with rose

water / Eye wash facility.

9.2 Fire Protection in Cutting and Welding

To avoid fire hazards the following additional precautions should be observed on all oxy-

acetylene cutting and welding:

(a) Keep hose and cylinder valves free from grease, oil, dust and dirt.

(b) Keep cylinders away from stoves, furnaces and other sources of heat.

(c) Only ‘Gas Lighter’ should be used to light the torch.

(d) Avoid use of oxyacetylene flame in confined spaces.

(e) Clean thoroughly with steam all containers that have been used for storage of

inflammable liquids, or wash with hot water and soda and ventilate thoroughly before

welding and cutting.

(f) When testing for leaks, use only soap water and watch for bubbles.

(g) Valve protection caps should be in place when cylinders are not in use.

(h) All employees must be made familiar with the location and with proper use of fire

extinguishers in their area of work.

9.3 Gas Welding and Cutting

a) Gas cylinders should not be used unless fitted with the following: high pressure gauge

on cylinder, reducing valve with pressure regulator and safety relief device, low

pressure gauge for indicating pressure on the torch. The fuel gas and oxygen cylinder

should have left hand and right hand threads respectively so that they cannot be

interchanged with distinct colours painted.

(b) Cylinder valves should be opened only with hand wheels or tools specially designed

for that purpose and left in place while cylinders are in use. Cylinder valves should be

closed when not in use.

(c) Since an explosion can occur oxygen/acetylene gas cylinders and fittings should be

kept away from oily or greasy substance and should not be handled with oily hands or

gloves. A jet of oxygen should not be directed at oil surfaces, greasy clothes, or within

a fuel oil or other storage tank or vessel.


Civil Engg.

10.3 ladders

(a) Every ladder and step-ladder should be of good construction, sound material and

adequate strength. These should be inspected at least once a fortnight and the

observations recorded:

(i) No ladder with a defective or missing rung or with any rung which depends for its

support solely on nails, spikes or other similar fixing should be used.

(ii) Wooden ladders should not be painted as paint covers up defects but instead linseed

oil or clear varnish should be used.

(b) The use of ladders for means other than that of access should be eliminated as far as

possible.

(c) For working platforms 1.5 m or more above the ground, a ladder or stairway should be

provided with safe access to and from the platform.

(d) Every ladder used for a vertical height of more than 9 m should be provided with an

intermediate landing and vertical distance between two successive landing places

should not exceed 9 m. All intermediate landings should be provided with suitable

guard rails to a height of at least 1 m above the landing place.

(e) Where a ladder is used as a means of communication or as a working place the

ladder should rise sufficiently above the place of landing of the highest rung to be

reached by the feet of any person working on the ladder. Adequate hand-hold should

be provided.

(f) When using a ladder or a step ladder, the user should always face the ladder. The

transportation of materials by ladders should be reduced to the minimum. Tools and

materials should, wherever practicable, be pulled up with a rope.

(g) Ladders should not be placed in front of doors opening or against window sashes.

Stepladders should be opened out fully before use, Two ladders should be spliced

together to provide access to a height greater than what can be reached with a single

ladder.

(h) When permanent or portable ladders are used, the upper ends should extend 110

cms above the platform. Portable ladders should be securely fastened at the bottom

and top.

(i) All ladders should be periodically inspected. The stability of ladders should be tested

before using these.

(j) A ladder should not be placed upon a box, barrel or other movable insecured objects.

(k) Portable ladders should be in a safe position before being climbed. The slipping of a

ladder at either end should be carefully guarded against, especially where the supporting

surfaces are smooth or vibrating. If necessary, a person should be stationed at the

base of the ladder to prevent slipping .

10.4 Safety Belts

For work in elevated positions, workmen should use suitable safety belts / life belts connected

to the support lines to guard against falling.


Civil Engg.

12.0 Other Precautions

12.1 During fracturing operation, the supervisor-in-charge should see that within 30 m of the well:

(a) No person other than those required for fracturing operation remains.

(b) No naked light or other source of ignitions permitted.

(c) All electrical equipment is de-energized.

(d) Adequate fire-fighting equipment is available for immediate use.

12.2 During fracturing, pumping units should be located cross wind at least 15 m from the well

head.

12.3 Except for fuel in the tanks of the operating equipment, no inflammable material should be

stored within 30 m of any well.

12.4 As per Oil Mines Regulation - 66, where gas test readings show the concentration of

inflammable gas to exceed 20% of its lowest explosive limit, the supply of electric energy

should be cut off immediately from all cables and apparatus lying within. 30 m of installation

and all sources of ignition should also be removed from the said area.

13.0 Safety Appliances and Protective Clothing/PPES

The following safely appliances and clothing will be provided to the workmen as required

and their use to be enforced (Refer HSE Management).

- Safety Boots (Industrial Safety Shoes)

- Helmets

- Gloves

- Goggles

- Gas Masks

- Canvas Shoes (Ribbed rubber sole)

- Gum Boots

14.0 Lead Compound and other Poisonous Materials

14.1 The following precautions should be taken in the use of lead compound and other poisonous

materials :

(a) No paint containing lead or lead products should be used except in the form of paste

or ready made paint.

(b) Suitable face masks should be supplied for use by the workers when paint is applied

in the form of spray or a surface having lead paint is dry rubbed and scraped.


Civil Engg.

18.0 Safety Against Snakes, Leeches and Mosquitoes

(a) Generally, snakes, leeches, mosquitoes and such other creatures and pests thrive

well in damp, dark and marshy areas. The areas under habitation (colony etc.). work

sites, yards and stores should therefore be well-lighted and well drained. If there is a

marshy, damp or water logged area, due attention should be given to sub-surface

drainage. If the wet lands are sizeable, a wet land management system should be

prepared. Consideration may be given to heavy planting of species of trees which are

fast growing to help in reducing soil moisture.

(b) Where leeches are prevalent, proper footwear and guards should be prescribed.

(c) The surveillance drill required for mitigating mosquito nuisance, as adopted by the

Malaria Eradication Department should be followed. The Contractor’s labour coming

from other areas, should be subjected to blood slide tests for malaria parasite or any

other suitable measures to be taken by the contractor.

19.0 Basic Principles of Road Safety

The design standards given below are absolute minimum for road safety. However, general

effort should be made to exceed these minimum values unless restricted by technical or

economical considerations.

Road Signs

Standard warning road signs as approved by Indian Road Congress should be provided at

all curves, hair pin bends, narrow bridges/culverts and pedestrian crossings. Speed limit

signs should be provided where the road conditions so demand. Standard road signs are

shown in Appendix B.

20.0 Work Permit for Hazardous Area and Installation

Before start of a work in an installation or in hazardous area, SOP on HSE management

activities should be followed.

21.0 Safe Operating Procedures for Excavation (OISD Guideline 192 may be referred)

All excavation work should be planned and the method of excavation and the type of support

work required should be decided considering the following:

i) The stability of the ground;

ii) The excavation will not affect adjoining buildings, structures or roadways;

iii) To prevent hazard, the gas, water, electrical and other public utilities should be shut

off or disconnected, if necessary;

iv) Presence of underground pipes, cable conductors, etc.,

v) The position of culvert/bridges, temporary roads and spoil heaps should be determined;

21.1 Before digging begins on site, all excavation work should be planned and the method of

excavation and the type of support work required decided.

21.2 All excavation work should be supervised.


Civil Engg.

Appendix - A

REFERENCES :

BUREAU OF INDIAN STANDARDS

1. IS 3764 - 1966 Excavation Work

2. IS 4756 - 1978 Tunneling Work (1st revision)

3. IS 7293 - 1974 Working with Construction Machinery

4. IS 7969 - 1975 Handling and Storage of Building

5. IS 3696 - 1966 Materials. Scaffolds and Ladders (Pt 1

(Pt II) Scaffolds)

6. IS 3696 - 1966 Scaffolds and ladders (Pt II Ladders)

7. IS 4138 - 1977 W orking in Compressed Air (1st revision)

8. IS 4912 - 1978 Safety and Health Protection in Electric and

Gas Welding and Cutting Operations.

9. IS 818 - 1968 Safety Requirements for Floor and Wall

Opening, Railings and Toe Board

10. IS 5121 - 1969 Piling and Other Deep Foundations

11. IS 4130 - 1976 Demolition of Buildings (1st revision)

12. IS 5916 - 1970 Construction Involving Use of Hot Bituminous

Materials

Note : Latest editions of the Standards should be used.


Civil Engg.

SAFETY DURING CONSTRUCTION OF ROAD WORKS

(A) WHEN TRAFFIC IS ALLOWED TO MOVE IN THE SAME ROUTE AND NO DIVERSION/

SUB-WAY ARE PROVIDED :-

• WORKING AREA TO BE PROPERLY BARRICADED TO AVOID ACCIDENT.

• CAUTIONARY / INFORMATO RY SIGN BOARDS TO BE PROVIDED AT BOTH END

OF THE WORK SITE MENTIONING THE RESTRICTED SPEED LIMIT.

• FOR SMOOTH MOVEMENT OF TRAFFIC MINIMUM TWO NUMBERS OF

SIGNALMEN WEARING PROPERLY VISIBLE REFLECTIVE JACKET WITH

NECESSARY FLAG TO BE PROVIDED AT BOTH END OF THE WORKING

STRETCH. THE NUMBERS OF SIGNALMEN MAY NEED TO BE ADJUSTED

DEPENDING UPON THE SITE CONDITION.

• FOR WORKING AT NIGHT OR IF THE BARRICADE NEED TO BE KEPT

PERMANENTLY FOR LONG PERIOD TILL THE WORKS OVER, PROPER

LIGHTING ARRANGEMENT IS REQUIRED AND RED COLOUR LAMP TO

PROVIDED AT BOTH END OF BARRICADE.

(B) WHEN DIVERSION / SUB-WAY ARE PROVIDED :-

• NECESSARY SIGN BOARD TO BE PROVIDED AT LEAST 50 METER BEFORE

SUCH DIVERSION ON BOTH SIDE INFORMING ABOUT THE DIVERSION.

• RESTRICTED SPEED LIMIT AND LOAD CARRYING CAPACITY OF THE SUB-WAY

SHOULD BE CLEARLY MENTIONED.

• RUMBLE STRIP / SPEED BREAKER NEED TO BE PROVIDED TO RESTRICT

THE SPEED LIMIT.


Drilling-Ts.

OIL INDIA LIMITED


Volume - II

Section - 7

DRILLING - TS

ACTIVITIES


Drilling-Ts.


1.0 ENGINES :

i) Internal combustion engines of over 30 HP should be provided with means, other than

manual, for starting them. It should also be provided with a lockout device to ensure that

the external source of power, if started inadvertently when the engine is under repairs,

does not result in any danger to persons undertaking the repair. All moving parts of the

engine, which may pose danger to persons working in the vicinity e.g. the cooling fan,

shaft ends, flexible drives etc. should be provided with suitable guards.

ii) The exhaust system of the engine should be fitted with silencer and spark arrestor to

prevent discharge of open flame and sparks from the exhausts, unless the exhaust are

otherwise cooled and conditioned. The engine should be provided with emergency stop

device and also fitted with accelerator with its control at the driller’s control panel, so that

the engine can be speeded-up whenever needed.

iii) Engine should be equipped with emergency shut-off device, which should have high engine

temperature cut off, low lub. oil pressure cut off, and high engine speed cut off system.

iv) Engine should be inspected periodically as recommended by OEM (Original Equipment

Manufacture) and updated as per our experience on the equipment.

v) Engine floor should be kept reasonably free from oil and grease so as to prevent slipping.

Proper staircase should be provided near the engine floor.

vi) Proper records for engine running hrs., maintenance jobs carried out, should be maintained

at well site.

vii) As the Rig engines are the main equipment of the drilling rig, proper daily check list should

be followed at the well site. Daily check list is enclosed in Annexure - 1 (5.0)

viii) Crew should wear personal protective equipment such as helmet, hand gloves, safety

boots, goggles and ear muffs during the operation as per the requirement.

ix) Fire extinguishers should be placed near the engine.

x) No inflammable materials should be placed in the vicinity of the engine.

xi) When the repair/maintenance job of the engine is in progress a warning signboard “REPAIR/

MAINTENANCE JOB IS IN PROGRESS, DO NOT OPERATE” should be displayed.

xii) Right and appropriate tools should be used during the maintenance of engine.

2.0 MUD PUMPS

i) The mud pumps provide fluids under high pressure to the drilling equipment and should

be fitted with safety pressure relief valve and pressure gauge. The relief valve should be

set to discharge if the pressure exceeds 10% above the set pressure. The discharge line

should be anchored and piped to a place where it will not endanger persons. No valve

should be installed between the pump and its safety pressure relief valve.

ii) The pump should also be provided with bleeder valve, so that if it necessary to release

pressure in the mud system during drilling operations, it could be released through the

bleeder valves. For example, with the line under pressure if the Kelly is to be opened, mud

will splash on the derrick floor, unless the pressure is first released through the bleeder

valve.

iii) The high pressure delivery line and pump manifold should be grouted and anchored properly.


Drilling-Ts.

ANNEXURE - I

5.0 DAILY CHECK LIST FOR RIG ENGINE

a. Check lub.oil level.

b. Check water level in the radiator.

c. Cheek panel reading.

d. Check actuator level and link.

e. Cheek fan belt.

f. Cheek any lub.oil leakage.

g. Cheek fuel line and injector line leakage.

h. Cheek breather.

i. Cheek fan shaft and jockey pulley bearing.

j. Cheek thermostat.

k. Cheek air cleaner.

l. Cheek turbocharger.

6.0 DAILY CHECK LIST FOR RIG PUMP

1) Visual inspection of pump.

2) Cheek tel-tale hole for any leakage.

3) Cheek module vibration.

4) Cheek valve insert.

5) Cheek valve cover gasket.

6) Cheek for any mud cut.

7) Cheek for proper tightening of valve cover.

8) Check suction manifold and suction line.

9) Check delivery manifold and delivery line.

10) Cheek module studs with pump body.

11) Check piston leakage.

12) Check liner flushing pump and direction of rotation.

13) Check lub.oil pump and direction of rotation.

14) Check pulsation dampener pressure.

15) Check oil level in crankcase.

16) Check proper functioning of all H. P valves.

17) Check all dresser coupling of suction side.

18) Check all flange connection of delivery lines.

19) Check delivery line strainer.


Drilling-Ts.

8.0 OXY-FUEL GAS WELDING

8.1 PRE-OPERATIONAL SAFETY CHECKS

1. Ensure no slip/trip hazards are present in workspaces and walkways.

2. Keep area clean and free of grease, oil and other flammable material.

3. Gas hoses must be in good condition and not create a tripping hazard.

4. Before lighting up make a visual inspection of all equipment for damage.

5. Check that the area is well ventilated and fume extraction unit is on.

6. Faulty equipment must not be used. Immediately report suspect equipment.

8.2 PRESSURE SETTING

1. Check that the oxygen and acetylene regulator adjusting knobs are loose.

2. Check that both blowpipe valves are closed.

3. Slowly open the cylinder valves on each cylinder for half a turn only.

4. Screw in the regulator adjusting knobs slowly until the delivery pressure gauges register

70k PA.

5. Purge and check for constant oxygen gas flow.

n Open the oxygen blowpipe for 2 seconds valve and check the delivery gauge.

n If necessary re-adjust the oxygen regulator to achieve a 70kPa pressure.

n Close the oxygen blowpipe valve.

6. Purge and check for constant acetylene gas flow.

n Open the acetylene blowpipe valve for 2 seconds and check the delivery gauge.

n If necessary re-adjust the acetylene regulator to achieve a 70kPa pressure.

n Close the acetylene blowpipe valve.

8.3 LIGHTING UP

1. Open the acetylene blowpipe valve slightly and light the blowpipe with a flint lighter.

2. Continue to slowly open the acetylene valve until the flame no longer produces soot.

3. Slowly open the oxygen blowpipe valve until a neutral flame is produced.

8.4 SHUTTING OFF BLOWPIPE

1. Close the acetylene blowpipe valve first.

2. Then close the oxygen blowpipe valve.


Drilling-Ts.

l Tank trailer brakes shall be set, the wheels shall be chocked, and the driver shall

remain with the vehicle during the entire unloading period.

l Witness hose connection, tank filling and hose disconnection to ensure proper

methods are used and precautions taken to avoid unnecessary dripping and/or releases

from hoses and connection equipment. Assure that the storage tank is vented prior to

connecting unloading line.

l For gasoline and diesel unloading, ensure that catch basins prior to unloading are

covered in order to prevent spills from going into the basins. Covers shall not be

removed until loading is completed and any spillage has been contained and removed.

l Prior to initiating fuel transfer; confirm that sufficient space is available in the receiving

storage tank to receive the contents of the tank truck. Document the tank

measurements.

l Prior to filling (and again prior to departure of tank truck), the lowermost drain and all

outlets of vehicle must be examined for leakage and if necessary tightened, adjusted

or replaced to prevent leakage while off-loading (or while in transit).

l Ensure all hoses are connected tight and that a collection bucket is placed under the

trailer unloading valve.

l Once unloading has ceased, the hoses will be disconnected such that any material in

the lines will gravity drain into the tank, or be pumped into the tank. Any small dripping

material shall be contained and removed.

l The fuel transfer operator shall visually inspect the area for any releases and document

the inspection.

l If any spill occurs during the filling process, stop filling and immediately follow Kean

spill reporting procedures.

l Determine the fuel level in the tank and calculate the volume required to be delivered

prior to ordering the fuel.

l Earthing to be provided in the tanker before unloading till the completion of the unloading.


Drilling-Ts.

Sequence of Job Potential Standard Operating Procedure Personal

Steps Hazards/Risks (How to do it) Protective

(What to do in the of Each Step Equipment

right order)

Place Battery on

Charger

Lifting

Carrying

Slipping

Chemical

Hazard

Eye Injury

Falling

Electrical

Hazard

Check that work area is clear.

Turn charger off.

Remove all battery cell caps and clean

battery terminals.

Connect positive lead to positive terminal

with charging lead.

Connect negative lead to negative terminal

with charging lead.

Select voltage as required.

Switch on charger, check Amp reading

and set as required.

Overalls

Safety Boots

Gloves

Face shield

Disconnect

Battery from

Charger

Chemical

Hazard

Electrical

Hazard Eye

Injury

Explosion

Turn charger off.

Remove NEGATIVE lead first.

Remove positive lead.

Replace caps.

Overalls

Safety Boots

Gloves

Face shield

Removal and

Washing Battery

Lifting

Carrying

Slipping

Falling

Dropping

Chemical

Hazard

Eye Injury

Place battery in sink and wash.

Place charged battery sign on terminal.

Place battery in charged area on bench.

Overalls

Safety Boots

Gloves

Face shield


Instrumentation

OIL INDIA LIMITED


Volume - II

Section - 8

INSTRUMENTATION

ACTIVITIES


Instrumentation


INSTRUMENTATION ACTIVITIES

CONTENTS


1.0 Safety Concerns............................................................................................... 1

2.0 Choosing a Protection Method...........................................................................6

3.0 Safe Installation & Maintenance Practice of intrinsically safe field

wiring in hazardous environment.......................................................................8

4.0 Maintenance Recommendations in Hazardous area....................................... 9

5.0 General Principle...............................................................................................10

6.0 General Safe Operating Procedures for working in Field

Instrumentation systems .................................................................................12

7.0 Standard Operating Procedure of Calibration..................................................13

8.0 Safe Operating Procedures for working in Gas/Air Compressor....................14

9.0 Safe Operating Procedures for working in Fired vessels

(IH, Glycol Reboiler, Heater Separator Units etc)............................................ 15

10.0 Safe Operating Procedures for working in Boiler Instrumentation systems/

Control panels................................................................................................. 16

11.0 Safe Operating procedures for working in Pressure vessel (OCS)

instrumentation system................................................................................... 17

12.0 Safe Operating procedures for working in Oil Storage Tank instrumentation

system............................................................................................................. 18

13.0 Standard Operating Procedure (S.O.P.) for Electronics Laboratory

Personnel.........................................................................................................21


Instrumentation

STANDARD OPERATING PROCEDURE (S.O.P.) FOR INSTRUMENTATION PERSONNELWORKING IN OIL AND GAS INSTALLATIONS

1.0 Safety Concerns :

There are safety concerns when installing an electrically powered device in a

hazardous area. Standards are developed by the National Electric Code (NEC), DGMS

for use of equipment in hazardous areas. Third party agencies such as Factory Mutual,

CMRI in India provide testing to insure that these standards are followed and that the

equipment is safe for use in hazardous areas.

When dealing with the use of instrumentation in hazardous areas consideration

must be given to :

- Definition of the area classification and

- Protection Method used to meet these standards.

1.0.1 Definition of Hazardous Area :

The Petroleum Act 1934 defines Hazardous Area as follows:

An Area shall be deemed to be an hazardous area, where:

i) Petroleum having Flash Point (FP) below 65 deg C or any other flammable

gas or vapour in concentration capable of ignition is likely to be present.

ii) Petroleum or any inflammable liquid having Flash Point above 65 deg C is

likely to be refined, blended, handled or stored at or above its FP

The Petroleum Act 1934 lists the earth resistance values as 4 ohms for electrical

systems, 10 ohms for non-current carrying metallic parts. It also states that all joints in

pipelines, valves etc shall be bonded and earth resistance between each joint shall be

1 ohm.

According to the IS 5572, Hazardous Area is an area in which an explosive gas

atmosphere is present or likely to be present, in quantities such as to require special

precautions for the construction, installation and use of electrical apparatus. The IS

5572 classifies Hazardous Areas in zones based on the frequency of the appearance and

the duration of an explosive gas atmosphere.

List of Indian Standards for various Protection Techniques:

• IS 5571 Guide for selection of Electrical Equipment for Hazardous Areas

• IS 5572 – Part I Classification of Hazardous Areas for Electrical installations

• IS 13408 Part I, II, III Code of Selection, Installation and Maintenance of Electrical

Apparatus for Use in Explosive Atmospheres

• IS 8239 Classification of Maximum Surface Temperature of Electrical

Equipment for Use In Explosive Atmospheres

• IS 6381 Construction and testing of Electrical Apparatus with type of

protection ‘e’

• IS 2148 Flameproof Enclosures of Electrical Apparatus


Instrumentation

• IS 13346 General Requirements for Electrical Apparatus for Explosive GasAtmospheres

• IS 5780 Specification For Intrinsically Safe Electrical Apparatus and Circuits• IS 8240 Guide for Electrical Equipment for Explosive Atmospheres• IS 2147 Degrees of Protection Provided by Enclosures For Low Voltage Switch

Gear & Control Gear• IS 4691 Degrees of Protection Provided by Enclosures For Rotating Electrical

Machinery• IS 8241 Methods of Marking for Identifying Electrical equipment for Explosive

Atmospheres• IS 8224 Specification for Electric Lighting fitting for Explosive Atmospheres• IS 8289 Electrical Equipment with Type of Protection ‘n’• IS 7389 Specification for Pressurized Enclosures• IS 2206 (PART I,III) Specification for Flame proof Electric Light Fixtures

1.0.2 Area Classification :

The North American (NFPA / API / NFPA 70E / NEC) systemArea classification is defined by :

Class – Category of the type of materialDivision - Frequency of a hazardous condition occurringGroup – Type of flammable material based on its ignition energy

1.0.2.1 Class: Type of material :

Class I – Flammable gases, vapor, or liquids are present in the air in quantitiessufficient to produce an explosive atmosphere.

Class II – Combustible dust and powder suspended in the air in quantitiessufficient to produce an explosive atmosphere.

Class III – Flammable fibers suspended in the air in quantities to produce anexplosive atmosphere.

Applications in the petroleum industry deal almost exclusively with hazardousliquids, vapor and gases which are Class I service. Approximately 85% of the all hazardouslocations in North America are defined as Class I.

1.0.2.2 Division :

Division : Indication of the frequency of a hazardous condition occurring.The National Electric Code defines these:

Division 1 – Hazardous locations are where an explosive atmosphere existscontinuously or intermittently under normal operating condition andunder fault conditions.

Division 2 – Hazardous locations that are adjacent to a Division 1 location orwhere an explosive atmosphere infrequently exists when there isa fault or breakdown of equipment.

1.0.2 Protection Method :


Instrumentation

When dealing with oil storage tanks, concern must be given to both the conditionsinside the tank and in the surrounding area (Figure 2). For instance, the area inside thetank is a Division 1 area where a hazardous condition continuously exists while the areaoutside the tank can be Division 1 or Division 2 hazardous area. This boundary betweena Division 1 area and a Division 2 area outside of the tank is up to the discretion of theindividual responsible for certifying an area.

1.0.2.3 Group :

The group classification specifies the type of the flammable material with regardto the type of vapor. The groups are based upon the ignition energy of the material.For Class I service dealing with flammable liquids and vapors, the Groups are dividedinto:

Group A – Atmospheres containing acetyleneGroup B – Atmospheres containing Hydrogen plus a few other hydrocarbonsGroup C – Atmospheres containing ethylene and similar vaporsGroup D – Atmospheres containing methane, ethane, propane and other similar gases.Groups C and D are the most common and are of concern to applications for vaporsfrom oil storage.

1.0.2.4 Temperature Code :

The last consideration is the amount of heat generated by the instrument. Aninstrument is classified for a specific maximum surface temperature which the devicecan reach during normal and fault conditions. To properly apply an instrument in ahazardous area the maximum surface temperature of the device must be less than theauto ignition temperature of any potential gases or vapor that may come in contactwith the device.

The National Electric Code has established various temperature codes, whichidentify the maximum surface temperature that the instrument can reach. This code ispart of the approval listing of the instrument.

The next step in safely applying instrumentation in hazardous areas concerns theselection of the protection method to meet the area classification.

Classification Outside North America, (The Indian system)

Zones

Zone 0 Area in which an explosive gas-air mixture is continuously present orpresent for long periods.

Zone 1 Combustible or conductive dusts are present. Area in which anexplosive gas-air mixture is likely to occur in normal operation.

Zone 2 Area in which an explosive gas-air mixture is not likely to occur, and ifit occurs it will only exist for a short time.


Instrumentation

Protection Types

Zone

d Flameproof (Explosion proof) Enclosure 1,2

e Increased Safety 1,2

ia Intrinsic Safety 0,1,2

ib Intrinsic Safety 1,2

o Oil Immersion 2

p Pressurized Apparatus (Purged Apparatus) 1,2

q Powder Filling (Sand Filling) 2

m Encapsulation 1,2

n Normally Nonsparking and/or Nonincendive Circuits) 2

Temperature Codes

°F °C

T1 842 450

T2 572 300

T3 392 200

T4 275 135

T5 212 100

T6 185 85

Groups

Group I For application in below ground installations (mines) where methane

(firedamp) and coal dust may be present.

Group IIA For application in above ground installation where hazards due to

propane may exist. This group most closely matches the North

American Group D.

Group IIB For application in above ground installations where hazards due to

ethylene may exist. This group most closely matches the North

American Group C.

Group IIC For application in above ground installations where hazards due to

hydrogen or acetylene may exist. This group most closely matches

the North American Groups A and B.


Instrumentation

There are three main protection methods used :

- Explosion Proof- Non- incendive- Intrinsically Safe

Explosion proof and intrinsically safe are suitable for use in both Division 1 andDivision 2 areas while non-incendive is useable only in Division 2 areas.

1.0.3.1 Explosion proof :

Items that are explosion proof are designed so that the enclosure will contain anexplosion and prevent flame propagation to the external atmosphere. An explosion isallowed to occur but it is confined within an enclosure built to resist the pressurescreated during the explosion.

This requires that the enclosure walls be thick enough to contain an explosiveforce. The internal pressure created during an explosion depends upon the gas or vaporthat was ignited. As a result, explosion proof designs require the heavy-duty enclosurethat is frequently seen in petroleum processing.

Explosion proof enclosures have historically been the primary method ofprotection in the petroleum industry for over fifty years.

1.0.3.2 Non-incendive :

The non-incendive method of protection is suitable only in Division 2 areaswhere hazardous conditions exist only under upset conditions. To obtain non-incendiveapproval, the electrical circuit is not capable of igniting an explosive atmosphere –there are no arcing or sparking components. It is important to note that this approval isbased on hazardous conditions occurring only during fault conditions and not duringnormal operation.

The primary advantage of this method of protection is that it is less expensiveto install than if the device is installed using explosion proof requirements.

1.0.3.3 Intrinsically safe :

Intrinsic safety is a technique that insures that the amount of energy available inthe instrument is too low to ignite the explosive mixture of vapor and air. The energyto the instrument is limited with the use of an intrinsically safe barrier that is located ina non-hazardous area. This limits the voltage and current going to the instrument. Thepower to intrinsically safe instruments is 24 VDC and the amount of current requiredwill vary between 4 and 20 mA. See Figure 3.

Intrinsic safety is a type of protection for electrical apparatus designed to operatein an environment in which explosive concentrations of combustible materials arepotentially present. Intrinsically safe circuits limit, by design, the available electrical


Instrumentation

and thermal energy to levels that are below the minimum necessary to ignite theflammable atmosphere under certain prescribed fault conditions and applied test safetyfactors.

Intrinsically safe designs do not depend upon the enclosure design however manyinstruments will use the same enclosure for both explosion proof and intrinsically safedesigns. This is often a question of economics for the instrument manufacturer.

2.0 Choosing a Protection Method :

The decision on which protection method to use depends upon several factors –the main ones are the instrument design, installation costs, and the user’s preferences.

2.0.1 Instrument Design :

An instrument may be available in either an intrinsically safe design or explosionproof design. The enclosure and external appearance is the same for both designs. Theonly difference is internal circuit between the intrinsically safe and explosion proofdesign.

To understand this difference, consider an instrument which is not rated explosionproof. Therefore, to meet the safety requirements for a Division 1 area, the amount ofenergy going into the hazardous area must be limited. If installed as an intrinsically safedevice the external safety barrier limits the energy to the instrument. However, ifinstalled as an explosion proof design there is nothing external to the instrument tolimit the energy. In order to install the instrument in a hazardous area the explosionproof design incorporates internal barriers that limit the energy into the instrument.Technically, this is referred to as an explosion proof design with intrinsically safe circuit.

Some instruments are only available as in explosion proof design. To operate thisinstrument requires more energy than can be supplied over a traditional intrinsicallysafe circuit. Four wires are required to operate this instrument – two wires for inputpower and two wires for the output 4-20 mA signal. The input power can be either 120/240 VAC or 24 VDC depending upon user preference. The intrinsically safe design requiresthe use of an external barrier in the control room.

2.0.2 Installation cost :

There are however, other costs saving issues by using an intrinsically safeimplementation. By using the intrinsically safe installation, the wiring from the controlroom to the instrument can be simpler and less expensive. Heavy duty explosion proofconduit is not needed with IS designs. An all intrinsically safe installation permits thewiring to and from the instrument to be placed in cable trays. Simple cable glands canbe used to seal the wiring at the instrument. Due to savings in wiring cost, an allintrinsically safe installation may be less expensive than an explosion proof installation.However, sometimes this is not the case due to the typical preference of using conduiteven in those installations when not required.


Instrumentation

As a result of technological advances in the oil and gas industry utilizing increased

automation and electronics, intrinsically safe circuits are being used to a greater extent.

Because of the increased applications for intrinsically safe circuits, installation and

maintenance of intrinsically safe field cables and wires remain an area of concern.

Because of the electrical energy in an intrinsically safe circuit is incapable of

igniting an explosive concentration, there has been a tendency to disregard the possibility

of any hazard arising from the improper installation and maintenance of intrinsically

safe field cables and wires. This is an erroneous and potentially dangerous practice.

Improper installation and maintenance of intrinsically safe field wiring can

compromise the safety of equipment complying with the design standards for intrinsic

safety. An intrinsically safe circuit may be compromised by improper cable routing,

mechanical damage or accidental contact with a non-intrinsically safe conductor; such

as a power conductor or a machine frame having an induced voltage due to eddy

currents, leakage, or ground loops.


Instrumentation

Another concern is the contact between separate intrinsically safe circuits from

different apparatus or systems due to the exposure of bare conductors as the result of

mechanical damage to cable insulation jackets. The additive energy from the contact

of two separate intrinsically safe circuits, each of which is individually intrinsically

safe, may not be intrinsically safe. The contact might occur through ground or direct

short circuit contact between cables.

3.0 Safe Installation & Maintenance Practice of intrinsically safe field wiring in

hazardous environment :

• Copper conductors shall be used and sized such that their maximum surface

temperature shall not exceed 1500C when carrying the maximum current that

could flow in the circuit under fault conditions.

• Conductors shall be covered with an insulation thickness of 0.25mm, minimum.

• The insulation shall be capable of withstanding an r.m.s. AC test voltage of twice

the nominal voltage of the intrinsically safe circuit with a minimum of 500 V.

• Multi-conductor cables shall contain all conductors within an insulative jacket

having a minimum thickness of 0.25mm.

• Cables and wires containing intrinsically safe circuits shall be identified. The use

of a bright blue colour on the outer jacket is the preferred method of

identification.

• Intrinsically safe circuits from different intrinsically safe systems shall not be run

in the same multiconductor cable. Multiple intrinsically safe circuits from a single

intrinsically safe system or apparatus shall not be run in the same multiconductor

cables unless allowed by authorized approval agencies. When allowed, each

intrinsically safe circuit will be required to be shielded with the shields connected

to ground at one end unless combinations of cable faults have been found to not

create a safety hazard.

• Cables and wires containing intrinsically safe circuit shall not be positioned close

to intense magnetic fields, power distribution lines, heavy current carrying single

conductor cables or wires, or high voltage un insulated conductors to avoid

electro-magnetic induction effects that might allow the energy level of intrinsically

safe circuits to become capable of producing an ignition. When physical separation

is not possible, attention should be given to twisting or shielding of the intrinsically

safe conductors.

• Intrinsically safe cables and wire between machine components shall be clamped

in place to prevent undue movement, protected from mechanical damage,

isolated from hydraulic lines and protected from abrasion by removing all sharp


Instrumentation

edges which they might contact.

• Protection from mechanical damage may be by Position, flame-resistant hose

conduit, armouring, metal tubing, or troughs and trays. The armouring of armoured

cables shall be grounded at both ends of the cables.

• Cables and wires containing intrinsically safe circuits shall not be intermingled

with cables and wires containing non- intrinsically safe circuits.

• When necessary for maintenance, cables shall be disconnected from intrinsically

safe equipment in such a way that live terminals or conductors are not left

exposed. Cables shall not be left unconnected and repairs shall be made in a

timely fashion.

• Although most intrinsically safe circuits are less voltage, less than 30 V, some

intrinsically safe circuits operate at voltage and current levels sufficient to

constitute a shock hazard, the same precautions against shock hazard shall be

observed when installing or servicing intrinsically safe circuits as are observed

with non- intrinsically safe circuits.

4.0 Maintenance Recommendations in Hazardous areas :

• Light alloy paint even for the purpose of maintenance must not be applied on

any external surface of the equipment to prevent incendive frictional sparking.

• Equipment shall not be tampered to open covers, etc.

• No components shall be added or removed or even replaced. This has to be

done after getting re-certified by the OEM.

• A scheme of regular inspection & maintenance of the items should be made on

the basis of guidelines / standards. Any equipment which is originally flameproof

may loose its integrity if not maintained properly.

• The equipment should be de-energized before attempting any repair Integrity

of IP equipment.

• Use of gasket is permitted if certified as part of the equipment.

• No sealing of flange faces (this could affect the ability of the enclosure to

withstand the maximum explosion pressure).

• Application of non-setting grease or anti-corrosive agent is permissible.


Instrumentation

• Non-hardening tape can be used in II A gas groups, in II B tape is to be avoided

and no use of tape in II C gas groups.

• Insulation integrity to be periodically tested and maintained Maintenance personnel.

• Inspection, Maintenance, testing, replacement and repair in Hazardous Areas

shall be carried out by trained personnel only.

• Refresher training for them is essential.

• Periodic examination of flange gaps and flange faces for any effects of corrosion

/ damage, etc.

• Maintenance Tests (at an interval not exceeding 3 years).

• Earth electrode resistance measurements.

• Earth loop resistance measurements. The value should not exceed 0.1 ohm.

• Operation & Setting of Protection devices.

• Surge protection devices will be used in electrical systems.

5.0 General principle :

The following aspects should be considered with respect to Safe Operating and

Maintenance Procedures:

• Human factors;

• Poorly skilled work force;

• Unconscious and conscious incompetence;

• Good maintainability principles;

• Knowledge of failure rate and maintainability; and

• Clear criteria for recognition of faults and marginal performance.

The following issues may contribute towards a major accident or hazard :

• Failure of safety critical equipment due to lack of maintenance;

• Human error during maintenance;

• Static or spark discharge during maintenance in an intrinsically safe zone;

• Incompetence of maintenance staff; and

• Poor communication between maintenance and production staff.


Instrumentation

5.1 Contributory factors to consider concerning maintenance procedures :

For Safe Operation of any instrumentation system the following points should be

addressed :

• The maintenance regimes (planned, risk-based, reliability centred, condition

based or breakdown maintenance) should be adequate for each instrumentation

item which has a safety function ;

• Proof check periods quoted for safety critical items should be adequate to ensure

risks are within acceptable limits ;

• Maintenance staff should be sufficiently trained to recognise plant or equipment

failing during maintenance inspections. Maintenance staff should be sufficiently

informed, instructed, trained and supervised to minimise a potential human

failing during maintenance. Hence proper training should be imparted from time

to time to staff. This is emphasized in Section 7.0 of OISD Standard 153.

• Maintenance schedules should be managed and regularly inspected and reviewed;

• Human factors (stress, fatigue, shift work, attitude) are to be addressed. No

staff should be asked to perform duties exceeding the safe human working time

limit

• Sufficient precautions should be taken prior to maintenance of hazardous plant

and equipment (isolation, draining, flushing, environmental monitoring, risk

assessments, permits to work, communication, time allotted for the work);

• Maintenance staff should be aware of the type of environment they are working

in (flammable, corrosive, explosive, zones 0, 1 & 2);

• Maintenance staff should use the correct equipment in the workplace during re-

conditioning, replacement and re-commissioning (static free, intrinsically safe,

flameproof, PPE/RPE);

• Sufficient reporting systems should be in place so that corrective maintenance

can be applied to mitigate a major accident or hazard.

5.2 Major hazards :

Major hazards could arise from the following :

• The lack of control of spares such that incorrect materials or items outside

specification (e.g. non-flameproof equipment) are used in replacement of

instrumentation items leading to increased risk of loss of containment, fire or

explosion. Hence proper spares are to be always used.


Instrumentation

• Failure to drain and/or isolate plant eqipments prior to dismantling causing release

of flammable substances. Thus proper procedures for drainage and isolation of

plant equipments should be followed.

• Maintenance being performed incompetently (particularly alarm/action set points

on instruments incorrectly set, safety features left disconnected/dismantled,

gaskets left out, non-return valves orientation incorrect). Extra caution is required

while maintenance is performed.

• Scheduled maintenance not being undertaken as required or breakdown

maintenance inadequate, leading to unrevealed failures of safety critical items.

Proper maintenance schedules should be followed.

• Lack of knowledge by maintenance staff of the working environment where

maintenance is being carried out (i.e. lack of risk assessments, warning signs,

method statements, emergency procedures), leading to ignition of flammable

substances (e.g. heat sources such as cigarettes or welding, static and electrical

discharge, use of non spark-resistant tools) or injury/fatality from incorrect

personal protective equipment (e.g. respirators) being worn. Proper knowledge

of the maintenance staff is an important criteria to avert such incidents.

• Unauthorised staff performing maintenance functions. Never allow personnel not

trained and knowledgeable to work on instrumentation systems.

6.0 General Safe Operating procedures for working in Field instrumentation systems:

• Be clear about the maintenance report. Ask further clarifications if required.

Read the Notification carefully. If it is not clear talk with the concerned person

filing the Notification.

• Assign personnel as required. See that they carry proper tools, documents,

instruments, hardware and wear PPE.

• While going to the field location never overspeed.

• Inform the Operator about your arrival and get first hand information about the

maintenance issue. Put a “Under Maintenance” sign board in front of the equipment

where work has to be done.

• Inform the concerned engineer as and when required.

• Carry out Preventive maintenance of instrumentation items every six months.

• All safety instrumentation devices must be considered critical utility system


Instrumentation

components. Inspection, testing, and maintenance records are required for all

critical components.

Records must include the :

a. Date of test, inspection, and/or maintenance;

b. Results of the test, inspection, and maintenance procedures accomplished;

c. Parts installed;

d. Names of individuals performing testing, inspection, and/or maintenance;

7.0 Standard Operating Procedure of Calibration :

The process of comparing and connecting the response of an instrument to agree

with a standard instrument over the measurement range is called Calibration.

7.1 The Basic Requirements for Calibration:

• Standard/Reference/calibrators

• Controlled environment conditions

• Competence of calibration personnel

• Traceability of standards

• Documentation

7.1.1 Traceability :

It is given to measurement made in industry that can be linked to nationally

maintained standard through the medium of traceable calibration. Traceability of

measurement implies that there is a documentable quantifiable unbroken chain of

calibration linking the measurement with national standards at the highest level.

7.1.2 Documentation :

Proper care shall be taken for documenting :

• Calibration procedure/method: Generally the Calibration method described in

the User’s Manual of the instrument/equipment under test should be followed.

Testing, repairing and calibrating instruments should be in accordance with

instrument-specific procedures.

• Calibration Result: The calibration result will be recorded.

• Calibration Report: A detailed Calibration report should be made in line with IS:

3624-1987


Instrumentation

• Calibration Certificate: A Calibration Certificate will be made with a Reference

Number and date identifying the conditions of calibration. A tamper-resistant

seal will be affixed to the instrument to ensure their internal integrity and a

Notice of Certification label to certify its performance and the calibration date.

The calibration expiration date shall be no longer than one year from the date of

last calibration and certification. Instruments whose calibration date has expired

shall not be used.

7.2 Frequency of Calibration :

The frequency of Calibration should meet the requirements as listed in section 5.0

of OISD Standard 153. Any prudent exercise for fixing interval or frequency of calibration

shall include:

• Type of equipment: The type of test equipment to be used for calibration

(Workshop Testing or Field Testing) should be as per Section 6.0 of OISD Standard

153

• Frequency of use

• Environmental conditions of use

• Maintenance and Services

• Accuracy of measurement sought

• Effect of instrument error on final product

7.3 Action when the Equipment is Out of Calibration :

• Examine the records of last calibration

• Confirm that the inaccuracy has occurred only after last calibration

• Where possible, recheck the product features measured with the equipment

that is out of calibration and initiate immediate action to isolate non-conforming

product on the final quality of the product

• Redefine the frequency of calibration for this particular item

7.4 Accreditation :

Accreditation is the unbiased assessment by a third party of a Laboratory’s quality

program and technical capabilities. The third party assesses the laboratory against a

recognized standard ISO/IEC 17025.

8.0 Safe Operating procedures for working in Gas/Air Compressor

• Before starting work on the compressor always inform the Operator of the station.

• Put a “Under Maintenance” sign board in front of the machine where work has to

be done.


Instrumentation

• Observe for any oil, water, and gas or air leak and bring it to the notice of the

Operator. Block the leak if applicable.

• Inspect the air filter regulator and drain the liquid collected.

• Carry out maintenance work as laid down in the manual provided by the OEM.

• Be careful about working on the control panel. Never step on the pneumatic

tubes.

• Never bypass any safety shutdown switch. If for emergency operation it is required

to bypass any switch, then take proper permission/approval from the concerned

engineer. Bring it to the notice of the Operator.

• Set the various switches according to the set points list provided. Use standard

test gauges and calibration equipments for calibrating the safety devices.

• A word of caution. If the gas compressor unit has been down or the gas system

has been exposed to the atmosphere, the system must be purged, otherwise a

gas-air mixture under pressure can explode violently. Hence purge the system by

the following :

Open the vent valve

Open the inlet (suction) valve

Open the bypass valve

• Alternately close then open the bypass valve to ensure a complete purge of the

system. After the purge cycle is complete close the vent valve and make sure

the bypass is open.

• After completion of the maintenance work, inform the Operator and ask him to

Test start the machine and observe its performance. Never start an engine at full

speed, even after pre-lubing. This eliminates over-speeding and unnecessary

wear. Observe for any abnormal condition (sound, vibration, leakage etc) and

take necessary action to prevent it. If the work has been satisfactorily completed,

remove the “Under Maintenance” sign board and hand over the machine to the

Operator.

• Safety Instrumentation system for Process Gas Compressors is outlined in section

4.9 of OISD Standard 152 and is outlined in Section 4.13 for Air Compressors and

the same should be strictly followed.

9.0 Safe Operating procedures for working in Fired vessels (IH, Glycol Reboiler,

Heater Separator Units etc)

• First understand the problem.


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• With the help of the Operator, cut off fuel supply to the vessel and open the

flame arrester.

• Wait for the system to cool down and allow time to purge the system of un-burnt

gas.

• Set the pilot gas regulator pressure to 5 psi.

• Check the operation of the Fuel shut off valve and the Temperature control

valve.

• While working inside the vessel wear proper aprons.

• While checking ignition is cautious to properly ground the remote ignitor. Maintain

safe distance to avoid injury and burn.

• Place the ignition rod and the pilot flame detector by clamping the system

properly.

• Safety Instrumentation system for Process Heaters is outlined in Section 4.7 of

OISD Standard 152 and the same should be followed. Safety Instrumentation

system for Gas Dehydrators is outlined in Section 4.3 of the same standard.

10.0 Safe Operating procedures for working in Boiler instrumentation systems/

control panels :

• Before working on a Boiler control panel, know fully well the significance of all

safety devices.

• Ensure that rubber mat is laid on the ground near the control panel.

• Check the functioning of main switch.

• Always use correct fuse. Never use over-rated fuse.

• Ensure that all electrical connections are firm and no loose connections are left

out.

• Never bypass any safety shutdown switch. If for emergency operation it is required

to bypass any switch then take proper permission/approval from the concerned

engineer. Bring it to the notice of the Operator.

• Set the various switches according to the set points list provided. Use standard

test gauges and calibration equipments for calibrating the safety devices. Check


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whether the gauges are showing correctly, otherwise calibrate.

• Check that the gauge glasses are clean and showing the correct level reading.

Otherwise inform Operator and carry out maintenance work.

• Clean the flame sensor and viewing glass often.

• Follow the scheduled maintenance on the instrumentation system as per the

OEM manual.

• The most important aspect in the operation of a boiler is that it is the presence

of water on the heating surfaces which prevents buckling of the pressure parts.

Taking the point of view of safety, one should consider that the water inside the

boiler is really to cool the boiler to prevent heat damage to the flame swept

areas rather than to produce steam.

• It should be borne in mind that combustion chamber of a boiler contains flame

and flue gases in the neighborhood of 1100C. Therefore it is imperative that the

water level is always kept much above the combustion chamber level. This is

achieved by a properly designed automatic water level controller. It is also

essential to make sure that in the case of a failure sufficient care is taken to

rectify immediately.

11.0 Safe Operating procedures for working in Pressure vessel (OCS)

instrumentation system :

• Inspect the exterior of the instruments for accumulation of oil, dust & dirt.

• Inspect the servo filter regulator and drain the liquid collected.

• Check the pressure setting of the air filter regulators.

• Do not attempt any maintenance without first isolating the instrument from

system pressure and releasing all internal pressure.

• Check that the gauge glasses are clean and showing the correct level reading.

• Check for electronic transmitter / controller enclosure caps are fully screwed

and enclosure o-ring is in proper condition.

• Check the 24V DC power supply to electronic transmitters / controllers.

• Check the zero drift of transmitter.

• Inspect all mounting bolts for tightness for instruments subjected to constant


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vibration.

• Inspect for any leakages from process connections.

• Inspect for possible moisture leaks through conduit entrances.

• Carry out maintenance as per the instructions provided by OEM manuals.

• Do not operate any instrument in excess of it’s specifications.

• Isolate power supply before opening an instrument in hazardous environment.

• Do not attempt any change of set points or control action override in the control

system without proper authorization.

• Know well the safety systems and their functions, their operating limits,

consequences of deviations in set points.

• Always inform the process personnel before taking up maintenance/ calibration

jobs.

• Proper tools to be used while servicing/ calibration.

12.0 Safe Operating procedures for working in Oil Storage Tank instrumentation

system :

The National Fire Protection Association (NFPA) states, in NFPA 77 “Static

Electricity”, that “Static electrification and the various effects that result from the

positive and negative charges so formed may constitute a fire or explosive hazard. The

generation of static electricity cannot be prevented absolutely, because its intrinsic

origins are present at every interface”.

Static electricity is generated when liquids move in contact with other materials.

This is a common occurrence when liquid is being moved through pipes, mixed, poured,

pumped, filtered, or otherwise agitated. Other causative processes include the settling

of solids or immiscible liquid through a liquid, the ejection of particles or droplets

through a nozzle, and the splashing of a liquid against a solid surface. NFPA 77 states

that “under certain conditions, particularly with liquid hydrocarbons, static may

accumulate in the liquid”, with the danger of subsequent sparking in a flammable

vapor-air mixture.

American Petroleum Institute Recommended Practice 2003 (API 2003) “Protection

against Ignitions Arising out of Static, Lightning, and Stray Currents”: This document

presents current technology in the prevention of hydrocarbon ignition by static electricity,

lightning, and stray currents. It contains good general principles of safety, and concentrates

largely on land based oil storage and transportation.

According to NFPA 77, the development of (static) electrical charges may not be


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in itself a potential fire or explosion hazard. There must be a discharge or a sudden

recombination of separated positive and negative charges. In order for static to be a

source of ignition, four conditions must be fulfilled:

(a) There must first of all be an effective means of static generation,

(b) There must be a means of accumulating the separate charges and

maintaining a suitable difference of electrical potential,

(c) There must be a spark discharge of adequate energy, and

(d) The spark must occur in an ignitable mixture.

12.1 Mechanisms for Producing Hazardous Conditions :

Static generation : Two differing substances in contact with each other will

often become charged as one surrenders electrons to the other. Although the net charge

remains constant, an electrical double layer is formed along the adjoining surfaces. The

separation of the two substances often causes them to remain disparately charged, an

effect which is exaggerated by increased speed of separation and increased mechanical

work (friction).

Piping of oil products Charge generation and separation occur when liquids move

in contact with other materials, as in operations involving piping, filtering, mixing or

agitating. Mechanisms which exacerbate static separation in tank filling operations are

the following:

· Turbulence and splashing of the fluid at the beginning of tank filling operations

when the pipe opening is not yet covered with oil.

· Impurities such as water, metals, rust, or other product in the oil.

· Pumping of entrained air or other gases bubbling in the tank.

Displacing of lines using air and water is a static charge generator.

Water mist and steam Mists formed during water washing or from the introduction

of steam can become electrostatically charged. The charge associated with water

washing may be much higher if cleaning chemicals are used.

Steaming produces mist clouds much more highly charged than water washing,

much more quickly, and can also cause the release of gases due to the heat and disturbance

of the process.

Potentials are higher in large tanks than small ones.

Loading overall Loading overall (from the top of the tank) can deliver charged

liquid into a tank which breaks up into small droplets and splashes into the tank. This

can produce a charged mist and an increased hydrocarbon gas concentration.

Air release in bottom of tanks Air or inert gas blown into the bottom of a tank

can generate a strong electrostatic charge by bubbling action and agitation of the fluid.


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Crude oil washing (COW) Mixtures of crude oil and water can produce an

electrically charged mist if used for COW operations.

12.2 Accumulation of charge and potential

Static accumulator and non-accumulator oils The conductivity of a liquid determines

whether or not it retains the generated static charge. A non-accumulator oil, defined

by an electrical conductivity of greater than 50 (pS/m) will relax quickly because it

transmits the charge to the steel tank, which is grounded in the water. Accumulator oils

are defined as having a conductivity of less than 50 pS/m; these oils relax (dissipate

charge) slowly. Crude oil is classified as non-accumulator oil.

Weather During periods of normal humidity, a film of water provides a leakage

path over most solid insulators. In the dry climates of places such as deserts and arctic

regions, humidity leakage may not be expected.

Synthetic clothing Industry experience shows that synthetic clothing does not

give rise to significant electrostatic hazard under normal operating conditions; such

clothing is not recommended because of its behavior when exposed to flames and heat

12.3 Spark discharge The cause and prevention of spark discharge has drawn the most

attention in the efforts to address this problem. Incendive sparks are those which

release adequate energy to ignite flammable vapors. Spark energy may be reduced by

physical factors such as electrode resistance, spark gap distance, and large gap areas.

Discharges are sometimes in the form of a “corona”, an ionization of gas which is not

incendive but may precede an incendive spark.

Known causes of incendive sparks are identified below.

· Insulated conductors Unbonded conductive objects in a tank can accumulate

available static charge and generate incendive sparks when discharging to another

conductor, such as a tank. They may be either trash or equipment unknowingly left in

the tank or equipment introduced to do work in the tank.

· Oil measuring devices (ullage tapes, thermometers, gas sensors, etc.) present

a particular hazard since they are often used during and immediately after filling when

some risk factors are at their highest. Use of these devices within a sounding tube is

acceptable; electrical potential there is low because of its small volume and the shielding

it affords from the rest of the tank.

12.4 Flammable vapor Oils give off hydrocarbon vapors whose flammable properties

are described, in part, by the lower and upper flammable limits (LFL and UFL). LFL and

UFL are the lowest and highest concentrations of the vapor in air that will ignite in the

presence of an ignition source, otherwise known as the flammable range. Concentrations

below LFL are too lean to burn and those above UFL too rich. Tank atmosphere control

measures aim either to make the air/vapor mixture too lean or too rich.

Tank atmosphere is a constant concern regardless of the loading condition. Several

factors can give rise to hazardous conditions, particularly as regards electrostatic


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discharge.

· Steam cleaning Steam cleaning of tanks is necessary between some product

loads and can release hydrocarbon gas in tanks thought to be gas free. This is due to the

heat introduced by the process and the disturbance of sludge, clingage, rust particles,

etc. on the surfaces of the tank. The released vapors are dangerous with the electrostatic

charge caused by the steam and the contaminants in the wash byproduct.

· Temperature fluctuations Hot/cold temperature extremes can result in locally

hazardous conditions, e.g., when some oil is heated by piping exposed to the sun. In

such a case, much lower Reid vapor pressures result, with a possible increased risk of

vapors within flammable limits.

12.5 Bonding and grounding The most important measure to prevent electrostatic

hazard is to bond all metal objects together, eliminating risk of discharge between

objects, and to assure that all components in the tank handling system are at the same

electrical potential. Equipment should be designed to facilitate bonding and, in particular,

to avoid the insulation of any conducting metal.

Permanently fitted float level gauges do not present a hazard if they are properly

grounded and the guide wires are intact.

12.6 Loose objects Every effort must also be made to ensure removing all loose

objects from a tank and to prevent loose metal objects from falling into a tank.

12.7 Free fall of liquid It is essential to avoid the free fall of water or slops in the oil

tank or a tank used for receiving slops.

The Safety Instrumentation system for Atmospheric storage Tanks for use in

petroleum industry is outlined in Section 4.12 of OISD Standard 152 and the same should

be followed.

13.0 Standard Operating Procedure (S.O.P.) for Electronics Laboratory Personnel

Typically, the Electronics Laboratory contains a wide variety of electrically-powered

equipment including power supplies, test equipments, defective equipments under

repair, heaters, production equipments, computers etc. These and all electrical devices

used in the lab setting present a potential danger of injury due to ? electric shock, fires

due to poorly installed or maintained systems and fires due to sparks serving as an

ignition source for flammable or combustible materials.

Personnel working in Electronic Laboratory of Instrumentation Department must

take some precautions to prevent hazard for which certain guidelines are provided.

The guidelines include maintaining awareness of the condition of lab equipment, the

proper use of lab equipment and safe Operating procedure. .

There is always a potential danger of electric shock or fire wherever there are


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outlets, plugs, wiring or connections, as there are in all labs. In addition to the usual

electrical hazards, some equipments under service, either at the laboratory or at other

departments, have high voltage electrical equipment which poses an even greater

potential problem.

The following are some do’s and don’ts for working with and around electricity.

• Don’t work with electricity if your hands, feet, or other body parts are wet or

when standing on a wet floor.

• Inspect electrical equipment (with power off and unplugged) for frayed cords

and damaged connections — if any are found, do not use the equipment

straightaway— report it to the appropriate person for repair or repair the same

if competent to carry out the same.

• If you receive even a mild shock from a piece of equipment, turn it off for

further probing immediately.

• Don’t use or store highly flammable liquids near electrical equipment — some

materials, such as ether or some other organic solvents, can be ignited by sparks

from electrical equipment.

• Use 3-prong plugs for 3-prong receptacles — never break off or alter a 3-prong

plug to fit into an outlet.

• Extension cords should not be used in place of permanent wiring — their use

should be temporary and they should not be run under doors, across walkways,

through windows or holes in the wall, around pipes or near sinks.

• Don’t overload circuits by using power strips or multiple outlets on regular sockets.

• Don’t remove or alter safety features of high voltage equipment — it is there to

protect you.

Low Voltage Equipments (DC 0 to 50V, AC ) :

• Make sure the power is off when wiring or making changes to circuit.

• Make sure instrumentation is set on proper range for the desired type of

measurement, BEFORE ENERGIZING CIRCUIT.

• Make sure components used are of a rating that will withstand applied current

and voltage.

• Replace blown fuses with the proper ones specified by type and rating.


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• High Voltage Labs (DC 0 to 2000V, AC 1 Phase 230V, 3 Phase 308 - 600V).

• To turn main power on and off in labs locate the mains panel and appropriate

circuit breakers in each lab before starting any work.

• When making connections to benches or panels a circuit breaker of suitable

rating and type must be used between power outlet and your circuit.

• Make sure the power is off when wiring or making changes to circuit.

• Make sure instrumentation is set on proper range for the desired type of

measurement, BEFORE ENERGIZING CIRCUIT.

• Make sure components used are of a rating that will withstand applied current

and voltage.

• Replace blown fuses with the proper ones specified by type and rating.

In the event of electrical shock :

• Do not touch the victim until the power has been shut off. See safety devices

below.

• Do not remove the victim from the electric source until the power has been

shut off.

• If you cannot shut off the power, use an insulator such as a dry rope, cloth or

broom handle to drag the person away from the live wire.

• If the person is breathing, put them in the recovery position. Get Emergency

Care.

• In the event of a mild shock, and the following symptoms are observed, see a

doctor: Heart skipping beats, fever or coughing up sputum.