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
SAFE OPERATING PROCEDURES
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
SAFE OPERATING PROCEDURES
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
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
Safe Operating Procedures
Volume - II
Section - 1
HSE MANAGEMENT
ACTIVITIES
3Safe Operating Procedures – Oil India Ltd.
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.
4 Safe Operating Procedures – Oil India Ltd.
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
5Safe Operating Procedures – Oil India Ltd.
HSE Management
6 Safe Operating Procedures – Oil India Ltd.
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.
7Safe Operating Procedures – Oil India Ltd.
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.
8 Safe Operating Procedures – Oil India Ltd.
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.
9Safe Operating Procedures – Oil India Ltd.
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.
10 Safe Operating Procedures – Oil India Ltd.
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.
11Safe Operating Procedures – Oil India Ltd.
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
12 Safe Operating Procedures – Oil India Ltd.
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.
13Safe Operating Procedures – Oil India Ltd.
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.
14 Safe Operating Procedures – Oil India Ltd.
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.
15Safe Operating Procedures – Oil India Ltd.
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.
16 Safe Operating Procedures – Oil India Ltd.
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.
17Safe Operating Procedures – Oil India Ltd.
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.
18 Safe Operating Procedures – Oil India Ltd.
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.
would forward the same to the statutory authorities.
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.
would forward the same to the statutory authorities.
� 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’
�
19Safe Operating Procedures – Oil India Ltd.
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.
����
20 Safe Operating Procedures – Oil India Ltd.
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.
21Safe Operating Procedures – Oil India Ltd.
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.....
22 Safe Operating Procedures – Oil India Ltd.
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.
23Safe Operating Procedures – Oil India Ltd.
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
24 Safe Operating Procedures – Oil India Ltd.
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
25Safe Operating Procedures – Oil India Ltd.
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.
26 Safe Operating Procedures – Oil India Ltd.
HSE Management
OIL INDIA LIMITED
(A Govt. India Enterprise)
ANNEXURE - ‘F’
27Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
28 Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
29Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
30 Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
31Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
32 Safe Operating Procedures – Oil India Ltd.
HSE Management
ANNEXURE - ‘F’
33Safe Operating Procedures – Oil India Ltd.
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........................................
34 Safe Operating Procedures – Oil India Ltd.
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
35Safe Operating Procedures – Oil India Ltd.
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
36 Safe Operating Procedures – Oil India Ltd.
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
37Safe Operating Procedures – Oil India Ltd.
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..................
Serial No. from Form B
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
38 Safe Operating Procedures – Oil India Ltd.
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.........................
Serial No. from Form B
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
Calculated daily rateof wages of earnings
including conces-sions
Period of leave
availed
Calculated leave
wages for the period
Leave wages
actually paid
Date of payment
Leave In
sta
lment
Calculated daily rateof wages of earnings
including conces-sions
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.
39Safe Operating Procedures – Oil India Ltd.
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.........................................
Serial No. from Form B
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
Date on whichovertime worked
Number of overtime hoursworked on that date
Number of overtimehours in the week
Overtime earning
Date of payment
Week e
ndin
g
Date on whichovertime worked
Number of overtime hoursworked on that date
Number of overtimehours in the week
Overtime earning
Date of payment
Week e
ndin
g
40 Safe Operating Procedures – Oil India Ltd.
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
Date on whichovertime worked
Number of overtimehours worked on
that date
Number of overtimehours in the week
Overtime earning
Date of payment
Week e
ndin
g
Date on whichovertime worked
Number of overtimehours worked on
that date
Number of overtimehours in the week
Overtime earning
Date of payment
Remarks
41Safe Operating Procedures – Oil India Ltd.
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
nce a
nd d
ay o
f re
join
ing a
nd n
ot in
clu
din
g e
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
r w
hen in
jure
d p
ers
on p
roceeds o
n le
ave o
r le
aves h
is e
mplo
ym
ent, p
art
icula
rs s
hould
be e
nte
red
in this
colu
mn.
Noto
:– C
opie
s o
f entr
ies regard
ing p
ers
ons in
jure
d in
pre
cedin
g q
uart
er (s
) and w
ho c
ontinued to a
bsent in
this
quart
er should
als
o b
e s
ubm
itte
d s
epara
tely
.
42 Safe Operating Procedures – Oil India Ltd.
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.
43Safe Operating Procedures – Oil India Ltd.
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
h a
ctio
n ta
ken
Rem
ark
s
Sig
na
ture
of
Wo
rkm
en
’s I
nsp
ecto
r w
ith
da
te :
...
....
....
....
....
....
....
....
....
....
....
....
....
....
..
Sig
na
ture
o
f m
ine
o
ffic
ial
acco
mp
an
yin
g th
e W
ork
me
n’s
In
sp
ecto
r :.
....
....
....
....
....
....
....
Da
te :
Desig
natio
n
44 Safe Operating Procedures – Oil India Ltd.
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).
45Safe Operating Procedures – Oil India Ltd.
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.”;]
46 Safe Operating Procedures – Oil India Ltd.
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.............................
47Safe Operating Procedures – Oil India Ltd.
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.............................
48 Safe Operating Procedures – Oil India Ltd.
HSE Management
FORM VI
(See regulation 51)
NOTICE OF CONSTRUCTION OF OR ALTERATION IN
A GROUP GATHERING STATION.
From
.....................................
.....................................
.....................................
TO,
1. The Chief Inspector of Mines, Dhanbad-826001
2. The Regional Inspector of Mines
.............................. 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 ...................................
49Safe Operating Procedures – Oil India Ltd.
HSE ManagementFORM VII
(See regulation 51)
SAFETY REPORT
From
........................
........................
To,
1. The Chief Inspector of Mines, Dhanbad-826001
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.
50 Safe Operating Procedures – Oil India Ltd.
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 ...........................
51Safe Operating Procedures – Oil India Ltd.
HSE ManagementFORM-VIII
(See regulation 61)
PERMISSION FOR LAYING A NEW PIPELINE OR MAKING
ANY SIGNIFICANT ALTERATION IN EXISTING PIPELINE
From
........................
........................
TO,
1. The Regional Inspector of Mines
.......................... 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 ...........................
52 Safe Operating Procedures – Oil India Ltd.
HSE Management
53Safe Operating Procedures – Oil India Ltd.
HSE Management
54 Safe Operating Procedures – Oil India Ltd.
HSE Management
55Safe Operating Procedures – Oil India Ltd.
HSE Management
56 Safe Operating Procedures – Oil India Ltd.
HSE Management
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 2
ELECTRICAL ENGG. ACTIVITIES
2 Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
VOLUME - II SECTION - 2
ELECTRICAL ENGINEERING ACTIVITIES
3Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
4 Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
5Safe Operating Procedures – Oil India Ltd.
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.
6 Safe Operating Procedures – Oil India Ltd.
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
7Safe Operating Procedures – Oil India Ltd.
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
8 Safe Operating Procedures – Oil India Ltd.
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
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) 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
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.
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
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) 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
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.
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.
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 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
15Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
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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Electrical Engg.
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.
21Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
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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24 Safe Operating Procedures – Oil India Ltd.
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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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27Safe Operating Procedures – Oil India Ltd.
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.
28 Safe Operating Procedures – Oil India Ltd.
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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.
a. Inform the Driller-in-charge & mechanical JE before starting the job.
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:
a. Inform the Driller-in-charge & mechanical JE before starting the job.
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.
30 Safe Operating Procedures – Oil India Ltd.
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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
extreme care while working in SCR panel due to presence of un-insulated high voltage
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
extreme care while working in SCR panel due to presence of un-insulated high voltage
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
31Safe Operating Procedures – Oil India Ltd.
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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.
52 Safe Operating Procedures – Oil India Ltd.
Electrical Engg.
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
1Safe Operating Procedures – Oil India Ltd.
Fire Service
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 3
FIRE SERVICE
ACTIVITIES
2Safe Operating Procedures – Oil India Ltd.
Fire Service
VOLUME - II SECTION - 3
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
3Safe Operating Procedures – Oil India Ltd.
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.
4Safe Operating Procedures – Oil India Ltd.
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
5Safe Operating Procedures – Oil India Ltd.
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
6Safe Operating Procedures – Oil India Ltd.
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).
7Safe Operating Procedures – Oil India Ltd.
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.
8Safe Operating Procedures – Oil India Ltd.
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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
9Safe Operating Procedures – Oil India Ltd.
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
10Safe Operating Procedures – Oil India Ltd.
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.
11Safe Operating Procedures – Oil India Ltd.
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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)
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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
13Safe Operating Procedures – Oil India Ltd.
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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
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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.
15Safe Operating Procedures – Oil India Ltd.
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.
16Safe Operating Procedures – Oil India Ltd.
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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.
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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.
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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.
19Safe Operating Procedures – Oil India Ltd.
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
20Safe Operating Procedures – Oil India Ltd.
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
Digboi (IOC - AOD) - 222
Ambulance Call : Duliajan - 6361
Moran - 312
Manabhum - 305
Digboi (IOC - AOD) - 282
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.
21Safe Operating Procedures – Oil India Ltd.
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
22Safe Operating Procedures – Oil India Ltd.
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)
1Safe Operating Procedures – Oil India Ltd.
Field Engg.
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 4
FIELD ENGG. ACTIVITIES
2Safe Operating Procedures – Oil India Ltd.
Field Engg.
VOLUME - II SECTION - 4
FIELD ENGG. ACTIVITIES
CONTENTS
SL. NO. DESCRIPTION PAGE NO.
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
3Safe Operating Procedures – Oil India Ltd.
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.
4Safe Operating Procedures – Oil India Ltd.
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.
2) Vacuum pump with electric motor (1.5 HP) — 2 nos.
3) Sluice valve with 300 mm dia wheel — 3 nos.
4) Sluice valve with 275 mm dia wheel — 3 nos.
5) Non-return valve of 275 mm dia — 3 nos.
6) Sluice valve with 75 mm dia wheel — 2 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.
3) Vacuum pump with electric motor (0.5 HP) — 2 nos.
4) Non-return valve of 100 mm dia — 2 nos.
5) Sluice valve with 200 mm dia — 1 no.
5Safe Operating Procedures – Oil India Ltd.
Field Engg.
6Safe Operating Procedures – Oil India Ltd.
Field Engg.
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)
7Safe Operating Procedures – Oil India Ltd.
Field Engg.
8Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
9Safe Operating Procedures – Oil India Ltd.
Field Engg.
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)
10Safe Operating Procedures – Oil India Ltd.
Field Engg.
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)
11Safe Operating Procedures – Oil India Ltd.
Field Engg.
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)
12Safe Operating Procedures – Oil India Ltd.
Field Engg.
13Safe Operating Procedures – Oil India Ltd.
Field Engg.
PUMP HOUSE (fig. - 9)
14Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
15Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
16Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
17Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
18Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
19Safe Operating Procedures – Oil India Ltd.
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.
20Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
21Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
22Safe Operating Procedures – Oil India Ltd.
Field Engg.
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)
23Safe Operating Procedures – Oil India Ltd.
Field Engg.
iv)
v)
5.6 FOR OPERATING HEAT EXCHANGER
24Safe Operating Procedures – Oil India Ltd.
Field Engg.
9.0 Emergency Shut-Down
i)
ii)
25Safe Operating Procedures – Oil India Ltd.
Field Engg.
5.7 FLOW IMPROVER CHEMICAL HANDLING SET-UP
26Safe Operating Procedures – Oil India Ltd.
Field Engg.
5.8 FOR OPERATING CHEMICAL DOZING PUMP SET
27Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
28Safe Operating Procedures – Oil India Ltd.
Field Engg.
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”
29Safe Operating Procedures – Oil India Ltd.
Field Engg.
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
30Safe Operating Procedures – Oil India Ltd.
Field Engg.
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.
31Safe Operating Procedures – Oil India Ltd.
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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.
32Safe Operating Procedures – Oil India Ltd.
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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.
33Safe Operating Procedures – Oil India Ltd.
Field Engg.
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
34Safe Operating Procedures – Oil India Ltd.
Field Engg.
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
35Safe Operating Procedures – Oil India Ltd.
Field Engg.
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
1Safe Operating Procedures – Oil India Ltd.
Transport Engg.
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 5
TRANSPORT ENGG.
ACTIVITIES
2Safe Operating Procedures – Oil India Ltd.
Transport Engg.
VOLUME - II SECTION - 5
TRANSPORT ENGG. ACTIVITIES
CONTENTS
SL. NO. DESCRIPTION PAGE NO.
SEC-1 M O TOR VEHICLE OPERATION ..................................................................... 1
SEC-2 CRANE OPERATION....................................................................................... 4
SEC-3 M ATERIAL HANDLING OPERATION .............................................................. 8
3Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
4Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
5Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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:
6Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
7Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
8Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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:
9Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
10Safe Operating Procedures – Oil India Ltd.
Transport Engg.
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.
11Safe Operating Procedures – Oil India Ltd.
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.
12Safe Operating Procedures – Oil India Ltd.
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.
13Safe Operating Procedures – Oil India Ltd.
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.
14Safe Operating Procedures – Oil India Ltd.
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.
1Safe Operating Procedures – Oil India Ltd.
Civil Engg.
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 6
CIVIL ENGG.
ACTIVITIES
3Safe Operating Procedures – Oil India Ltd.
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.
5Safe Operating Procedures – Oil India Ltd.
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.
7Safe Operating Procedures – Oil India Ltd.
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.
9Safe Operating Procedures – Oil India Ltd.
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.
11Safe Operating Procedures – Oil India Ltd.
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.
13Safe Operating Procedures – Oil India Ltd.
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.
15Safe Operating Procedures – Oil India Ltd.
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.
17Safe Operating Procedures – Oil India Ltd.
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.
19Safe Operating Procedures – Oil India Ltd.
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.
1Safe Operating Procedures – Oil India Ltd.
Drilling-Ts.
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 7
DRILLING - TS
ACTIVITIES
3Safe Operating Procedures – Oil India Ltd.
Drilling-Ts.
SAFE OPERATING PROCEDURES
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.
5Safe Operating Procedures – Oil India Ltd.
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.
7Safe Operating Procedures – Oil India Ltd.
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.
9Safe Operating Procedures – Oil India Ltd.
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.
11Safe Operating Procedures – Oil India Ltd.
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
1Safe Operating Procedures – Oil India Ltd.
Instrumentation
OIL INDIA LIMITED
Safe Operating Procedures
Volume - II
Section - 8
INSTRUMENTATION
ACTIVITIES
2 Safe Operating Procedures – Oil India Ltd.
Instrumentation
VOLUME - II SECTION - 8
INSTRUMENTATION ACTIVITIES
CONTENTS
SL. NO. DESCRIPTION PAGE NO.
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
3Safe Operating Procedures – Oil India Ltd.
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
4 Safe Operating Procedures – Oil India Ltd.
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 :
5Safe Operating Procedures – Oil India Ltd.
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.
6 Safe Operating Procedures – Oil India Ltd.
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.
7Safe Operating Procedures – Oil India Ltd.
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
8 Safe Operating Procedures – Oil India Ltd.
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.
9Safe Operating Procedures – Oil India Ltd.
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.
10 Safe Operating Procedures – Oil India Ltd.
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
11Safe Operating Procedures – Oil India Ltd.
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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.
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• 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.
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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.
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• 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
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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
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• 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.
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• 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
20 Safe Operating Procedures – Oil India Ltd.
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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
21Safe Operating Procedures – Oil India Ltd.
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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
24 Safe Operating Procedures – Oil India Ltd.
Instrumentation
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.