STANDARD OPERATING

PROCEDURE
OPERATION & MAINTENANCE OF
HYDROCARBON PIPELINE

This Manual describes the Standard Operating Procedures (SOPs) for Operation &
Maintenance of Hydrocarbon Pipeline. The compliance to Manual is mandatory for all works
listed down in this document.

NOTE: This Manual is property of SANMARG Projects Pvt Ltd, and any unauthorized use of this Document is prohibited.
 SANMARG PROJECTS PRIVATE LIMITED
SPPL/MANUAL/O&M/01
A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

A MANUAL ON STANDARD OPERATING PROCEDURE OF HYDROCARBON

PIPELINE MAINTENANCE

TABLE OF CONTENTS
Sr. No. Description Page No.

1 Preface 2

2 Introduction 3

3 Purpose 3

4 Objective 4

5 Scope 4

6 Health, Safety and Environment 5

7 Configuration of Pipeline System 6

8 List of Equipment and Instrument Used 7

9 Mobilization Plan and Checklist on Award of Contract 11

10 Demobilization 15

11 PIC/SIC Roles and Responsibilities 20

12 Site photographs 24

13 Standard Operating Procedure 25

14 References 421

15 Philosophy 425

Note: The above procedure / formats need to be read in conjunction with SPPL IMS Manual

(SPPL/IM-01) and after document of references.

*IMS Integrated Management System (ISO 9001:2015 14001:2015 and OHSAS 18001:2007)

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A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

PREFACE
Petroleum Industry is the energy lifeline of the nation and its continuous performance on sustainable
performance is essential for continual development, sovereignty and prosperity of the country.

SANMARG is a big stake holder in the Indian Petroleum Industries and providing best Engineering and Knowledge
based Management Services. So far it has completed more than 50 projects and 25 assignments are ongoing in
the energy sector. Majority of the completed and ongoing assignments pertains to operation, upkeeping and
maintenance of mainline, equipment’s and other assets of the running cross-country pipelines (Oil and Gas) and
allied installations to ensure un-interrupted supply of crude oil, Petroleum products. LPG, Gas to the end users.

SANMARG is totally committed to Quality and Ontime delivery of oil/gas by maintaining the assets efficiently,
safely and environment friendly manner for which it has acquired latest certification of ISO-9001:2015 (Quality),
ISO 14001:2015 (Environment) OHSAS 18001:2007 (Occupational Health and Safety).

SANMARG was hitherto adopting SOPs manual which was the part of old ISO 9001 system and was last updated
in March’2015. Since then lot of changes have been taken place due to updating in the technology, OISD
guidelines and addition of new contracts. Although updated codes and standards were in practice, there was a
need to upgrade the existing SOP manual pertaining to O& M activities being undertaken for the Operational Oil
and Gas Pipelines.

The updated manual consists of SOPs on various pipeline maintenance works pertaining to ROU (Right of Use),
Mechanical, Electrical, Cathodic Protection, Related to Mainline emergency handling due to leak and pilferage.
However as and when Sanmarg undertakes operations work, the related SOPs shall be added / modified
progressively.

Sanmarg Projects aims to achieve 100 percent availability of the assets through a quality and timely maintenance
so that Client’s commitment to supply the quality and on time delivery of products to their customers is honored.

The manual on SOPs shall be useful to all concerned who are involved in the maintenance of the Oil & Gas
Pipelines in operation.

The manual will be reviewed and updated once in two years depending upon technology improvement /
additions of new works

Date: Sanjay Kaul

Managing Director

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1. INTRODUCTION:
The pipeline network is a transportation system used to move liquid, gas or slurry. The most
common products transported for energy purposes include Natural Gas, biofuels, and liquid
petroleum etc.

Oil and gas (O&G) pipelines are expensive assets that cross through both the ecologically sensitive
and densely populated urban areas. The pipeline failure may have potentially significant
consequences for both the natural and human environments. In order to maintain the integrity of
O&G pipelines, inspection and maintenance processes should be governed by efficient policies.
Maintenance policies can be categorized into corrective, preventive, predictive and proactive.

There are two main categories of pipelines used to transport energy products: petroleum pipelines
and natural gas pipelines.

i. Petroleum pipelines transport crude oil or natural gas liquids, and there are three main
types of petroleum pipelines involved in this process: gathering systems, crude oil pipeline
systems, and refined products pipelines systems. The gathering pipeline systems gather the
crude oil or natural gas liquid from the production wells. Then it is transported through
crude oil pipeline system to a refinery. Once the petroleum is refined into products such as
Diesel, gasoline or kerosene etc. it is transported via the refined products pipeline systems to
storage or distribution stations.

ii. Natural gas pipelines transport natural gas from stationary facilities such as gas wells or
import/export facilities, and delivered to a variety of locations, such as homes or directly to
other export facilities. This process also involves three different types of pipelines: gathering
systems, transmission systems, and distribution systems. Like the petroleum gathering
systems, the natural gas gathering pipeline system gathers the raw material from production
wells. It is then transported with large lines of transmission pipelines that move natural gas
from facilities to ports, refiners, and cities across the country. Lastly, the distribution systems
consist of a network that distributes the product to homes and businesses. The two types of
distribution systems are the main distribution line, which are larger lines that move products
close to cities, and the service distribution lines, which are smaller lines that connect main
lines into homes and businesses.

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2. PURPOSE:
The purpose of this document is standardization of operational procedure and to have an
effective pipeline operations & maintenance system, ensuring overall safety of pipeline.

3. OBJECTIVE:
Once a pipeline system is successfully constructed and commissioned for operation, it is the
responsibility of the operations and maintenance personnel to operate and maintain the
pipelines with the safety of the public and operating personnel and to prevent pipeline failures
through proactive measures such as periodical maintenance / monitoring / checks & balance
thru the standard operating procedures.

4. SCOPE:
The scope of any maintenance contract is divided in two parts.

1. Technical Scope: This involves the technical work which is to be implemented thru the
related SOPs. These SOPs shall form part of procedure to be adopted while carry out the
technical jobs related to maintenance of pipeline.
Following are the few major maintenances which are required during operation and maintenance of
Pipelines.

Mechanical Maintenance
• Valves Operation & Maintenance
• Maintenance of Filters
• O & M of Launcher & Receiver Barrels
• O&M of Pig handling facilities
• Support Services for Pigging activities
• Ultrasonic Thickness gage – Thickness Survey
• Ultrasonic flow detector - FLAW Detection
• Leak Repair and Welding
• Sleeve Welding
• Pipe Support Modification

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Electrical/CP
• Battery bank maintenance
• Cleaning of all electrical panels, monitoring & recording of electrical parameters
• PSP ON survey for pipeline, checking integrity of Insulating Joints
• Checking and maintenance of Earth pits
• Monitoring and maintenance of Anode Bed.
• Close interval potential Survey / Current attenuation test / Direct current Voltage gradient
Survey
• Anode Bed Installation
• Locating Pilferage point by DCVG survey

2. Commercial Scope: This involves the schedule of works to be executed in the contracts,
involving specification, payment etc.

5. HEALTH SAFETY AND ENVIROMENT:

Health, Safety & Environment (HSE) will be the topmost priority to the operation of our organization
and constitute an integral part of our business process. We will follow our HSE Vision by adopting an
integrated approach to the management of Health, Safety & Environment by focusing on
employees, Users, Processes, Systems, Technology and Facilities. HSE in the organization will be
driven by the leadership and be demonstrated through employee commitment at all levels.

Our HSE policy spell out our commitment to prevent, reduce or eliminate all undesired events in
operations that could result in injury, loss of property /Life or damage environment.

This policy is implemented by establishing, and adhering to the HSE management system as under:

• Complying with all the applicable codes and statutory requirements to promote occupational
health, safety and environment care.
• Working in tandem with our clients, following their HSE policies, procedures and requirements.
Proper focus and attention are paid to specific requirements of clients and customers in respect
of health, safety and environment care practices.
• Imparting relevant training with validation to all our employees and contractors. We shall
continuously enhance our awareness and involvement in promoting occupational health, safety
and environmental care.
• Conducting regular HSE audits and inspections at working sites to ensure compliance of safe
procedures.
• Periodic reporting of HSE performance.

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• Taking all actions necessary to protect the integrity of the systems in order to avoid accidental
related of any hazardous substances.
• Receiving of Near-Misses incidents regularly & encourage it.
• Investing in detail any incident including the minor ones and followed by recommendations to
avoid recurrence.
• Keeping ourselves abreast with the latest international codes, standards and practices.
• Learning lesson from accidents in similar industry and taking steps to prevent such accidents in
our operations.
• Being always alert, equipped and ready to respond to emergencies.

6. TYPICALLY, CONFIGURATION OF PIPELINE SYSTEM: -

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7. LIST OF EQUIPMENT AND INSTRUMENTS: -

Following is the typical list of equipment’s and instruments frequently used during maintenance of
oil and gas pipeline is

i. Tyre Mounted Crane.

ii. Pipe Trailer.
iii. Excavator/Backhoe.
iv. Grit Blasting Unit with Compressor.
v. Beveling/Cutting Machine.
vi. Welding Machine.
vii. DG Set.
viii. Rectifier.
ix. Chain pully Block
x. Holiday detector.
xi. Digital Ultrasonic Thickness Gauge.
xii. Wet Film Thickness Gauge.
xiii. Thermo Meter.
xiv. Multi-Purpose Weld Gauge.
xv. Digital Insulation Tester (Meggar)
xvi. Degree Protector.
xvii. Filler Gauge.
xviii. Digital Clamp Meter.
xix. Gas detector.
xx. Pipeline Locator.
xxi. Pin brazing machine/CAD welding Machine

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Tyre Mounted Crane Pipe Trailer

Excavator/Backhoe Grit Blasting Unit with Compressor

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Beveling/Cutting Machine Welding Machine

DG Set Rectifier

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Pin brazing machine Holiday detector

Pipeline Locator Filler Gauge

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8. MOBLIZATION PLAN AND CHECKLIST ON AWARD OF CONTRACT:

Mobilization plan covers the following

A. Scope of work.
It includes briefing of work, deliverables, time duration of contract, penalty, bonus for early
completion and payment terms.

B. Time plan of project schedule: Typical

Sample time plan is as follows.

08/06/2018 To

15/06/2018 To

22/06/2018 To

29/06/2018 To

06/07/2018 To

13/07/2018 To

20/07/2018 To

27/07/2018 To
14/06/2018

21/06/2018

28/06/2018

05/07/2018

12/07/2018

19/07/2018

26/07/2018

02/08/2018
ACTIVITIES

Mobilization

Positioning of manpower, vehicle

accommodation at Site

Arrangement & Procurement of Tools,

Tackles and Consumables.

Completion

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C. Mobilization schedule and responsibilities – Format No. 1

Finished
Start Date
S.No. Description of Action Date Responsibility Remarks
(Tentative)
(Tentative)
1 FOA / LOA No.

2 Contract period

3 Kick -Off meeting

4 Submission of Bank Account Details

5 Signing of Contract agreement with

as per format on non-judicial stamp
paper of appropriate value

6 Duly signed copies of LOA to be sent

by SANMARG as receipt of letter of
acceptance.

Bank Guarantee
7
Labor License
8
Electrical License
9
Individuals Police Verification
10
Employee Insurance under
11 workmen compensation Act.

Submission of necessary EPF & ESIC

12 code, before commencement of
work.

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D. Mobilization – Format No. 2

Finished
Start Date
S.No. Description of Action Date Responsibility
(Tentative) Remarks
(Tentative)

1. Mobilization Period

2. Nomination/Deputing qualified
engineer as Project-In-Charge

3. Manpower deployment

4. Accommodation Arrangements

5. Vehicle Arrangement

6. Instruments/Tools and Tackles

7. PPEs, Uniform, ID cards

9. Budget Circulation

E. Manpower to be deployed- Format No. 3

Sr. List of No. of Qualification Blood Group Remarks

No. Manpower Manpower
Required

1
2
3
4
5

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F. List of PPE’s – Format No. 4

Sr. PPE’s Qty Remarks

No.
1 Safety shoes with steel toe cap as per IS:5852
2 Safety goggles IS:7524
3 Dangri, Torches, First Aid Kit
4 Safety helmet (IS:2925-1984)
5 Dotted hand gloves
6 Insulated rubber hand gloves (25 KVA)

G. List of equipment, instruments, tools and inventory – Format No. 5

Sr. Item Descriptions Quantity Ref. of Validity of Remarks

No Calibration load calibration
test etc. certificate
1
2
3
4
5

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9. DEMOBLIZATION PLAN AND CHECKLIST:

A. Demobilization plan – Format No. 5

Project Name Client Name

Project Duration Project Start Date Project End Date

Project Extension Defect Liability Period PBG Claim Period

PBG Amount PBG Validity Retention Money

Contract Value Executed value as on Date

Total Manpower Engineers Technicians

Project In-charge/
Mobile
Site In-charge E-Mail ID
Engineer In-charge of
Mobile
Client E-Mail ID
Handing Over
- -
Documents

B. Responsibilities of respective departments – Format No. 6

1. PIC's / SITE SPECIFIC ACTIVITIES

COMPLE
Sr. STATUS AS ON
ACTIVITY DESCRIPTION RESPONSIBILITY TION
No. ___________
DATE
Site attendance sheet duly certified
1.1 PIC
by EIC of Client
JMS to be signed for preparation of
1.2 PIC
final bill
1.3 Invoice to be submitted along with all PIC/Operation/

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reports and supporting documents Finance

Area cleaning / Restoration and

temporary stores / office to be
1.4 PIC
removed and clearance to be taken
from EIC / Client
Reconciliation of supplied
items/materials to be checked, PIC/Materials
1.5
verified and submitted to client for Finance
payment
Bills of all local vendors / contractors
1.6 PIC/ Finance
to be cleared
Reconciliation of Free Issue Materials
1.7 (FIM) by clients and NOC for their PIC
handover to the client
NOC to be taken from different
1.8 departments of Client / Local PIC
Authority for processing of final bill

2. HR DEPARTMENT'S SPECIFIC ACTIVITES

COMPLE
Sr. STATUS AS ON
ACTIVITY DESCRIPTION RESPONSIBILITY TION
No. ___________
DATE

Notice to be issued to contract

employees as per employment HR
conditions, whose services are not
2.1 further needed
Employees to be retained and their
relocation plan need to be finalized HR / OPERATIONS
2.2 prior to closure of project
Compilation of Wage register
HR
2.3 indicating PF A/C no. & IP no.
PF-electronic challan & ECR
HR
2.4 Highlighting employee at site

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Labour welfare fund challan, if HR

2.5 applicable

Notice of commencement &

completion, if any, to the labour HR
department / other concerned
2.6 departments
Reconciliation of Bonus/leave
encashment of departing employees HR
2.7 to be kept ready
Experience letter / Reliving Letters to
HR
2.8 be issued to Employees
Notice to be issued to vehicle owners
of hired vehicles for releasing of PIC / Admn
2.9 vehicles
Notice to be issued to Guest house’s PIC / Admn /
2.10 owners for vacating the guest house Operations
Reconciliation and Shifting of all the
office assets, Infrastructure HR / Admn/
equipment, documents, manuals, PIC
2.11 transit camp materials etc.

3. MATERIALS / PROCUREMENT DEPARTMENT'S SPECIFIC

ACTIVITIES

COMPLE
Sr. STATUS AS ON
ACTIVITY DESCRIPTION RESPONSIBILITY TION
No. ___________
DATE
Reconciliation of tools, tackles,
PIC / Operations /
instruments, equipment, PPE, etc.
Materials
3.1 w.r.t asset register

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Shortfall in issued tools, tackles,

instruments, equipment, PPE, etc. for
the project and approval of write- off PIC / Operations /
to be taken from competent Materials
authority for any short fall before
3.2 transfer of PIC
Reconciliation of balance
consumables/materials at site and PIC / Operations /
further shifting to other sites as per Materials
3.3 direction

4. CONTRACT / OPERATIONS / FINANCE DEPARTMENT

SPECIFIC ACTIVITIES

COMPLE
Sr. STATUS AS ON
ACTIVITY DESCRIPTION RESPONSIBILITY TION
No. ___________
DATE
Status for any Contract Amendment /
Contract /
Quantity / SOR items Amendment
Operations
4.1 request made to the client
Billing / Payment status of any extra
work / SOR items carried out during Finance / Operations
4.2 execution of Project
Indemnity bond on judicial stamp
paper duly notarized as per client’s Contract
4.3 requirement
Final Bill Submission along with all
necessary Compliance Certificates,
Challans, reports and closure Finance / Operations
documents as per client’s
4.4 requirement
Financial Reconciliation for the
project regarding any balance Finance
4.5 payment
Professional tax challan or any kind
Finance
4.6 of applicable taxes, if applicable.
Performance Bank Guarantee to be
Finance / Contracts
4.7 extended, if the contract is extended

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by client

Bank Guarantee / Retention Money

Finance / Contracts
4.8 status
Submission of No dues certificate to
Contract / Finance
4.9 client
Application for Completion Operations /
4.10 Certificate Contracts
Lessons learnt to be discussed,
documented, distributed and PIC / Operations
4.11 archived
Submission of Project Profitability
Finance
4.12 report with Management

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10. PIC ROLES AND RESPONSIBILITIES:

Project Incharge (PIC) / Site Incharge

a) Technical

A1 Reports to Project-head.

A2 Ensure Operation and Maintenance for Pipeline, Terminals & Terminals & another
establishment under the specified contract.

A3 Ensure to carry out all activities required for maintenance of ROU (Right of user),
Mechanical, Instrumentation and Electrical, Telecom, as per specified schedule and
approved SOP (Standard Operating Procedure) of respective activities under the contract.

A4 Interact with Engineer-in-Charge & ensure timely completion of all operation and
maintenance activities as per contract delivery schedule.

A5 Ensure process evaluation of work assigned in terms of Delivery / Quality & Reliability
performance by close interaction with EIC.

A6 Ensure mobilization of resources as per contract & within time.

A7 Ensure timely availability of all resources i.e. tools, consumables, instruments, Vehicles etc.
& maintain Mobile Maintenance Vehicle (MMV)/ Emergency Response Vehicle (ERV) to
complete the assigned work & take remedial corrective and preventive measures accordingly.

A8 Ensure maximum execution of SOR items.

A9 Ensure calibration of all measuring instruments under the contract & maintain the records.

A10 Plan the activities calendar for month, then break into week and daily activities.

A11 Prepare monthly program v/s actual achieved in the past and program for next month.

A12 Keep the track of delays and reasons thereof. Augment the resources to bridge the gaps.

A13 Maintain and update data & records as per Client’s requirements.

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b) Financial/Commercial

B1 Consolidate & checking the measurement of work by all Base-Incharges by 3rd day of
succeeding month and countersigning by Engineer-in-Charge.
B2 Preparation of running bill based upon signed measurement sheets of all Base Incharges by
7th day of succeeding month.
B3 Source the invoice number from HO.
B4 Submission of bill with all supporting documents with EIC: By 10th of succeeding month.
B5 Follow up and ensure that EIC certified bill is forwarded to Client Finance deptt for
payment: By 15th of succeeding month.
B6 Ensure Sub-contractors / vendors bills are processed well in time and forwarded to HO By
15th of succeeding month.
B7 Maintain the best customer relations with client and other stake holders.
B8 Keep yourself updated with happenings in respective fields to enhance your business
confidence.
B9 Inventory stock – Ensure that all hardware, office furniture, tool-tackles & consumables stocks
are periodically.
B10 As a part of PIC Role – The incharge also should be ensure the availability of following –
Availability of Resources nearby market.
Availability of details related to Contact like, Local Hospitals, Local Police, Fire brigade no. etc.

c) Statutory/Legal/Standard
C1 Ensure compliance under various Labour / Industrial laws as specified in the contract.
C2 Responsible for Environmental Aspects/Impact analysis and its program and feed back to
HO for updating at least annually.
C3 Responsible for compliance of Environmental legislation & regulations and feed back to
HO.
C4 Responsible for identification of Risk under OH&S and reviewed/updated at least
annually.
C5 Responsible for compliance of occupational legislation & regulations and feed back to HO.
C6 Responsible & accountable for aspects of OH&S under his control, including adherence to
organization’s applicable OH&S requirements.

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C7 Responsible & accountable for implementation of Quality Management Systems,

Environment Management System and Occupational Health and Safety Management System
as per ISO 9001:2015, ISO-14001:2015 and ISO 45001:2018 standard in & around the
site.
C8 Identification of Training needs and awareness i.e. Hazard identification, risk assessment
and determination of controls (HIRA DC) related to
➢ Human factors such as behavior, capabilities.
➢ Hazards originating outside of the workplace.
➢ Checked, reconciled & documented as per SOP, the same is to be shared with HO.
➢ Hazards created in the vicinity of the work-related activities.
➢ Change management in terms of modifications to OH&S management system.
➢ Legal obligations on the conduct of HIRA.

C9 Occupational safety of workmen, Visitors and all employees as per OH&S.

C10 Establishment, implementation and maintenance of a procedure for identifying and

accessing applicable legal and other OH&S requirements as well as the requirement to
communicate relevant information on legal and other requirements to personnel working
under its control and to other relevant interested parties.

C11 Keep handy and display local phone numbers – Police, Fire Station, Ambulance etc.

d) Administrative

D1 Ensure transportation facilities are well maintained, mileages are logged on daily basis

D2 Ensure timely submission of vendor’s bill to HO for release of payments.

D3 Ensure necessary Site office/Go down/workshop, guest house accommodation is well

maintained with basic ethics of joint livings

D4 Be vigilant and no anti-social activity to be allowed in our premises

D5 Keep handy and display local phone/Mobile numbers/address of workforce under his control,
HO, Police, Fire Station and Ambulance etc.

e) Liaison with HO

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E1 The due priority is to be accorded to queries from HO and replied.

E2 Daily/weekly/monthly reports to be mailed on time

E3 Prepare budget for your region and share with HO in time for fund flow.

E4 Look out for new business opportunities for our expanded engagement.

E5 Explore other business areas where you think we can engage and bring to BD, HO
knowledge.

E6 Following support shall be ensured whenever any official from HO visits sites.

➢ Arrange meeting with Client/EIC.

➢ Arrange meeting with all staff as per requirement.
➢ Keep ready the Performance reports and status of all activities as per specified
format/check list.
➢ Keep all registers ready as per statutory requirements
➢ Update all information in the register
➢ Keep ready all queries or difficulties in any work and areas of improvement Discuss
business opportunities.
➢ Keep ready what support is required from HO for smooth and efficient working.

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11. SITE PHOTOGRAPHS:

Spray painting – Prevalence

Maintenance Sub: Toolbox Talk –
Before start of the day

Repair work at cross country Location

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Sanmarg Projects Private Limited

12. STANDARD OPERATING PROCEDURE (SOP): ANNEXURE -A

PREPARED BY CHECKED BY APPROVED BY

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ANNEXURE-A

LIST OF STANDARD OPERATING PROCEDURE

SR. Pg. No.

DESCRIPTION SOP NO.
NO.

1 ROU Maintenance and Emergency Preparedness SPPL/SOP/01 31-33

2 Inspection and Removal of Encroachments SPPL/SOP/02 34-36

3 Inspection of ROU Washout and Excavation SPPL/SOP/03 37-39

4 Line Walk/Patrolling SPPL/SOP/04 40-42

5 Routine Maintenance of Ball Valve SPPL/SOP/05 43-45

6 Yearly maintenance of Ball Valve SPPL/SOP/06 46-48

7 Sump Pump Maintenance Procedure SPPL/SOP/07 49-51

8 Sump Pump Operation Procedure SPPL/SOP/08 52-54

9 Slop Pump Maintenance Procedure SPPL/SOP/09 55-58

10 Slop Pump Operation Procedure SPPL/SOP/10 59-61

11 Meter Testing Calibration SPPL/SOP/11 62-63

12 Maintenance of Metering Pump SPPL/SOP/12 64-66

13 Monthly Maintenance of Plug valve SPPL/SOP/13 67-71

14 Borewell Operation Procedure SPPL/SOP/14 72-76

15 Fire Extinguisher and Fire Alarm System Maintenance Procedure SPPL/SOP/15 77-85

16 Attending mainline Leakage or Pilferage Maintenance Procedure SPPL/SOP/16 86-89

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 SANMARG PROJECTS PRIVATE LIMITED
SPPL/MANUAL/O&M/01
A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

SR. Pg. No.

DESCRIPTION SOP NO.
NO.

17 Pigging Operation Procedure SPPL/SOP/17 90-99

18 River/Water Course Crossing inspection and Maintenance Procedure SPPL/SOP/18 100-104

19 Scrapper Barrell Maintenance Procedure SPPL/SOP/19 105-111

20 Pipe Valve Thickness Measurement SPPL/SOP/20 112-115

21 Venting at Cased Crossing location Operation Procedure SPPL/SOP/21 116-120

22 Pest & Rodent Control SPPL/SOP/22 121-123

23 Earth Resistance Test Operation Procedure SPPL/SOP/23 124-131

24 Extension of Casing Pipe SPPL/SOP/24 132-134

25 Direct Current Voltage Gradient (DCVG) SURVEY SPPL/SOP/25 135-142

26 Sleeve Welding SPPL/SOP/26 143-147

27 Installation of Clock Spring SPPL/SOP/27 148-151

28 Excavation and Backfilling Near Live Line SPPL/SOP/28 152-155

29 Recoating using Visco Elastic Coating Material SPPL/SOP/29 156-158

Non – Destructive Test using Ultrasonic Flaw Detector and Ultrasonic 159-162
30 SPPL/SOP/30
Thickness Meter

31 Pipeline Leak Repair SPPL/SOP/31 163-176

32 Procedure for Replacement of Mechanical seal SPPL/SOP/32 177-180

33 Procedure for Cartridge or Basket filter cleaning SPPL/SOP/33 181-183

34 Procedure for Lube oil replacement of mechanical seal SPPL/SOP/34 184-187

35 Procedure for CI & Dosing of Pumps SPPL/SOP/35 188-190

36 Procedure for Painting of above ground piping structure SPPL/SOP/36 191-194

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 SANMARG PROJECTS PRIVATE LIMITED
SPPL/MANUAL/O&M/01
A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

SR. Pg. No.

DESCRIPTION SOP NO.
NO.

37 Procedure for Underground Sump Tank Cleaning SPPL/SOP/37 195-197

38 Procedure for Calibration & Inspection Overhauling of TSV'S SPPL/SOP/38 198-199

39 Procedure for Prevention Maintenance of Plug Valves SPPL/SOP/39 200-204

40 Procedure for Strainer Cleaning of a Pump SPPL/SOP/40 205-207

41 Procedure for Flow Meter Removal and Fitting of Spool Piece SPPL/SOP/41 208-210

42 Repair of Welding Joint of Pump Casting and Vent Drain Piping SPPL/SOP/42 211-214

43 Procedure for Prevention Maintenance of Pumps SPPL/SOP/43 215-218

44 Procedure for Replacement of Pipeline Section SPPL/SOP/44 219-222

45 Coating Defects Survey SPPL/SOP/45 223-225

46 Maintenance of PSP Monitoring Operation SPPL/SOP/46 226-233

47 Inspection & Maintenance of CP Panel & Its System Operation SPPL/SOP/47 234-239

48 Rectification of Damaged Coating Maintenance SPPL/SOP/48 240-244

49 Maintenance of TR Unit SPPL/SOP/49 245-247

50 CIPS Survey SPPL/SOP/50 248-253

51 Current Attenuation Test Survey SPPL/SOP/51 254-257

52 Polarization Coupon Installation &Measurement SPPL/SOP/52 258-265

53 Procedure for Pipeline Coating Refurbishment SPPL/SOP/53 266-268

54 Monthly Maintenance of ACDB Panel SPPL/SOP/54 269-271

55 Yearly Maintenance of ACDB Panel SPPL/SOP/55 272-274

56 Maintenance of Switch Gear SPPL/SOP/56 275-277

57 Battery Bank Inspection & Maintenance Operation SPPL/SOP/57 278-289

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 SANMARG PROJECTS PRIVATE LIMITED
SPPL/MANUAL/O&M/01
A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

SR. Pg. No.

DESCRIPTION SOP NO.
NO.

58 Maintenance of Lead Acid Batteries SPPL/SOP/58 290-292

59 Motor Operating Valve (Actuator) Maintenance SPPL/SOP/59 293-295

60 Motor Operating Valve (Actuator) Operation SPPL/SOP/60 296-299

61 Maintenance of Lead Acid Batteries SPPL/SOP/61 300-302

62 IPS Power Transformer SPPL/SOP/62 303-305

63 Maintenance of Power Transformer SPPL/SOP/63 306-308

64 Maintenance of Lead Acid Batteries (Monthly) SPPL/SOP/64 309-310

65 Maintenance of Lead Acid Batteries (Weekly) SPPL/SOP/65 311-314-

66 Diesel Generator Maintenance (300 Hrs.) SPPL/SOP/66 315-317

67 Diesel Generator Maintenance (600 Hrs.) SPPL/SOP/67 318-320

68 Diesel Generator Maintenance (Weekly) SPPL/SOP/68 321-324

69 Maintenance Of 48v70a Battery Charger SPPL/SOP/69 325-327

70 Operation Of 18V70A CELL BOOSTER SPPL/SOP/70 328-330

71 Maintenance Of 18V70A CELL BOOSTER SPPL/SOP/71 331-332

72 Operation Of 48v45a Battery Charger SPPL/SOP/72 333-335

73 Battery Charger For 48v250 Ah L.A. Battery SPPL/SOP/73 336-338

74 Operation Of 48v70a Battery Charger SPPL/SOP/74 339-341

75 Major Maintenance of MOV Motor SPPL/SOP/75 342-344

76 Yearly Maintenance of MOV Motor SPPL/SOP/76 345-346

77 Weekly Maintenance of Indoor Lighting SPPL/SOP/77 347-349

78 Major Maintenance of Indoor Lighting SPPL/SOP/78 350-351

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 SANMARG PROJECTS PRIVATE LIMITED
SPPL/MANUAL/O&M/01
A MANUAL ON HYDROCARBON
PIPELINE MAINTENANCE

SR. Pg. No.

DESCRIPTION SOP NO.
NO.

79 Weekly Maintenance of Plant Lighting SPPL/SOP/79 352-353

80 Monthly Maintenance of Plant Lighting SPPL/SOP/80 354-355

81 Maintenance of UPS (Monthly) SPPL/SOP/81 356-358

82 Maintenance Of UPS(Yearly) SPPL/SOP/82 359-361

83 Maintenance of Electrical Cable SPPL/SOP/83 362-363

84 Maintenance of Circuit Breaker SPPL/SOP/84 364-366

85 Fault finding in Electrical System SPPL/SOP/85 367-369

86 Relay Testing and Calibration SPPL/SOP/86 370-372

87 Maintenance Of 3ph-1ph (SVR) SPPL/SOP/87 373-374

88 Transformer Oil Testing SPPL/SOP/88 375-377

89 Outsource Process SPPL/SOP/89 378-381

90 Purchase SPPL/SOP/90 382-387

91 Client Invoicing SPPL/SOP/91 388-391

92 Fixed Assets Management SPPL/SOP/92 392-398

93 Expenses and Control SPPL/SOP/93 399-402

94 Operations Budgeting SPPL/SOP/94 403-404

95 Giving Advances to Employees & Reconciliation SPPL/SOP/95 405-408

96 Stores SPPL/SOP/96 409-418

97 Outsourcing of Welders SPPL/SOP/97 419-420

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/01
REVISION:01
ROU Maintenance and Emergency Preparedness W.E.F.:
15.05.2019

Sanmarg Projects Private Limited

ROU Maintenance and Emergency Preparedness

P a g e | 31
 STANDARD OPERATING PROCEDURE
SPPL/SOP/01
REVISION:01
ROU Maintenance and Emergency Preparedness W.E.F.:
15.05.2019

1. PURPOSE
To prevent the pipes, structures and other metallic surfaces from Corrosion.

2. SCOPE
The work includes cleaning of the surface by removal of loose rust, loose mill scale, oil
bound dust, loose paint to degree specified by power tool chipping, de-scaling, sanding,
wire brushing & grinding etc., after removal of dust; surface should have a pronounced
metallic sheen on Piping & structures by mechanical means and surface preparation as
per the recommendation of paint manufacturer & Painting with one coat of inorganic
zinc silicate coating of 65-75 micron DFT + 01 coat of epoxy zinc phosphate primer of 40
micron DFT + 01 coat of epoxy high build finish paint of 100micron DFT + 01 coat of
Acrylic Polyurethane paint of 40 micron DFT of approved brand of required color to give
an even shade, complete to the entire satisfaction of Engineer-in-charge (E-I-C). The
work includes the cost of supply of material, manpower, tools & tackles, consumables,
transportation to site and any other work required to complete the job in all respects at
all heights and locations. The painting work at the height more than 03 meters is to be
done by using the metallic scaffolding platform. The scaffolding material shall be
arranged by the contractor.

3. SAFETY REQUIREMENTS
Person available or working at the site should always wear helmet, goggles, reflector
jacket and shoes while working at site, i.e. requisite PPEs.

4. PROCEDURE:
• To study thoroughly the specification of contract.
• Discussion with site Engineer/EIC with respect to type/brand/make of paint.
• Obtain approval of S.No.2 above and producing of brochure/as the case may be or
taking client representative to designated paint supplier/ shop/ distributor.
• On securing approval, procuring paint through contractor and ask for manufacturing
quality certificate.
• On arrival at site, note Batch no./Brand/Make/Manufacturing Date/Expire etc. and
obtain approval of client with respect to Brand/Make/Expiry Date.
• Store the paint in safe place like storeroom.
• Mark the job area as per drawing and arrange for surface preparation. Surface should be
cleaned mechanically either by hand brush/emery paper, water cleaning or combination
of all above to remove rust, loose paint etc.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/01
REVISION:01
ROU Maintenance and Emergency Preparedness W.E.F.:
15.05.2019

• Surface should be coated within 6 hours of preparation operation. In case, it is not

painted within 6 hours, the same shall be prepared before application of paint.
• After Surface preparation, apply primer as per specification and allow for drying for
minimum half an hour, depending on climatic condition and note down the DFT reading
and get signed by Client representative.
• Apply second coat of primer (if applicable) as per above and note down the DFT reading
and get signed by Client representative.
• Apply first coat of paint as per specification and thickness mentioned in SOR item and
allow for drying for minimum half an hour as per site condition and note down the DFT
reading and get signed by Client representative.
• Apply second coat of paint as per and note down the DFT reading and get signed by
Client representative.
• Make Detail Measurement sheet/JMS indicating primer coating and paint coating and
get signed from Client representative.

5. RESPONSIBILTY:
• Discuss with client personnel for the type/brand/make of paint.
• As per discussion purchase the paint and ask for manufacturing quality certificate.
• Note down Batch no./Brand/Make/Manufacturing Date/Expire Date, etc. and obtain
approval of Client with respect to Brand/Make/Expiry Date as per format.
• Look after the work for proper preparation of painting surface.
• After each coat take the DFT Reading and get signed by GAIL representatives.
• After completion of painting take the measurement of painted areas and get the JMS
signed by Client representatives.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/02
REVISION:01
INSPECTION & REMOVAL OF ENCROACHMENTS W.E.F.:
05.05.2019

Sanmarg Projects Private Limited

INSPECTION & REMOVAL OF ENCROACHMENTS

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/02
REVISION:01
INSPECTION & REMOVAL OF ENCROACHMENTS W.E.F.:
05.05.2019

1. PURPOSE:

To specify guidelines for Inspection & removal of encroachments.

2. SCOPE:

This standard covers the guidelines on Inspection & Removal of

Encroachments.
Frequency of inspection & checking: As per the instruction of Engineer
Incharge.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Line walker report.

• ROU Inspection report.

5. PROCEDURE:

1. Obtain the work permit from operating department.

2. Study Line walk report

3. Plan your visit & arrange vehicle

4. Reach the site, Inspect the site of encroachment.

5. Note down the location/chainage/village and take photographs on mobile.
6. Note down type of encroachment
7. Inform about the encroachment to the pipeline owner within 3 hrs. period.
8. Measure distance from pipeline and give detail report to the Client & wait for
further instruction.
9. Return work permit to control room.

6. RESPONSIBILTY:
P a g e | 35
 STANDARD OPERATING PROCEDURE
SPPL/SOP/02
REVISION:01
INSPECTION & REMOVAL OF ENCROACHMENTS W.E.F.:
05.05.2019

Site In charge / Civil / Mechanical team & engineers responsible for removal of
encroachment.

7. RECORD:

Following record should be prepared in case of encroachment.

Sr. No. Location/ Chainage Measurement of Encroachment Total Remarks

Area Volume
Depth Length Breadth (m³)

P a g e | 36
 STANDARD OPERATING PROCEDURE
SPPL/SOP/03
REVISION:01
INSPECTION OF ROU WASHOUT/EXCAVATION
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Inspection of ROU Washout/Excavation

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/03
REVISION:01
INSPECTION OF ROU WASHOUT/EXCAVATION
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for Inspection of ROU Washout/Excavation.

2. SCOPE:

This section covers the guidelines on Inspection of ROU washout/ Excavation. Frequency
of inspection & checking: As per the instruction of Engineer Incharge.

3. SAFETY REQUIREMENTS:

Safety shoes and safety helmet.

4. REFERENCES:

• Line walker report.

• ROU Inspection report.

5. PROCEDURE:

1. Obtain the work permit from operating department.

2. Study Line walk report.
3. Plan your visit & arrange vehicle.
4. Reach the site.
5. Inspect the site of washout/excavation.
6. Note down location/chainage/village and take photographs
on mobile.
7. Note whether the pipeline is exposed.
8. Assess damage caused to P/L or coating.
9. Measure dimensions of W/O/excavation.
10. Assess Quantity of earth required for restoration.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/03
REVISION:01
INSPECTION OF ROU WASHOUT/EXCAVATION
W.E.F.: 15.05.2019

11. Prepare action plan.

12. Mobilize contractor/team
13. Submit report to the management.
14. Return permit to control room.

6. RESPONSIBILTY:

Site Incharge, Mechanical team & engineers responsible for inspection of ROU
washout/ Inspection.

7. RECORD:

Following record should be prepared for inspection of ROU washout/ Excavation.

Sr. No. Location/ Dimension of washout area Quantity Remarks

Chainage Depth Length Breadth of earth
required
for
restoration

P a g e | 39
 STANDARD OPERATING PROCEDURE
SPPL/SOP/04
REVISION:01
LINE WALK/PATROLLING W.E.F.:
15.05.2019

Sanmarg Projects Private Limited

LINE WALK/PATROLLING

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/04
REVISION:01
LINE WALK/PATROLLING W.E.F.:
15.05.2019

1. PURPOSE:

To specify written procedure for Line walk/Patrolling.

2. SCOPE:

This standard covers the guidelines online walk/Patrolling. Frequency of

inspection & checking: As per the instruction of Engineer Incharge.

3. SAFETY REQUIREMENTS:

Safety shoes and safety helmet.

4. REFERENCES:

• Line walker report.

• ROU Inspection report.

5. PROCEDURE:

1. Obtain the work permit from operating department.

2. Planning for Line walk
3. Obtain clearance for Line Walk
4. Intimate concerned engineers.
5. Make Vehicle arrangement.
6. Pick up engineers for Line Walk
7. Drop them at Starting Point
8. Perform Line Walk and Record the Observation
9. Pick up at End Point
10. Return to Base station
11. Submission of Report
12. Plan corrective action
13. Return permit to control room.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/04
REVISION:01
LINE WALK/PATROLLING W.E.F.:
15.05.2019

6. RESPONSIBILTY:

Mechanical team/Electrical team & engineers responsible for the line walking/
patrolling.

7. RECORD:

Following record should be prepared in case of Line walk/ Patrolling.

Sr. ROU Inspection Condition of Remarks

No. Encroachment Washout Marker Signboards TLP

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/05
REVISION:01
ROUTINE MAINTENANCE OF BALL VALVES
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

ROUTINE MAINTENANCE OF BALL VALVES

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/05
REVISION:01
ROUTINE MAINTENANCE OF BALL VALVES
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for routine maintenance of Ball valves to ensure

Its optimum performance.

2. SCOPE:

This standard covers the guidelines on Routine Maintenance of Ball valves.

Frequency of inspection & checking: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, safety goggles and use of proper
insulating tools. Ensure all the safety requirements for doing the job safely are met a per
OISD guidelines.

4. REFERENCES:

AUDCO operation and maintenance manual.

5. PROCEDURE:

1. Obtain the work permit from operating department.

2. Examine the valve and determine purpose of fittings; confirm fitting safety.
3. Topping up the seat sealant system.
4. Injection of the required quantity of lubricant at low injection pressure to fill from
empty.
5. Cycling valve from open to fully closed position then all the way back open. This needs to
be repeated several times to ensure the spread of the sealant and easy valve turn.
6. If operational considerations prevent a full cycle, a partial cycle one-third of the 90-
degree rotation is generally acceptable
7. Examine the valve for signs of corrosion or damage to the paint or coating.
8. Record the observations
9. Submission of report.
10. Return permit to control room.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/05
REVISION:01
ROUTINE MAINTENANCE OF BALL VALVES
W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site- In charge and Mechanical team/ Electrical team responsible for the proper
Maintenance ball valve.

7. RECORD:

Maintain records as per formats is to be maintained and maintenance carried out with
parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/06
YEARLY MAINTENANCE OF BALL VALVES REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

YEARLY MAINTENANCE OF BALL VALVES

P a g e | 46
 STANDARD OPERATING PROCEDURE
SPPL/SOP/06
YEARLY MAINTENANCE OF BALL VALVES REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for maintenance of Ball valves, to ensure its

Optimum performance.

2. SCOPE:

This standard covers the guidelines on Yearly Maintenance of Ball valves.

Frequency of inspection & checking: Yearly

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet, safety goggles and use of
Proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD
Guidelines.

4. REFERENCES:

AUDCO operation and maintenance manual.

5. PROCEDURE:

1. Obtain the work permit from operating department.

2. Examine the valve and determine purpose of fittings; confirm fitting safety.
3. Purge out the old lubricant/sealant with a valve cleaner, inject to fill from empty and
cycling the valve to spread the cleaner across the seal face. Valve cleaner may be left to
soak in the valve for up to 2 days.
4. With the ball in closed position, open the body vent or body drain fitting to depressurize
the body cavity. Safety precautions are necessary in case of gas service to remove all
sources of ignition or spark downwind. Venting the body will cause the seat rings to flex
or may loosen debris and corrosion.
5. Capture liquids from the Valve body, even in Gas service and dispose as per
environmental procedures
6. Close the body vent, top up with additional cleaner as required and cycle the valve as
necessary.
7. Inject/lubricant/sealant and cycle the valve to ensure ease of operation.
8. Open the body vent fitting to test the seat seals. If seat leakage is continuous, adjust the
ball alignment position. Even a small misalignment can result in severe seat leakage.

P a g e | 47
 STANDARD OPERATING PROCEDURE
SPPL/SOP/06
YEARLY MAINTENANCE OF BALL VALVES REVISION:01
W.E.F.: 15.05.2019

9. If seat leakage is continuous even after ball position adjustment, the industry typically
uses sea weld ball valve sealant to ensure sealing. During this operation it is best to
leave the body vent open and venting, as this will create a pressure differential, which
will draw the sealant into the leak path.
10. Record the observations
11. Submission of report.
12. Return work permit to control room.

6. RESPONSIBILTY:

Mechanical team & engineers responsible for the proper maintenance ball valve.

7. RECORD:

Logbook/ Register is to be maintained and also maintenance carried out with parts
consumed is maintained.

P a g e | 48
 STANDARD OPERATING PROCEDURE
SPPL/SOP/07
SUMP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Pvt Limited

Sump Pump Maintenance Procedure

P a g e | 49
 STANDARD OPERATING PROCEDURE
SPPL/SOP/07
SUMP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure of Sump pumps for the proper pumping of crude oil
from the underground sump tank to the crude oil pipeline.

2. SCOPE:

This standard covers the guidelines on operation of Sump pump.

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD
guidelines.

4. PROCEDURES FOR MAINTENANCE:

❖ All electrical power supplies to the sump pump must be isolated before any
maintenance or inspection is carried out.

❖ We should check the starter panel of the sump pump before operating.
❖ Seals, impellers etc. if worn out should be checked & if minor/major problems then
to be intimated to in charge.
❖ When Sump pump is operated then we should check that the pump should not run
dry.
❖ Check the insulation resistance of the winding & check if the pump is not body earth.
❖ Ensure there is not an excessive buildup of dust or contaminant on the sump.
❖ Check for any loss of lubricant.
❖ Check for the available spares as per recommended by OEM.

• Obtain work permit from control room

• Isolate from PMCC Panel
• Fix danger Tag on the feeder panel
• Check for external damage
• Check terminations for over-heating
• Check the winding resistance
• Check & replace faulty items if any by OEM parts
• Replace the faulty motor if burnt or send it to rewind
• Checking of earthing pits
• We should keep in mind that relay should be in correct limits as per motor
name plate details.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/07
SUMP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

• Do Cleaning of site
• Return the permit to control room

5. RESPONSIBILTY:

Site In-charge and Mechanical team responsible for the inspection & maintenance of
Sump pump at IPS Stations.

6. DEFINITION:

Main Objective behind is to pump crude oil from sump tank to the main pipeline.

7. RECORDS:

Maintain records as per required formats.

P a g e | 51
 STANDARD OPERATING PROCEDURE
SPPL/SOP/08
SUMP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Pvt Limited

Sump Pump Operation Procedure

P a g e | 52
 STANDARD OPERATING PROCEDURE
SPPL/SOP/08
SUMP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure of Sump pumps operation for proper pumping of crude oil
from the underground sump tank to the crude oil pipeline.

2. SCOPE:

This standard covers the guidelines on operation of Sump pump.

• There are generally two types of sump pumps — pedestal and submersible. The
pedestal pump's motor is mounted above the sump, where it is more easily serviced, but
is also more conspicuous. The pump impeller is driven by a long, vertical extension shaft
and the impeller is in scroll housing in the base of the pump.
• The submersible pump is entirely mounted inside the sump, and is specially sealed to
prevent electrical short circuits.
• These sumps are typically ten feet in depth or more; lined with corrugated metal pipe
that contains perforations or drain holes throughout. They may include electronic
control systems with visual and audible alarms and are usually covered to prevent debris
and animals from falling in.

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet and use of proper insulating tools.

4. PROCEDURES FOR OPERATION:

• Obtain the work permit from operating department.

• When the ERV collects the crude oil from leakage or pilferage area, oil is then bringing to
the sump tank.
• We should check the starter panel of the sump pump before operating.
• When Sump pump is operated then we should check that the pump should not run dry.
• Proper maintenance should be done of sump.
• We should measure current in each phase through clamp meter & check whether it is in
specified range or not.
• Seals, impellers etc. if worn out should be checked & if minor/major problems then to
be intimated to M/s HMPL & Incharge.
• Return work permit to control room.

5. RESPONSIBILTY:

P a g e | 53
 STANDARD OPERATING PROCEDURE
SPPL/SOP/08
SUMP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Site In-charge and Electrical team responsible for the inspection & maintenance of Sump
pump at IPS Stations.

6. DEFINITION:

Main Objective behind is to pump crude oil from sump tank to the main pipeline.

7. RECORDS:

Maintain records as per required formats.

P a g e | 54
 STANDARD OPERATING PROCEDURE
SPPL/SOP/09
SLOP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited.

Slop Pump Maintenance Procedure

P a g e | 55
 STANDARD OPERATING PROCEDURE
SPPL/SOP/09
SLOP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written maintenance procedure of Slop pump for the proper pumping of
crude oil to the main pipeline at different pressure modes.

2. SCOPE:

This standard covers the guidelines on checking of Slop pump & maintenance.

3. SAFETY REQUIREMENTS:
Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

4. PROCEDURES: This is typical to a situation at Cot & Dhansa.

Obtain the work permit from operating department.

Initially made the arrangements for filling the nitrogen gas into damper of
Slop Pump with the help of Service Engineer.

The main line pressure at that time was 42kg/cm2 and the design pressure of
Slop pump as mentioned on name plate was 38kg/cm2 and to transfer crude
Oil to mainline during shut down was difficult, so circulation of crude oil from
Sump Tank B to Sump Tank A was carried through scrapper receiver.

Then process of filling nitrogen gas was carried out and pressure was
Maintained up to 23kg/cm2 (which is 60% of design pressure of slop pump
i.e. 38kg/cm2). After filling nitrogen gas, it was blinded with the help of 3/8"
dummy. We observed for few minutes and found that there was no pressure
drop which confirmed that diaphragm is in good condition.

Before circulation of crude oil by passed MOV-2817 and kept in close

position with prior intimation to COT & DHANSA. During this process it was
noticed that pressure was not building up on discharge line of slop transfer
pump, due to slop transfer pump suction strainer got choked up.

After removal of strainer we found a lot of debris and cotton waste trapped
inside the strainer. Cleaned strainer for both slop pumps and checked on trial
basis and found in working condition.

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W.E.F.: 15.05.2019

Switched on the Sump pump motor and then switched on slop transfer pump
Motor and started the process of circulating crude oil. At last the level
Maintained in both the sump pumps were 1.898 mt and 0.74 mt. Return Work Permit
to control room.

5. RESPONSIBILTY:

Site In-charge and Mechanical team are responsible for the inspection & maintenance of
Slop at IPS Stations.

6. DEFINITION:

Main Objective behind is to pump crude oil from sump tank to the main pipeline at
various pressures.
Proven design of plunger type Metering Pumps confirming to API 675 requirement.

• Positive return Welcrank Stroke Mechanism

• ±1% Accuracy
• Robust construction
• Maintains reliability & accuracy for longer period

APPLICATIONS:

• Suitable for any liquid metering application

• Chemical Processing
• Pulp & Paper
• Refineries
• Fertilizer
• Oil & Gas
• Power Generation

GENERAL SPECIFICATION:

• Flow rates: Up to 10000 L/Hr. per head

• Pressures: Up to 1000 Kg/cm2
• Multiplexing: Up to Nine heads

PERIODIC CHECKS:

• Physically inspection of the pump.

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 STANDARD OPERATING PROCEDURE
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SLOP PUMP MAINTENANCE PROCEDURE REVISION:01
W.E.F.: 15.05.2019

• We recommend performing maintenance every six to twelve months. This includes

changing the NRV and seal rings, plungers & gaskets.

• Proper motor greasing is to be done as per recommended hours.

• Should use proper rating of motor starters with suitable relay range.

• Should keep standby spares as prescribed by the OEM.

• Pump does not build pressure just by starting it. Pump discharge line must be
contacted to elevated pressure point to build pressure of discharge side. If still pump
does not generate pressure or deliver desired flow, check Pump discharge & suction
valve for dirt's & foreign particles.

7. DETAILS:

Pump is mainly reciprocating type with various pressure settings.

Manufacturer: Swelore Engineering Pvt. Ltd

Model No: WH-5000/52 (T)

Pump Serial No: 23762 – 09

23763 – 09

Item No: 087PARP115 A & B

8. RECORDS:

Maintain records as per required formats.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/10
SLOP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited.

Slop Pump Operation Procedure

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/10
SLOP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for operation of Slop pumps for the proper pumping of
crude oil to the main pipeline at different pressure modes.

2. SCOPE:

This standard covers the guidelines on operation of Slop pump.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES FOR OPERATION:

Initially made the arrangements for filling the nitrogen gas into damper of Slop Pump
with the help of manufactures recommendation.

Before circulation of crude oil by passed MOV-2817 and kept in close position with prior
intimation to COT & DHANSA. During this process it was noticed that pressure was not
building up on discharge line of slop transfer pump, due to slop transfer pump suction
strainer got choked up.

After removal of strainer we found a lot of debris and cotton waste trapped inside the
strainer. Cleaned strainer for both slop pumps and checked on trial basis and found in
working condition.

Switched on the Sump pump motor and then switched on slop transfer pump motor and
started the process of circulating crude oil. At last the level maintained in both the sump
pumps were 1.898 mt and 0.74 mt.

5. RESPONSIBILTY:

Site In-charge and Mechanical team are responsible for the inspection & maintenance of
Slop at IPS Stations.

6. DEFINITION:

Main Objective behind is to pump crude oil from sump tank to the main pipeline at
various pressures.
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 STANDARD OPERATING PROCEDURE
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SLOP PUMP OPERATION PROCEDURE REVISION:01
W.E.F.: 15.05.2019

Proven design of plunger type Metering Pumps confirming to API 675 requirement.

• Positive return Welcrank Stroke Mechanism

• ±1% Accuracy
• Robust construction
• Maintains reliability & accuracy for longer period

APPLICATIONS :

• Suitable for any liquid metering application

• Chemical Processing
• Pulp & Paper
• Refineries
• Fertilizer
• Oil & Gas
• Power Generation

GENERAL SPECIFICATION:

• Flow rates : Up to 10000 L/Hr. per head

• Pressures : Up to 1000 Kg/cm2
• Multiplexing : Up to Nine heads

7. DETAILS:

Pump is mainly reciprocating type with various pressure settings.

Manufacturer.

Model No: WH-5000/52 (T) (typical to manufactures recommendation)

Pump Serial No: 23762 – 09

23763 – 09

Item No: 087PARP115 A & B

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/11
REVISION:01
METER TESTING AND CALLIBRATION
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

METER TESTING AND CALLIBRATION

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 STANDARD OPERATING PROCEDURE
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REVISION:01
METER TESTING AND CALLIBRATION
W.E.F.: 15.05.2019

1. PURPOSE:

To specify guidelines for meter testing and calibration of installed equipment at SV/IPS.

2. SCOPE:

This standard covers the guidelines on the meter testing and calibration.

Frequency: Yearly

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet, insulating mats and use of proper insulating
tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

Reference equipment.

5. PROCEDURE:
• Obtain clearance from Control room
• Isolate the meter to be tested
• Calibrate the meter, make records
• Reconnect the meter
• Mark error on the meter
• Defective meter to be identified
• Replace defective meter
• Return the permit

6. RESPONSIBILTY:

Electrical team & engineers responsible for the calibration and meter testing.

7. RECORD:

SR Description of Calibrated Calibration due Remarks

NO. Equipment date date
1 Voltmeter
2 Ammeter
3 Multimeter

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/12
REVISION:01
MAINTENANCE OF METERING PUMP
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF METERING PUMP

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/12
REVISION:01
MAINTENANCE OF METERING PUMP
W.E.F.: 15.05.2019

1. PURPOSE:

To specify general maintenance instructions for a metering pump.

2. SCOPE:

This standard covers the guidelines on yearly Maintenance of Metering Pump

Which includes:
• Gland packing
• Plunger maintenance
• Lubricating procedure
• Troubleshooting

Frequency of inspection & checking: yearly

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PRINCIPLE OF OPERATION
Reciprocating motion of the plunger is generated through crank drive. When plunger
retracts, (during suction stroke). Pressure drops in pump cylinder &liquid from suction
vessel enters cylinder chamber by lifting suction valve. During discharge stroke liquid
inside cylinder chamber is pushed to discharge piping by lifting discharge valve. This
process is repeated every cycle & thus pumping action is achieved

5. REFERENCES:

Operation and maintenance manual of metering pump.

6. PROCEDURE:

Gland packing
• Obtain the work permit from operating department

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REVISION:01
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W.E.F.: 15.05.2019

• Plunger type packing are chevron type PTTE packing, extreme care must be taken while
tightening these packing.
• Packing adjustment nut is provided with peripheral holes.
• Insert steel rod in one of these holes & tighten the gland nut, do not tighten nut more
than 30”.
• Wait for some time to arrest leakage & observe the temperature of cylinder gets heated
up.
• Small amount of leakage from packing should be allowed as dry running may result in
wear of plunger and seal.

Plunger Maintenance
• Plunger must be checked at yearly interval for scratches, wear etc. under packing area.
• If such defects are observed plunger must be replaced.

Lubricating Procedure
• To drain the drive case oil, remove lower socket head set screw.
• Allow complete drainage, then replace plug, using an anti-galling thread sealant.
• Refill drive case with proper type and quantity of oil.
• Return permit to control room.

7. RESPONSIBILTY:

Mechanical team & engineers responsible for the proper maintenance of metering
pump.

8. RECORD:

Logbook/ Register are to be maintained for yearly/Major maintenance record and the
Record for the parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/13
REVISION:01
MONTHLY MAINTENANCE OF PLUG VALVES
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MONTHLY MAINTENANCE OF PLUG VALVES

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/13
REVISION:01
MONTHLY MAINTENANCE OF PLUG VALVES
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for monthly maintenance of super H pressure balanced

plug valves.

2. SCOPE:

This standard covers the guidelines on monthly Maintenance of Plug Valves which
includes:
1. Injection of plug sealant
2. Injection of stem packing
3. Adjustment of the plug loading screw

Frequency of inspection & checking: Monthly/Quarterly as per schedule.

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Hand gloves, safety shoes, safety helmet and use of proper insulating tools.

4. REFERENCES:

RotorK- Controls Installation and Maintenance Instructions

5. PROCEDURE:

A. Injection of Plug Sealant

The reason for injecting plug sealant onto the valve seats of AUDCO Super-H valves is to
maintain the bubble tight shut capabilities and to ensure smooth operation of the valve.

1. Frequency of Sealant Injection

Service Conditions Frequency of Sealant injection

In non-abrasive gas or liquid service Every 5O operations, minimum once a
year

In abrasive gas or liquid service Every 25 operations, minimum 2 times a

year

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W.E.F.: 15.05.2019

In abrasive slurries Every 10 operations, minimum 4 times a

year

2. All Super-H valves are fitted with ‘Sealant Injector’ fittings. To inject sealant into super
H valves sealant gun with a button head coupler is required.

3. The following instructions should be used in conjunction with the sealant gun
operating instructions. Sealant can be injected with the valve in line and on pressure.

4. The valve should be either fully opened or fully closed, this ensures that all four
sealant grooves on the plug are connected to the sealant supply. If the valve is
partially open, injection is less effective as only two of the grooves are connected to
the supply.

5. Identify and clean the sealant injector on the valve. Scrape-off any paint on the small
hole in the end and the groove of the fitting.

6. Ensure that the gun is filled and primed with a suitable plug valve sealant. Follow the
gun operating instructions to fill the gun with the sealant.

7. Slide the button coupler at the end of the gun hose, over the valve’s sealant injector
ensuring that the lip of the coupler fits into the groove in the fitting.

8. Inject sealant by pumping the handle of the gun. For sealant ‘to flow onto the valve
seats, enough sealant at enough pressure must be injected to overcome the line
pressure, to fill any cavities in the sealant chamber and grooves and to overcome the
resistance to flow through the valve sealant system.

9. After enough sealant has been injected, relieve the internal pressure i the gun by
loosening hack screw of the gun and disconnect it from the sealant injector.
The sealant gun should not be connected or disassembled while it has internal
pressure.

10. It is desirable but not essential to operate the valve either partially or fully, after
injecting sealant as this helps to spread the seal over the entire seating surfaces. If it is
critical that it stays in its current position (either open or close), it is advisable that the
valve is operated through just 5o to 10o and returned to its position.
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REVISION:01
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W.E.F.: 15.05.2019

B. Stem Packing Adjustment

All Super plug valves are fitted with an emergency stem packing fitting. In the unlikely
event of a super-H valve developing a stem leak, this fitting can be used to inject stem
sealant into the stem area and reseal the valve stem. This can safely be done with the
valve under pressure.

On threaded stem Super-H valves, the injected stem sealant is the primary stem seal. On
the ‘Plain stem ‘design with bolted gland, it is purely an emergency feature to back up
the main stem packing.

CAUTION: Never attempt to replace the stem. Packing’s in bolted gland Super valves
while under pressure.

1. The stem packing injector fitting consists of an outer hexagonal shaped casing that is
screwed into the valve body. Stem packing is forced, through a check valve inside, with a
screw that threads into the end of the casing. Stem packing injectors on Super-H plug
valves are pre-loaded at the factory with enough AUDCO Stem sealing Compound to re
small leaks

2. To inject the stem sealing compound already in the fitting, into the valve stem area,
rotate the screw slowly in the end of the stem packing injector clockwise until it
becomes hard to turn, normally only 1-3 turns will be possible. A maximum torque of 10
lb. ft. is all that required to sufficiently inject the stem.

Operating the valve during the injection of stem sealing compound can assist in
resealing the valve stem.

3. Even after tightening the screw if stem leak is noticed, more stem sealant needs to be
loaded into the stem sealant injector. This is done by backing out the screw putting in a
new piece of AUDCO stem sealing compound into the fitting and screwing the screw
back in.
Caution: While the valve is under pressure never unscrew the stem sealant injector
fitting

C. Adjustment of Plug Loading Screw

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REVISION:01
MONTHLY MAINTENANCE OF PLUG VALVES
W.E.F.: 15.05.2019

All Super-H plug valves have a plug loading screw which is preset at the factory to
position the tapered plug in the optimum contact with the tapered body, i.e., the valve
will seal bubble tight and be readily operated Users of Super plug valves will never need
to adjust this fitting but occasionally it can be of benefit to adjust the plug into the body
seat, This operation can be carried out with the valve on pressure.

EQUIPMENT NEEDED Adjustable Crescent Wrench, Hammer & Steel punch (to loosen
cap over the plug loading screw).

1. If a Super-H valve Leaks across the seats even after injection of sufficient sealant
onto the valve seats and it is very easy to operate, then the plug is probably out of
adjustment (not in close enough contact with the body seat) and needs to be
adjusted into the tapered body seat.
Please note that damaged metal seats can also produce these symptoms.
As Plug Loading Screw adjustment is critical valve performance, it should be
executed by Factory Trained personnel only.

2. Emergency stem sealing compound

Supply in stick form for sealing stems, should under no circumstances be used in the
plug sealant system. Plug sealants are not suitable for sealing items.

6. RESPONSIBILTY:

Mechanical team & engineers responsible for the proper maintenance of plug valve in
scheduled time.

7. RECORD:
Maintain records as per formats given by M/s HMPL & Logbook/ Register is to be
maintained and also maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/14
Bore Well Operation Procedure REVISION:01
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Bore Well Operation Procedure

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/14
Bore Well Operation Procedure REVISION:01
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for monthly Operation & maintenance of bore well
pump motor to ensures its optimum performance.

2. SCOPE:

This standard covers the guidelines on the Operation & maintenance of Bore well
pump motor.

Frequency: Yearly

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD
guidelines.

4. PROCEDURES FOR OPERATING:

When you require installation of a new bore pump,

• Make sure no sand or fine gravel into the water being pumped.

• In the event that the water is entering the bore from a level above the pump (“a
cascading bore”), or in a river or other open water sources, a shroud may be
required over the pump to ensure that all water being pumped is drawn over the
full length of the motor’s surface.

• Do not lift the submersible bore pump by its attached electric motor cables.
Safety stainless steel support cable should be use instead.

• Bore water should be at PH - 6 to 8 as corrosive water will shorten life of the

pump.

• Do not run pump dry. The bore pump should be located between intake end and
discharge end. It should install at least one (1) meter, preferably 3 meters above
the bottom of the bore, and one (1) meter below the maximum draw down level.

With Single Phase 1 HP Submersible Bore Pump you can add Electronic
Pressure Controller which enable automation of garden watering. Or choose the
Bore Pump with Digital Automatic Control Box. It has water level monitoring

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Bore Well Operation Procedure REVISION:01
W.E.F.: 15.05.2019

probes. It also displays running voltage and current and have built in overload
protection. Water Full and Water Lack indicator light display.

Lowering the Bore Pump

• Align the pump carefully when beginning to lower it down well casing. Do not let
the pump, cables or pipe rub against the well casing. Take care that cable
insulation is not dragged or scraped over the top lip of the well casing.
• Depth of pump setup. Lower pump into well slowly. Use foot clamp to hold
galvanized iron or PVC pipe while connecting the next length of pipe and taping
the power cables. The bore pump should be located between intake end and
discharge end. It should install at least one (1) meter, preferably 3 meters above
the bottom of the bore, and one (1) meter below the maximum draw down level.
• Use Pipe fitting and Safety stainless steel support cable to support pump. When
a well seal is used, either a coupling, tee or elbow is installed on the top end of
pipe and is allowed to rest on the outside of the well seals provide a fitting to seal
the power cables to support the pipe, power cables, safety cable and pump.
Stainless steel support cable should be secured to the bore cap.

Ensure electrical power is turned off and disconnected before install,

service or perform submersible well pump replacement

• All electrical connections should be checked before the bore pump install into the
bore. If possible, it is a good practice to run the pump briefly in a container of
water (water level must be well over the suction inlet screen)
• For Three Phase Bore Pump it connected to a supply line for the first time may
rotate in either direction. It is, therefore, necessary to find out whether motor is
rotating in right direction.
• Pour clean water into the discharge by holding the non-return valve open so that
the shaft bearings and impellers become wet.
• Turn the power on and off for a very short time and check the shaft rotation and
correct rotation is anti-clockwise by looking down from the discharge.

Bore Pump startup at first time

• Before connecting the pump outlet pipe from the bore, a bend and gate valve
should be screwed into the top of the bore cap.

• Never start the pump at full flow.

• Gate valve should be only slightly open by recommend.

• For first 10-20min of operation, it is suggested to keep the gate valve only
slightly open, to maintain low flow. This low flow will prevent, in the case of
excessive sand in the water.
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Bore Well Operation Procedure REVISION:01
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• If excessive amounts of sand being pumped, the pump should be shut down
immediate and the bore should be attending before use the pump again

Bore Pump Accessories: pressure switch kit, control box, pressure gauge, bore
level pump controls, gate valve, pump shroud, bore cap and stainless steel
support cable might need for your installation.

5. PROCEDURES FOR MAINTENANCE:

• Obtain work permit from control room

• Isolate the power supply
• Fix tag on the panel
• Check the condition of starter /panel
• Check current consumed by motor
• Check the thermal relay setting, condition of fuse, overload relay,
contactor, MCB, etc. , if faulty then replace as per instruction of Site
Incharge
• Check for IR value for cable/wire
• Remove connections of motor
• Lift out the motor-pump if required
• Check & change the bush for motor
• Checking & rectification of windings
• Lower the set after repair/ testing
• Connect the cable
• Checking of earthing of all power point
• Check all the internal connections
• Check tightness of outgoing cable
• Checking of mechanical seals, impellers.
• Check the DE & NDE Bearings
• Grease DE & NDE bearings if required
• Replace DE/ NDE Bearings if required
• Do Cleaning of site
• Normalize the system & take trial
• Return the permit to control room

6. EQUIPMENTS:

Digital Multimeter, Digital Clamp meter

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Bore Well Operation Procedure REVISION:01
W.E.F.: 15.05.2019

7. RESPONSIBILTY:

Electrical team & Company engineers responsible for the inspection &
maintenance of Bore well Pumps at IPS & SV Stations.

8. DEFINITION:

Main Objective behind Inspection & maintenance is to ensure that we should

Properly maintain the bore well pump for its purpose.

9. RECORDS:

Maintain Records as per required formats.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/15
REVISION:01
Fire Extinguisher & Fire Alarm System Maintenance
Procedure W.E.F.: 15.05.2019

Sanmarg Projects Private Limited.

Fire Extinguisher & Fire Alarm System Maintenance Procedure

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/15
REVISION:01
Fire Extinguisher & Fire Alarm System Maintenance
Procedure W.E.F.: 15.05.2019

1. PURPOSE:

To provide written maintenance procedure of fire extinguisher & Fire Alarm system.

2. SCOPE:

This standard covers the guidelines on Weekly checking, measuring and maintaining the
Fire extinguisher & fire Alarm system in a safe condition for emergencies.
Frequency of inspection & Checking: Weekly

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.

Hand gloves, safety shoes, safety helmet, fire extinguisher and use of proper insulating
tools.

4. SAFETY PROCEDURES:

Fire is the result of a chemical combustion reaction, typically a reaction between

oxygen in the atmosphere and some sort of fuel (wood or for example). Of course, wood
and gasoline don't spontaneously catch on fire just because they're surrounded by
oxygen. For the combustion reaction to take place, the fuel must be heated to its
ignition temperature.

Fire is the result of a chemical combustion reaction, typically a reaction between oxygen
in the atmosphere and some sort of fuel (wood or gasoline, for example). Of course,
wood and gasoline don't spontaneously catch on fire just because they're surrounded by
oxygen. For the combustion reaction to take place, the fuel must be heated to its
ignition temperature.

Here's the sequence of events in a typical wood fire:

• Something heats the wood to very high temperatures. This could be any number of
things -- focused light, friction, something else that is already burning.
• When the wood reaches about 500 degrees Fahrenheit (260 degrees Celsius), the heat
decomposes some of the cellulose material that makes up the wood.
• Decomposed material is released as volatile gases, typically a compound of hydrogen,
carbon and oxygen.

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• When the gas is hot enough, the compound molecules break apart, and the atoms
recombine with the oxygen to form water, carbon dioxide and other products.
• The gases, which rise through the air, make up the flame. Carbon atoms rising in the
flame emit light as they heat up.
• The heat of the flame keeps the fuel at the ignition temperature, so it continues to burn
if there is fuel and oxygen.

As you can see, there are three essential elements involved in this process:

• Extreme heat
• Oxygen (or similar gas)
• Fuel

Fire extinguishers are designed to remove at least one of these elements so that a fire
will die out.

5. PROCEDURES:

• Obtain the work permit from operating department.

Portable fire extinguishers apply an extinguishing agent that will cool burning fuel,
displace or remove oxygen, or stop the chemical reaction so a fire cannot continue to
burn. When the handle of an extinguisher is compressed, agent is expelled out the
nozzle. A fire extinguisher works much like a can of hair spray.

1. Fire Extinguisher Types:

Flammable Liquids
Fires in oils, gasoline, some paints, lacquers, grease,
solvents, and other flammable liquids require an
extinguisher labeled B.

CO2

Electrical Equipment
Dry
Fires in wiring, fuse boxes, energized
electrical equipment, computers, and other
electrical sources require an extinguisher
Chemical
labeled C.
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 STANDARD OPERATING PROCEDURE
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REVISION:01
Fire Extinguisher & Fire Alarm System Maintenance
Procedure W.E.F.: 15.05.2019

Portable fire extinguishers apply an extinguishing agent that will either cool burning fuel,
displace or remove oxygen, or stop the chemical reaction so a fire cannot continue to burn.
When the handle of an extinguisher is
compressed, agent is expelled out the nozzle.
A fire extinguisher works much like a can of
hair spray.

All portable fire extinguishers must be

approved by a nationally recognized testing
laboratory to verify compliance with
applicable standards [29 CFR 1910.157(c)(2)].
Equipment that passes the laboratory's tests
are labeled and given an alpha-numeric
classification based on the type and size of
fire it will extinguish.

Let's take a look at the label pictured. The classification is: 1-A:10-BC

The letters (A, B, and C) represent the type(s) of fire for which the extinguisher has been
approved.

The number in front of the A rating indicates how much water the extinguisher is equal
to and represents 1.25 gallons of water for every unit of one. For example, a 4-A rated
extinguisher would be equal to five (4 x 1.25) gallons of water.

The number in front of the B rating represents the area in square feet of a class B fire
that a non-expert user should be able to extinguish. Using the above example, a non-
expert user should be able to put out a flammable liquid fire that is as large as 10 square
feet.

2. Fire Alarm System:

If the alarm sounds for longer than this, you must evacuate using the procedure below.
At all other times you must evacuate as soon as the fire alarm sounds.

Raise the alarm by activating the nearest Break Glass Unit. Do not attempt to tackle a
fire unless it is safe to do so.
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− Fire Action Notices are displayed throughout the Sites. You should familiarize yourself
with these instructions so that in the event of the alarm sounding you know what to do.
− Evacuate as soon as the alarm sounds – do not go out of your way to collect personal
belongings
− Follow the evacuation arrows (green “running man” signs) to your nearest safe
emergency exit. Your nearest safe emergency exit will not necessarily be the normal exit
route therefore it is important you follow the signage.
− If it is safe to do so:
• Stop/close all machinery & electrical equipment
• Isolate electrical supplies to equipment
• Turn off gas supplies and gas cylinders

− Fire Marshalls will check each area of the Main Building and then report to the Fire
Control Point.
− On leaving the building make your way to the designated Fire Assembly Point which is
indicated on Fire Action Notices.
− Remain at the Assembly Point until given instruction to do otherwise
− Do not under any circumstances re-enter the building until given authority to do so.
− Return permit to control room.

6. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers to check the Fire Extinguishers &
Fire Alarm system on routine basis at SV & IPS Stations.

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7. DEFINITION:

Main objective behind fire extinguisher & fire alarm system is to avoid loss of manpower
at project site & to stop the minimum loss of equipments at project site.

8. EQUIPMENTS DETAILS:

Carbon dioxide Fire extinguisher (B Type-Flammable liquid & electrical).

Dry Powder Fire extinguisher (C Type-Multipurpose).

9. CHECKLIST:

For Fire Extinguishers:

Portable fire extinguishers are a great safety tool to keep around in case of a fire.
According to federal safety guidelines, all fire extinguishers, including CO2 extinguishers,
need to be visually inspected.

Here's how to inspect your CO2 fire extinguisher:

1. Locate your extinguisher this seems obvious, but you need to know where the fire
extinguishers around your office are located. Make sure they're in an accessible
place, where you can get to them if there's a fire emergency.
2. Verify extinguisher class Check your CO2 fire extinguishers labeling to make sure it's
safe for the types of fires that could happen in the immediate area. If there isn't
enough information on the label, search the Internet or contact your local fire
department for more information.
3. Check the plastic seal all fire extinguishers should have a seal holding a safety pin in
place. Report any extinguishers with missing or broken seals to your local fire
department.
4. Weigh the canister CO2 fire extinguishers are highly pressurized. They don't have
gauges like other types of extinguishers and need to be weighed to see how much is
inside. Most CO2 units are labeled for weight. The common sizes are 5, 10, 15 and 20
pounds (2.3, 4.5, 6.8 and 9 kilograms).
5. Check the pin, nozzle and nameplate everything should look brand new on a CO2
fire extinguisher. Check the pin, nozzle and nameplate for any damage or signs of
tampering.

For Fire alarm systems:

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Semiannually
1. Certain fire alarm system components need to be visually inspected semiannually.
These visual inspections can be performed by facility staff and include:

a. Control unit trouble signals – verify that they are readily visible
b. Remote annunciators – verify that they are in proper operating condition and free
of damage
c. Initiating devices – verify that they are in place, unobstructed and free of damage–
to include:
• Manual fire alarm boxes
• Heat detectors
d. Notification appliances – verify that they are unobstructed and free of damage
e. Magnetic hold-open devices – verify that they are free of damage and function
properly

2. A visual inspection of fire alarm interconnect switches on kitchen hood extinguishing

systems is also required.

3. By exception, where a listed addressable fire alarm system is present that performs
at least weekly automatic inspections of system components, the visual inspections
can be conducted annually. The system would need to be capable of producing a
print-out documenting these weekly inspections.

4. Inspection and testing of batteries, smoke detectors (both hard-wired and battery
operated) and equipment used to transmit signals to a supervising station are
covered later in this guide.

Annually
• The entire system is required to be thoroughly inspected, tested and maintained
each year by an approved servicing company.
Testing must include control equipment, remote annunciators, initiating devices,
HVAC shutdown devices and alarm notification appliances.

• Fire alarm interconnect switches on kitchen hood extinguishing systems are also
required to be tested annually.

• Inspection, testing and maintenance of batteries, smoke detectors (both systems

connected and battery-operated) and equipment used to transmit signals to a
supervising station are covered later on in this guide.

Batteries for fire alarm system

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Batteries serving as a secondary power supply for fire alarm systems must be visually
inspected at the following intervals to verify that they are free of damage & replace
if necessary.

Smoke detectors
1. Battery-operated detectors

Some facilities have battery-operated smoke detectors installed to meet the

requirements that apply to buildings that are either unsprinklered or only partially
sprinkle red.
These detectors must be tested and maintained in accordance with manufacturer’s
instructions. This means that:
Detectors must be tested on a weekly or monthly basis as specified.
Detectors must be cleaned monthly in accordance with manufacturers
Instructions
Batteries must be replaced annually or semiannually as specified by the
Manufacturer.

2. Hard-wired detectors

a. Hard-wired (including low voltage) automatic smoke detectors, including duct smoke
detectors, must be visually inspected semiannually
Exception: For listed addressable fire alarm systems that perform automatic
Inspections at a frequency of not less than weekly, the visual inspections are
Allowed to be conducted annually. The system would need to be capable of
Producing a print-out documenting these weekly inspections.

b. Hard-wired (including low voltage) smoke detectors must be sensitivity tested.

This section requires that detector sensitivity be checked within 1 year after
Installation and every other year thereafter.
Detectors found to have a sensitivity outside the listed and marked sensitivity
Range must be cleaned and recalibrated or be replaced.
If, after the second test, detectors are found to have remained within their
Listed and marked sensitivity range (or 4 percent obscuration light gray smoke,
if not marked), the length of time between sensitivity tests may be extended to
a maximum of 5 years.

c. Something to keep in mind about detector testing: Smoke entry tests are required
for functional and sensitivity testing of smoke detectors. Magnet tests do not
Replace smoke entry tests.

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10. REFERENCES:

1. Fire Extinguishers Used at Site.

2. Fire Alarm Used At various sites.

11. RECORDS:

Maintain records as per formats given by M/s HMPL & monthly check up of fire
extinguishers & fire alarm system at site.

Fire Alarm System Format:

1) Indicator Light

2) Battery condition
3) Detector test
4) Panel testing
5) Hooter performance

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Attending Mainline Leakage or Pilferage
Maintenance Procedure W.E.F.: 15.05.2019

Sanmarg Projects Private Limited.

Attending Mainline Leakage or Pilferage Maintenance Procedure

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1. PURPOSE:

To provide written maintenance procedure for attending the mainline leakage or

pilferage in the pipeline.

2. SCOPE:

This standard covers the maintenance guidelines of mainline leakage or pilferage.

Frequency: Weekly

3. SAFETY REQUIREMENTS:
Hand Gloves, Eye sheds, Safety shoes and safety helmet.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Inform Control Room and RT.

• Pilferage spot will be isolated by closing nearest upstream / downstream valve.

• Depressurization

• For smooth suction and discharge of crude oil from ERV, fabrication of valve from 4” to
2” with 2” hose pipe connected to it. Decanting of crude oil by ERV from SV and
transferring into tanker.

• Transfer spillage or line crude to nearest IPS location and putting it in sump tank.

• Lining up of ERV, MMV, cordoning of the area, fire tender

• Excavation and exposure of the line.

• Visual inspection of pilferage point.

• Rectification / Repair / Removal of any valve etc. on the line by MMV team using cold
cutting, use of wooden plug and providing leak clamp.

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• After cleaning the surface area of the pipeline, tightening of the leak clamp to the
desired torque.

• Lining up of crew consisting of fitter, grinder, welder, welding sets, generator, oil
absorbents, DCP in presence of fire department.

• Testing of welders or approved welders.

• Welding with desired electrodes conforming to API 1107 using 2.5mm, 3.15mm heated
to 300 degree centigrade in mother oven and then welding with preheated to 100
degree centigrade in mother oven.

• In presence of Quality and Control team, checking out DPT / MPT for welding quality.

• Restoration of pumping, opening of valve and pressurization.

• Return permit to control room.

If situation demands for replacement of section of pipeline, metal sleeving of pipeline.

(1) Measurement of pipeline.

(2) Cold cutting

(3) Beveling

(4) Mud Plugging

(5) DCP sprinkling in the pipeline

(6) Preparation of the section of pipe duly beveled putting the cut pipeline in the position
matching to the ends of pipe ends.

5. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers to check for pipeline leakages for
pilferages if any, on routine basis at SV & IPS Stations.

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6. DEFINITION:

Main objective is to isolate i.e. open or close the flow of crude oil through the pipeline.

7. EQUIPMENTS DETAILS:

Clamps for leakages rectification

8. RECORDS:

Logbook/ Register is to be maintained and also maintenance carried out with parts
consumed is maintained.

9. CHECKLIST FOR PREVENTION OF LEAKAGES:

• ERV & MMV should be present at site to recover the crude oil from the leakage.

• Spares i.e. clamps, welding set etc. should be available of proper size or make.

• Approved welder required for welding of clamp properly on crude pipelines.

• Only Skilled manpower should attend the leakage for pilferage operations.

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Sanmarg Projects Private Limited

Pigging Operation Procedure

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1. PURPOSE:

To provide written operating procedure for pipeline pigging. Main purpose is to clean
crude and dry cleaning of pipelines in concert with running mechanical cleaning pigs and
the effectiveness of the respective results.

2. SCOPE:

This standard covers the guidelines on pigging operation to remove unwanted materials
from inside the crude pipelines.

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Hand gloves, safety shoes and safety helmet.

4. SAFETY PROCEDURES:

Pigging systems are designed so that the pig is loaded into the launcher, which is
pressured up to launch the pig into the pipeline through a kicker line. In some cases, the
pig is removed from the pipeline via the receiver at the end of each run. All systems
must allow for the receipt of pigs at the launcher, as blockages in the pipeline may
require the pigs to be pushed back to the launcher. Most of the time, systems are
designed to pig the pipeline in either direction.

The pig is pushed either with an inert gas or a liquid; if pushed by gas, some system can
be adapted in the gas inlet in order to ensure pig's constant speed, whatever the
pressure drop is. The pigs must be removed, as many pigs are rented, pigs wear and
must be replaced, and cleaning pigs push contaminants from the pipeline such as wax,
foreign objects, hydrates, etc., which must be removed from the pipeline.

There are inherent risks in opening the barrel to atmosphere and care must be taken to
ensure that the barrel is depressed prior to opening. If the barrel is not completely
depressed, the pig can be ejected from the barrel and operators have been severely
injured when standing in front of an open pig door.

When the product is sour, the barrel should be evacuated to a flare system where
the sour gas is burnt. Operators should be wearing a self-contained breathing
apparatus when working on sour systems.

A few pigging systems utilize a "captive pig", and the pipeline is only opened up very
occasionally to check the condition of the pig. At all other times, the pig is shuttled

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up and down the pipeline at the end of each transfer, and the pipeline itself is never
opened during process operation. These systems are not common.

5. WHAT IS PIG:

Pig is a device inserted into a pipeline which travels freely through it, driven by the
product flow to do a specific task within the pipeline.

These tasks fall into several different areas which further forms the basis for their
classification
Pipeline maintenance is one of the most important aspects in piping engineering and
pigging is one such maintenance tool. Pigging is done..

Use During construction phase: To remove accumulated debris.

During operation:

To remove liquid hold-up in theline as well as to clean wax off the pipe wall

During hydro testing:

Pigs are used to fill the line with water and subsequently to dewater the line after
the successful test

During inspection of line:

Inspection pigs are used to estimate the wall thickness and extent of corrosion in the
line

During repair:

Plugs can be used to isolate the pipeline during a repair.

6. PROCEDURES:

Obtain the work permit from operating department.

Pigging of any type requires planning and assistance from the pig manufacturers and/or
qualified pipeline-cleaning service companies. The goal of pipeline cleaning is to
minimize or eliminate sensor liftoff of the ILI tool. A side benefit is increased pipeline
efficiency. Technology today allows for a proven product from the pig manufacturing
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process to assist companies in achieving maximum results whether they are

mechanically dry pigging or liquid cleaning using mechanical pigs.

Pigging in the context of pipelines refers to the practice of using pipeline inspection
gauges or 'pigs' to perform various maintenance operations on a pipeline. This is done
without stopping the flow of the product in the pipeline.

These operations include but are not limited to cleaning and inspecting of the pipeline.
This is accomplished by inserting the pig into a 'pig launcher' (or 'launching station') - a
funnel shaped Y section in the pipeline. The launcher / launching station is then closed
and the pressure driven flow of the product in the pipeline is used to push it along down
the pipe until it reaches the receiving trap - the 'pig catcher' (or receiving station).

If the pipeline contains butterfly valves, the pipeline cannot be pigged. Ball valves cause
no problems because the inside diameter of the ball can be specified to be the same as
that of the pipe (assuming they are full bore valves).

Pigging has been used for many years to clean larger diameter pipelines in the oil
industry. Today, however, the use of smaller diameter pigging systems is now increasing
in many continuous and batch process plants as plant operators search for increased
efficiencies and reduced costs.

Pigging can be used for almost any section of the transfer process between, for example,
blending, storage or filling systems. Pigging systems are already installed in industries
handling products as diverse as lubricating oils, paints, chemicals, toiletries, cosmetics
and foodstuffs.

Pigs are used in lube oil or painting blending: they are used to clean the pipes to avoid
cross-contamination, and to empty the pipes into the product tanks (or sometimes to
send a component back to its tank). Usually pigging is done at the beginning and at the
end of each batch, but sometimes it is done in the midst of a batch, e.g. when producing
a premix that will be used as an intermediate component.

Pigs are also used in oil and gas pipelines: they are used to clean the pipes but also there
are "smart pigs" used to measure things like pipe thickness and corrosion along the
pipeline. They usually do not interrupt production, though some product can be lost
when the pig is extracted. They can also be used to separate different products in a
multiproduct pipeline.

A major advantage of piggable systems is the potential resulting product savings. At the
end of each product transfer, it is possible to clear out the entire line contents with the
pig, either forwards towards the receipt point, or backwards to the source tank. There is
no requirement for extensive line flushing.

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Without the need for line flushing, pigging offers the additional advantage of a much
more rapid and reliable product changeover. Product sampling at the receipt point
becomes faster because the interface between products is very clear, and the old
method of checking at intervals, until the product is on-specification, is considerably
shortened.

Pigging can also be operated totally by a programmable logic controller (PLC).

Pig launchers are used to launch the pig into the pipeline, and pig receivers are used to
receive the pigs after they have made a successful run. The choice of these pig traps will
depend on the type of pig to be run and pipeline design conditions. Provisions in the
station design should include handling equipment for pigs 20" and larger. Caution should
be taken for liquid spillage from the pig traps.

6.1 TYPICAL PIG LAUNCHING PROCEDURES:

The operational sequence described below is for general information only. It is not
intended, nor should it be used, to train pigging system operators. Operating procedures
will vary from one Pipeline Company to another. The following pig launching procedures
can be used as a guideline for developing operating procedures.

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Since company policies vary regarding whether the pig launcher is left on stream or
isolated from the pipeline after the pig is launched, the operator should verify that the
trap is isolated from the pipeline and depressurized before commencing any part of the
launch procedure.

1. Make sure that the isolation valve and the kicker valve are closed.
2. In liquid systems, open the drain valve and allow air to displace the liquid by opening the
vent valve. In natural gas systems, open the vent and vent the launcher to atmospheric
pressure.
3. When the pig launcher is completely drained (0 psig), with the vent and drain valves still
open, open the trap (quick opening closure) door.
4. Install the pig with the nose firmly in contact with the reducer between the barrel and
the nominal bore section of the launcher.
5. Clean the closure seal and other sealing surfaces, lubricate if necessary, and close and
secure the closure door.
6. Close the drain valve. Slowly fill the trap by gradually opening the kicker valve and
venting through the vent valve.
7. When filling is complete, close the vent valve to allow pressure to equalize across the
isolation valve.
8. Open the isolation valve. The pig is ready for launching.
9. Partially close the main line valve. This will increase the flow through the kicker valve
and behind the pig. Continue to close the main line valve until the pig leaves the trap
into the main line as indicated by the pig signaler.
10. After the pig leaves the trap and enters the main line, fully open the main line valve.
Close the isolation valve and the kicker valve.
11. The pig launching is complete.

6.2 TYPICAL PIG RECEIVING PROCEDURES:

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The operational sequence described below is for general information only. It is not
intended, nor should it be used, to train pigging system operators. Operating procedures
will vary from one pipeline company to another.

The following pig receiving procedures can be used as a guideline for developing
operating procedures.

Since company policies vary regarding whether the pig receiver is left on stream or
isolated from the pipeline, the operator should verify whether there is any internal
pressure in the receiving trap before starting any part of the receiving procedures.

1. Make sure the receiver is pressurized.

2. Fully open the bypass valve.
3. Fully open the isolation valve and partially close the main line valve.
4. Monitor the pig signaler for pig arrival.
5. Close the isolation valve and bypass valve.
6. Open the drain valve and the vent valve.
7. Check the pressure gauge on the receiver to assure the trap is depressurized (0 psi).
8. Open the trap closure and remove the pig from the receiver.
9. Clean the closure seal and other sealing surfaces, lubricate if necessary, and close and
secure the trap (quick opening closure) door.
10. Return the receiver to the original condition.
11. Return the permit to control room.

7. SCHEMATIC DIAGRAM:

Standard Pig Launcher / Receiver

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• All launchers are primed.

• All launchers are hydrostatically tested.
• Valves on launchers & receivers must be round.
• Full port with a 100% pipe size opening.

Launching & Receiving Configurations

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Conventional Pig Launching

Launching Pig in Water Main Section

Trapping Pig with Slotted Tray

Conventional Pig Trapping

8. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the operation &
maintenance of Pigging at IPS Stations.
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9. DEFINITION:

Main objective is that the pipeline should be cleaned from inside with the help of pigs to
achieve maximum efficiency through the pipeline.

10. EQUIPMENTS DETAILS:

PIG, PIG LAUNCHER & PIG RECIEVER.

11. RECORDS:

Maintain records as per required formats.

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 STANDARD OPERATING PROCEDURE
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REVISION:01
River/Water Course Crossing Inspection &
Maintenance Procedure W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

River/Water Course Crossing Inspection & Maintenance Procedure

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River/Water Course Crossing Inspection &
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1. PURPOSE:

To provide written monthly/ Quarterly procedure of Inspection of River/Watercourse

crossings of Mainline.

Physical checking for any scouring, Erosion in the watercourse, to ascertain and maintain
the health & safe condition of the River/Watercourse crossings, in case of any
abnormality is observed/found same can be attended timely and safe condition and
protection of pipeline is maintained. Also, to detect washout/exposure of
Mainline/Casing pipe/OFC duct within the watercourse if any preventive actions can be
taken to restore safe condition.

2. SCOPE:
This standard covers Inspection & Maintenance of River/Watercourse crossings of
mainline.

3. SAFETY REQUIREMENTS:
Hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Physical checking of both ends of River/Watercourse crossing is carried out.
• Physical checking of Marker Board/Warning Board/TLP/OFC is done.
• Inspection schedule for River/Rail/Road/Highway crossing is referred
• Checking of both the Vent Pipes for their Integrity, Internal Jalli is carried out
• Taking PSP values of both Carrier and Casing Pipes to check if there is any shorting.
Record the reading in the prescribed format.
• If the PSP values of both Carrier and Casing Pipes are OK and there is no shorting, then
checking is complete.
• Physical checking for any Scouring, Erosion in the Watercourse & take photographs.

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• Physical checking for any bank protection damages & take photographs.
• Checking of Pipeline Markers, Warning Boards, TLP etc. and their condition.
• Checking for any Washout/Exposure of M/L pipe/ OFC duct within the Watercourse &
River crossing.
• In case any washout or exposures of Mainline Pipe/OFC duct damage to bank protection
is observed, Verbal and written information is immediately given to concerned Site
Incharge, Project Incharge, Client and HO.
• In case of Poor PSP value or shorting is observed the proper maintenance is needed. The
compiled report with observations and comments/suggested actions is sent to Client
with a copy to HO immediately through/by Project Incharge.
• All corrective/preventive actions will be taken up including maintenance as per
instructions and advise of Client i.e. EIC, HMPL. Upon obtaining/receiving the clearance
from EIC of HMPL the maintenance is carried out as per steps needed for restoration,
depending upon the nature, severity and development of unsafe condition i.e. Scouring,
Erosion in the Watercourse, damage to bank protection Washout/Exposure of M/L pipe/
OFC duct within the Watercourse & River crossing.

• As per standard practice/procedure, the proposal with estimate to be sent to EIC. client
for approval for the Rectification/Restoration work to be taken prior to taking up the job
by Project In charge in consultation with HO, SPPL

• Return permit to control room.

5. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers to check & inspect of
River/Water Course Crossing.

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6. DEFINITION:

Main objective is to clear the passage between crude oil pipeline & casing pipe by
applying different pressure with help of MMV compressor.

7. REFERENCES:

• List of River/Rail/Road/Highway crossings

• Inspection Schedule/plan of Crossings.
• Route Map of the ROW/ROU.
• As built drawings of each crossing.
• Daily / Monthly report of Patrolling done by Line Inspectors / Mainline Security
Guards/Patrolmen i.e. Format No. & Format No.
• Concerned Registers

8. RECORDS:

Logbook/ Register is to be maintained and maintenance carried out with parts

consumed is maintained.

INSPECTION REPORT OF RIVER/WATERCOURSE CROSSINGS:

Form No.: - SPPL/HMPL/ML-FORM-3
INSPECTION REPORT OF RIVER/WATERCOURSE CROSSINGS

Location

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Sr. Date of Type of Chainage PSP Condition OK / not Details of

No. Inspection Crossing & Crossing Value of OK (give Nature, actions taken
Number Carrier & Severity & type of and proposed
Casing unsafe condition for rectification
observed)

Signatures

Executed by; ________ Reviewed by; _________ EIC; ______

Technician: - Engineer: -

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Scrapper Barrel Maintenance Procedure
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Sanmarg Projects Private Limited

Scrapper Barrel Maintenance Procedure

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Scrapper Barrel Maintenance Procedure
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1. PURPOSE:

To provide written procedure for maintenance of Scrapper Barrel.

Scrapper Barrels are used to enhance and speed the initial purge and fill operations and
to clean the pipeline of contaminates and obstructions that cause excessive drop in
pressure.

2. SCOPE:

This standard covers the guidelines on checking of Scrapper barrel & maintenance.

3. SAFETY REQUIREMENTS:
Hand gloves, safety shoes and safety helmet

4. PROCEDURES:
Before a scraper can be launched, the downstream receiver must be ready to trap the
scraper. Insert the scraper into the pipeline using the following procedures:

➢ Obtain the work permit from operating department.

➢ Check to make sure the launcher bypass valve is fully open.
➢ Close the side and mainline valves to isolate the barrel of the launcher assembly.
➢ Open the launcher assembly vent valve to relieve pressure from the barrel.
➢ Open the drain valve and drain the fuel from the launcher barrel into a container.
➢ Open the safety vent on the end closure and then open the launcher barrel end
closure.
➢ Insert the scraper into the launcher barrel. Push the scraper as far as it will go into
the launcher barrel.
➢ Close and tighten the end closure, close the safety vent valve, and close the drain
valve.
➢ NOTE: Close the safety vent valve only hand tight. If it leaks after the barrel has been
filled, use a crescent wrench to tighten it.
➢ Set by pushing the flag down.
➢ Slowly open the side valve completely.
➢ Close the launcher assembly vent valve when the barrel is full.
➢ When directed by the dispatcher to launch the scraper, slowly open the mainline
valve completely.
➢ Slowly close the bypass valve. As the bypass valve is closed, the flow is diverted
through the barrel causing the scraper to be carried or forced into the pipeline.
➢ Watch the scraper indicator (Figure 7-11) for indication that the scraper has been
launched. Notify the dispatcher the moment the scraper is launched.
➢ Open the bypass valve after the scraper has been carried out of the launcher barrel
by the flow of fuel.

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➢ Always operate with "wet" barrel, leaving the side, mainline, and bypass valves
open.

Figure 7-11. Scraper indicator

4.1. RECEIVER OPERATIONS

The recommended standard procedures to operate the receiver are discussed below. To
receive the scraper:

➢ Make sure the receiver barrel end closure is closed and tight. Ensure the drain valve and
safety vents are closed.
➢ Open the side, bypasses, and mainline valves on the receiver assembly during normal
operations

➢ Set the scraper indicator.

➢ Close the bypass valve. This directs the flow of fuel through the barrel.
➢ Remove the scraper from the receiver using the following procedures:

➢ When the scraper has entered the receiver barrel the scraper indicator will pop up.
➢ Notify the dispatcher of the scraper arrival.

➢ Open the bypass valve.

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➢ Close the mainline and side valves.

➢ Open the receiver barrel vent and drain valve. Drain the product into a suitable
container. Dispose of hazardous waste IAW federal, state, local, and host nation
regulatory guidance.

➢ Open the safety vent and then open the receiver barrel end closure.
➢ Remove the scraper and clean out the receiver barrel.
➢ Close and tighten the end closure safety vent.
➢ Close the drain valve.
➢ Open the side valve slowly to fill the receiver with fuel and close the receiver barrel vent.
➢ After the receiver barrel is full, open the mainline valve.

➢ During normal operations, leave all valves open. The system should be run with a "wet"
barrel
➢ Return permit to control room.
The launcher assembly used to launch the pipeline scraper consists of the steel skid, the
launching barrel, and related piping and valves (Figure 7-8).

All components of the launcher assembly are steel. The launching barrel has a quick-
opening closure, a pressure gage, a drain valve, and vent valve. Located on the bypass is
a ball valve under a 1-inch thermal relief valve. The initial set relief pressure is 740 PSI.
The set pressure can be adjusted as necessary, depending on the location of the system.
The relief valve discharge is tied into the discharge line from the vent valve on the
launching barrel.

A 2-inch diameter, 25-foot long hoseline is connected to the vent and drain to dispose of
fuel when the barrel is being emptied. A scraper passage signal is provided on the
downstream part of the assembly. The scraper launcher assemblies are supplied with
the pump stations and are on the outlet side of the pump stations.

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Figure 7-8. Scraper launcher assembly

4.2. SCRAPER RECEIVER ASSEMBLY

The skid-mounted scraper receiver assembly consists of the receiver barrel and the
related piping and valves as shown in Figure 7-9. All components of the receiver
assembly are steel. The receiver assembly has a quick-opening closure, a pressure gage,
a drain valve, and a vent valve. The set pressure is 990 PSI. The set pressure is to be
adjusted, as necessary, depending on the location in the system.

A scraper signal is located at the entrance of the receiving barrel.

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Figure 7-9. Scraper receiver assembly

4.3. PIPELINE SCRAPER OPERATIONS

Line scrapers are run through the pipeline to prevent the debris from building up in the
line. The pipeline dispatcher will schedule the actual scraper operation on a pumping
order. Scrapers are run from the launcher at one pump station to the receiver at the
next pump station. There is a scraper indicator on each barrel that shows when the
scraper has been launched and received. By walking along the pipeline, the scraper can
be heard as it passes each coupling.

Types of Scrapers

Various types of scrapers or pigs for different services are available on the market.
Cupped scrapers constructed entirely of polyurethane have been found to be the most
serviceable in the IPDS pipeline. They are intended for general service, including purge
and fill operations. Initially, five scrapers have been supplied with each launcher
cleaning.

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Tracing of a Scraper

Scrapers are run from the launcher from one pump station to the receiver of the next
pump station. There are several ways to trace scraper movement in the pipeline. A small
battery-operated transmitter attached to the scraper sends a signal which is picked up
on a receiver by a pipeline patroller. A magnetized metal scraper can be used with a
detector sensitive to magnetic forces. The detector, used by a pipeline patroller,
registers an increase in magnetic activity as the magnetic scraper passes by. Because the
IPDS uses aluminum pipe, do not use a chain attached to the scraper. This method could
cause damage to the pipe sections.

Stuck Scraper

It is possible that a scraper could get stuck in a line during a run. The scraper can
probably be freed by increasing the pressure in the line. The increased force behind the
scraper should push the scraper loose and move it along with the flow of fuel. Care
should be taken not to overpressure the line. If increasing the pressure in the line does
not free the scraper, the line must be taken apart to remove the scraper. Do not try to
free a stuck scraper by putting another scraper in the line. The second scraper may not
free the first one and get stuck behind it.

5. RESPONSIBILTY:

Shift In-charge, Mechanical team & Company engineers responsible for the inspection &
maintenance of Scrapper Barrel at IPS Stations.

6. DEFINITION:

Main Objective behind is to clean the crude oil pipeline with the help of pigging to
increase the efficiency of pipeline.

7. RECORDS:

Maintain records as per required formats.

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REVISION:01
PIPE WALL THICKNESS MEASUREMENT
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

PIPE WALL THICKNESS MEASUREMENT

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1. PURPOSE:

To provide written procedure of Ultrasonic Thickness Gauge.

2. SCOPE:

This standard is applicable to measure the thickness of pipe wall with high accuracy as
0.1/0.01 millimetres.

Instrument Used: Ultrasonic Thickness Gauge

3. SAFETY REQUIREMENTS:

Safety Precaution should be taken while operating the instrument. The safety precautions
are as follows:

1. The operator should wear safety shoes and hand gloves.

2. While operating no person should get in contact with the probe and job.
3. The job material should be placed on wooden log and should not get in touch with
any waterlogged place.

4. PROCEDURES:

Operating Procedure
• Obtain the work permit from operating department.
• The digital Ultrasonic Thickness Gauge determines the thickness of a part or
structure by accurately measuring the time required for a short ultrasonic pulse
generated by a transducer to travel through the thickness of the material, reflect
from the back or inside surface, and be returned to the transducer. The measured
two way transit time is divided by two to account for the down and back travel path,
and then multiplied by the velocity of sound in the material.
• Condition and preparation of surfaces – In any Ultrasonic measurement scenario, the
shape and roughness of the test surface are of paramount importance. Rough,
uneven surfaces may limit the penetration of ultrasound through the material, and
result in unstable, and therefore unreliable measurements. The surface being

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measured should be clean, and free of any small particulate matter, rust or scale.
Often a wire brush or scraper will be helpful in cleaning surfaces. In more extreme
cases, rotary sanders or grinding wheels may be used, through care must be taken to
prevent surface gouging, which will inhibit proper transducer coupling.
• Transducer should be inspected on the regular basis, for signs of uneven wear of the
wearface. If the wearface is worn on one side more than another, the sound beam
penetrated the test material may no longer be perpendicular to the material surface.
In this case, it will be difficult to exactly locate tiny irregularities in the material being
measured, as the focus of the sound beams no longer lies directly beneath the
transducer.
• Probe Zero: The key is used to “zero” the instrument in much the same way that a
mechanical micro meter is zeroed. If the gauge is not zeroed correctly, all the
measurements that the gauge makes may be in error or by some fixed value. When
the instrument is “zeroed”, this fixed error value is measured and automatically
corrected for all subsequent measurements.
• Sound Velocity Calibration: In order for the gauge to make accurate measurements,
it must be set to the correct sound velocity for the material being measured.
Different types of material have different inherent sound velocities. If the gauge is
not set to the correct sound velocity; all of the measurements the gauge makes will
be erroneous by some fixed percentage.
• Calibration to a Known Thickness: It requires a sample piece of the specific
material to be measured, the exact thickness of which is known, e.g. from
having been measured by some other means.
• Calibration to a Known velocity: It ensures that the operator knows the sound
velocity of the material to be measured.
o Return permit to control room.

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NOTE:
• The instrument should always be free from vibration, strong magnetic field,
corrosive medium, dumpiness and dust. Storage in ordinary temperature.

5. RESPONSIBILTY:

Electrical team & engineers responsible for the proper functioning of Ultrasonic Thickness
Gauge when required.

6. REFERENCES:

Manufacturer’s (MiTech) operation manual of Ultrasonic thickness gauge model MT

150/160.

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REVISION:01
Venting at Cased Crossing Location Operation
Procedure W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Venting at Cased Crossing Location Operation Procedure

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Venting at Cased Crossing Location Operation
Procedure W.E.F.: 15.05.2019

1. PURPOSE:

To provide written operating procedure of venting at cased crossing area to prevent

Corrosion and shorting of casing pipe with carrier pipe by removal of trapped water
between the two crossing locations.

2. SCOPE:

This standard covers the guidelines on the Operation of Venting at cased crossing
locations.

Frequency: Yearly

3. SAFETY REQUIREMENTS:

Hand gloves, safety shoes and safety helmet

4. PROCEDURE FOR OPERATING:

 Obtain the work permit from operating department.

 We must observe the PSP of carrier and casing pipe on both sides of crossings (Vent &
Drain).

 It should be within the range of -.850mv and -125mv.

 The casing pipe should have the natural potential of iron/steel (0.24 to .3V) and the
carrier pipe should have the potential of -1.25V through impressed current system of
permanent CP of the carrier pipe.

 We should check the insulation between carrier & casing pipe for shorting if any by
means of continuity test with the help of a multimeter. Normally resistance between
carrier and casing pipe will be infinity in case of no shorting when the leads of the
multimeter are connected between P-1 and C-1 in the TLP or P-2 and C-2. And casing
insulators are in position to segregate both the pipes.

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 Electrical shielding by a shorted pipeline casing and the short circuit in place CP current
collects on the outside of the casing and flows along the casing to the point of contact
between the pipe and the casing. At the point of contact CP current flows to the carrier
pipe to the point of metallic contact and then along the carrier pipe back to the CP
installation.

 Under these conditions essentially no CP current flows through the casing to the pipe
surface, leaving pipe inside the casing walls free to corrode, even though the rest of line
is fully protected. If the casing pipe is free of a metallic contact with the carrier pipe the
metallic casing material, simply serves as part of the conducting environment. CP
current than can flow straight through the casing to those portions of pipeline in contact
with any electrolyte inside the casing. Current discharge from inner surface of the casing
walls would corrode the inside of the casing and the level of protection of a cased carrier
pipe will be less than that afforded an uncased carrier pipe even in absence of a short
because of the voltage drop across the metal electrolyte interface on the ID and OD
surface of the casing.

 Taste point must be inspected to assure that installation complies with construction
plans.

 Shorting can also occur from contacts between the test point wires and the casing vent
or between the test wire and the test point conduit mounted on the casing vent.

 Then we check the presence of water with the help of dip tape.

 Dip tape should be inserted from drain side.

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 If there is any water content than it should be removed by suction method at a low
compressed air pressure at 2.5kg/cm2.

 For the suction we need one 0.5 HP single phase motor, half inch PVC pipe of length 4
mtr.

 If there is no water content, then we should go straight to compress air method for
driving out any moisture.

 Then we again take the PSP on both sides of the cased crossing.

 Then we must use the compressed air for venting from the vent side of the crossing. The
compress air should come out from the drain side.

 We need the compressor with capacity of 5Kg/cm2, half inch pipe of at least 15 mtr in
length,3-inch hose pipe which will be fitted at vent side.

 The compressor air should be maintaining in-between of 1.5 to 2 Kg/cm2.

 Return permit to control room.

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5. EQUIPMENTS:

MMV vehicle & Compressors.

6. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the inspection &
maintenance of Venting at Cased Crossing Location at site.

7. DEFINITION:

Main Objective behind is to remove the trapped water or any dust so that it can prevent
the corrosion of the crude pipeline.

8. RECORDS:

Maintain Records as per required formats.

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REVISION:01
Pest & Rodent Control
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Pest & Rodent Control Procedure

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1. PURPOSE:

To provide a written procedure for taking pest and rodent control measures.

2. SCOPE:

The Procedure is applicable to control Pest and Rodents in all SV’s and IPS Stations.

3. SAFETY REQUIREMENTS:

Hand Gloves, Mask to cover the face, safety shoes. Precautionary measures as per MSDS
of the chemicals used like Bromadiolone and Carbolic Acid have to be taken by the
person executing the work.

4. PROCEDURE:

A. Rodent Control:

❖ Obtain the work permit from operating department.

❖ This treatment is for the management of rodents i.e., rats, mice, bandicoots in the
respective locations.
❖ Roda boxes are kept around the periphery of the main building and utility block with
Bromadiolone 0.005% as bait.
❖ Bromadiolone Baiting shall be carried out along the periphery of the building and at
the entry points.
❖ Baits shall be placed in tamper proof bait station boxes and shall be monitored/
replaced during technician’s visits.
❖ Glue board traps shall be kept inside the building at the entry points and at other
vulnerable spots keepings in view the movement of rodents (rats, mice).
❖ No food or poison baits are used and the catch can be disposed off without the dead
mouse or rate causing odour/contamination problems from in accessible production
areas.
❖ The placement of the glue boards will be along the walls in all areas close to doors
and other openings into an area.
❖ Housekeeping supervisor daily checks for the presence of rodent in the glue board
and the observations have to be recorded.

B. Snake Control Services:

❖ This treatment is for control of snakes in the SV’s and IPS Locations.
❖ Carbolic acid shall be applied at shelters of these pests such as the earth pits and the
trenches to repel the snakes.

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❖ Application of carbolic acid shall also be carried out along the periphery of building
and along the compound wall.
❖ Return permit to control room.

5. RESPONSIBILTY:

❖ Authorized person appointed for pest control. He would be qualified to carry out
the job.

6. REFERENCE:

❖ Material Safety Data Sheet (MSDS) Sheet of Delthamehtrin

❖ Material Safety Data Sheet (MSDS) Sheet of Bromadiolone

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REVISION:01
Earth Resistance Test Operation
W.E.F.: 15.05.2019
Procedure

Sanmarg Projects Private Limited

Earth Resistance Test Operation Procedure

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Procedure

1. PURPOSE:

To provide written procedure for measurement of Earth Pit Resistance for Electrical System,
Instrumentation System, D.G. and Telecommunication System. Measured Values are to be
recorded. To ascertain that Earthing System is in perfect Condition and effective to give
proper safety to ensure optimum performance and life of the equipment.

2. SCOPE:

This standard covers the guidelines on Half Yearly checking, measuring and maintaining the
value of earthing system as per Indian Electricity Rules 1956 and as per IS: 3043-1987 and is
applicable to earthing System installed for Electrical System, D.G. Instrumentation System
and Telecommunication Systems.

Frequency of inspection & Checking: Half Yearly

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD guidelines.

4. SAFETY PROCEDURES:

To protect the operator performing the earth resistance measurement (when the earth
resistance measurement has to be done in online condition i.e. HT yard is in energized
condition) as well as to identify the presence of electrical problems in the system, the
ground electrode shall be first checked for the presence of leakage current.

A digital clamp-on milli-ammeter shall be used to detect the current (Refer Fig.5). The
leakage current shall be less than 10 milliamps. The leakage current measurement shall be
carried out only at earthing strips provided for equipment body earthing.

Leakage current measurement shall not be carried out for G.I. strips connected to lightning
arrester
.
Caution: In case the leakage current is more than 10mA, earth resistance measurement
shall not be carried out.

To ascertain the cause for higher leakage current, shutdown shall be taken for the
equipment and necessary maintenance shall be carried out. After rectifying the fault the
equipment can be put in service.

Digital leakage Clamp Meter (Range: 0-30mA/ 300mA/ 300A):- 1 no.

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Procedure

Make: MOTWANE/Fluke/Megger

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

5. PROCEDURES:

• Obtain the work permit from operating department.

• The surface of the earth electrode where the crocodile clip is to be connected for
measurement shall be cleaned thoroughly, there shall not be any rust stains, paint,
deposition of foreign material etc.

• The E1 & P1 terminals provided on Earth tester shall be shorted using 2.5 sq. mm PVC
insulated, flexible copper wire. The terminal P1 shall be connected to the earth
electrode by Blue wire with the help of a crocodile clip/ copper alligator clip covered
with 1.1kV insulation protective rubber boot/PVC insulation. The wire between P1
&earth electrode shall be as short as possible, approximately 0.5 meters (in order to
reduce the lead resistance).

• The current spike shall be inserted/driven up to 300 mm into the ground at a distance of
30 meters in a straight line from the earth electrode (which is under
• Measurement). The current spike shall be inserted/driven straight in to the ground
• With the help of hammer. This spike shall be connected to E2 terminal of tester by Red
wire with the help of a crocodile clip.

• The voltage spike shall be inserted/driven up to 300 mm into the ground at midpoint
(i.e. at a distance of 15 meter on either side) between the current spike and the earth
electrode. The voltage spike shall be inserted/driven straight in to the ground with the
help of hammer. This spike shall be connected to P2 terminal of tester by Black wire with
the help of a crocodile clip.

• The three points i.e. earth electrode, voltage spike & current spike shall lie in a
• Straight line. After insertion, watering (approximately ½ bucket, i.e. 10 liters of water
shall be poured) shall be done at current spike & voltage spike in order to reduce the
contact resistance of the spike with soil.

• Initially the selector switch for range of the tester shall be kept on 100 ohms position.
The digital display shall come in action and shall read zero.

• Then the “TEST” push button on the meter shall be pressed till a stable value is obtained
on the display & then release the push button. As the reading shall be
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Procedure

• Generally small, the range selector switch shall be further turned to 10 ohms range.
• Note down the reading appeared on the display. After recording the earth resistance
value, the selector knob shall be turned to ‘OFF’ position and digits
• on the display shall disappear. Use crow bar to remove spikes from the ground.

• Don’t: The push button shall not be pressed for duration of more than three minutes.

• Repeat the above steps (1 to 7) for measurement of earth resistance for all the earth
pits.

• In case of erratic readings for any of the earth electrode check the tightness of
• Crocodile clips & the cleanliness of the contact area of the earth electrode. If the
• readings are still erratic then two more readings shall be taken with the voltage spike
moved some 6 meter away from the earth electrode under measurement and some 6
meter nearer to the earth electrode. If the three results are substantially in agreement,
the mean of the three readings shall be taken as the final resistance value of the earth
electrode. If there is no such agreement, the test shall be repeated with distance
between earth electrode & current spike increased. In such a case the current spike shall
be located at 50 meter and the voltage spike shall be located at 25 meter.

• For carrying out this measurement use continuous wires (50 meters long 2.5 sq.
• mm. wire shall be used for connecting to current spike and 25 meters long 2.5 sq.

• Return permit to control room.

mm. wire shall be used for connecting to voltage spike).

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Procedure

6. PRECAUTIONS:

The earth resistance measurement shall be preferably carried out when the Outdoor Switch
Yard is not energized i.e. it is isolated from the grid (offline). In case of unavoidable
circumstances, when the measurement has to be done in online condition i.e. when the HT
yard is in energized condition, the operator shall wear protective rubber hand gloves for
handling connections required for carrying earth resistance measurement & the operator
shall stand on a rubber mat while operating the earth tester.

Before making the connections, the operator shall measure the leakage current.

− Ensure that all the earth pits are interconnected with the earth grid.

− Select any one earth electrode for measurement & clean the surface of the earth
electrode where the crocodile clip is to be connected for measurement.

− Earth resistance measurement shall be carried out in three different directions.

− For earth resistance measurement in three different directions the electrode under
measurement shall remain same, only the point of insertion of the voltage spike &

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Procedure

current spike shall change. In all three directions it shall be ensured that the current
spike, voltage spike & the electrode under measurement are in a straight line.

− The mean of the three readings (A direction, B /B’ direction, C direction) shall be taken
as the resistance of the combined earth electrode/ earth grid.

− Earth resistance of the earthling grid shall be taken twice i.e. before & after watering.
The earth resistance value measured after watering shall be considered as the final
value of the entire earthing system.

Measurement of Earth Resistance for each Electrical Earthing Pit & Grid,
Instrumentation Earthing Pits & Grid System, D.G. and Telecom System Earthing Pits and
measured values are to be recorded.
• Obtain clearance from Control room
• Check corrosion on earth bolts & nuts
• Measure earth electrode resistance
• Measure electrode resistance with Grid
• Check the condition of electrode
• Take necessary corrective action
• Check the tightness of connections
• Return the permit to control room

7. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the inspection &
maintenance of Earth pits at SV & IPS Stations.

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Procedure

8. DEFINITION:

Main objective behind earth resistance measurement is to ensure that the

earth electrodes resistance value/ combined earth resistance value of the earthing system is
within the defined limits.

9. EQUIPMENTS DETAILS:

Digital Earth Testing Kit (Calibrated)

Digital Earth Resistance meter (Range: 0.01-10 Ohms/ 0.1-100 Ohms):- 1 no.,
Make: WACO/Cambridge/ Megger
Spikes (Aux. electrodes) :- 2 nos.; 450 mm long, 12.5 mm dia., Mild Steel rod
Testing wires:- PVC insulated, 2.5 sq. mm
Black colour – 30 mtrs. (To be connected to Voltage spike)
Red colour – 60 mtrs. (To be connected to Current spike)
Blue colour – 0.5 mtrs. (To be connected to Earth electrode)
Shorting link: - 1 No.
Crocodile clips: - 3 Nos.
Hammer (3kg):- 1 No.
Crow bar: - 1 No.
Screw driver: - 1 No.
Insulated plier: - 1 No.
Bucket (appx. 50 ltrs. capacity):- 1 No.

10. REFERENCES:

1. As built drawing of Electrical Earthing Systems

2. Earth Pit Typical Drawing

11. RECORDS:

Maintain records as per required formats.

HALF YEARLY EARTH PIT RESISTANCE MEASUREMENTS

STATION/LOCATION: DATE OF MEASUREMENT:

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Procedure

PLANNED/DUE MONTH: REASON FOR DELAY(if any):

Details of Earth Pit Resistance Measurement

Sl. Earth Pit No. Works Remarks

No. Value obtained (In Ohms) recommend
Individual Combined / carried out

NOTE: Suitable corrective actions to be taken in case individual earth pit resistance is > 2
ohms.

Earthing grid resistance measured: ____________ Ohms.

12. CHECK AFTER MEASUREMENT OF EARTH PIT RESISTANCE.

MAINTENANCE
• Watering of earth pits Done
• Tightening of Connections Done
• Greasing of Nut And bolts
• Status of Cables/Strips (OK/NOT OK)
• Status of Earth Pits Including Covers
• Numbering of Earth Pit Done

OPEARTION
• Inter Connection Earth Pit Diagram Displayed

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EXTENSION OF CASING PIPE
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Extension of Casing Pipe

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1. PURPOSE:

To specify working procedure for extension of casing pipe due to proper venting of high
pressure crude pipeline.

2. SCOPE:

This standard covers the guidelines on Extension of casing pipe.

3. SAFETY REQUIREMENTS:
Ensure that all the Safety requirements for doing the job safety are met as per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs
1. Leather Hand Gloves.
2. Safety Shoes.
3. Permit Hot Work/Cold work.
4. Fire Extinguisher/Absorbent pad/DCP Powder.
5. Helmet.

4. PROCEDURES:

• Inform Control Room before starting work.

• Obtain Permit from Control room duly signed by maintenance Incharge for various Cold and
Hot work.
• Before starting the work inform control room for final clearance to start the job.
• Barricade the location with cordoning tape/Caution tape along with display of work in
progress for identification of work.
• Trace the location of the pipeline.
• Excavate up to 1 meter depth by JCB from ground level.
• After 1 meter excavate manually pipeline to trace pipe and OFC cable.
• OFC cable to be handling carefully.
• Remove TLP connection and place it aside carefully.
• Clean the mainline carefully by cotton waste and do the Holiday test.
• Cut casing pipe in a section of 3-3 meter each of 12 meter length.
• Cut the casing pipe half and weld the border by MS strip and do primer inside the pipe.
• To avoid the touching of casing pipe with carrier pipe suitable insulators at a gap of 1 meter
will be installed for total 12 meter length of pipe as per site requirement and instructions of
EIC.
• Laying of absorbent pad and sprinkling of DCP powder to the excavated area for stopping of
any fire/Crude leak.
• Remove the vent pipe from its location by cutting and extend to last point and then welding
it.
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• Welding the complete casing pipe. The welding will be done in such a manner that the heat
of the welding does not pass to the carrier pipe. The welding will be done longitudinally
along the split portion.
• Application of primer outside casing pipe area.
• Around the casing pipe doing concrete grade M-20.
• At the last point of extended casing fix the end seal to close the casing end.
• Shifting of TLP to new end location with extension of cable.
• Shifting of warning board to the new end location.
• Checking of PSP reading and then backfilling and restoration of excavated area.
• Inform Control Room, Site incharge for the completion of work.

5. RESPONSIBILTY:

Shift In-charge, contractor & Company engineers to execute the job safely in line with
Control Room.

6. DEFINITION:

Main objective is to Extend casing pipe length for proper venting at pipeline location.

7. RECORDS:

Maintain records as per formats of Daily activity along with progress to be

Submitted to client.

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REVISION:01
DCVG SURVEY
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Direct Current Voltage Gradient (DCVG) SURVEY

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DCVG SURVEY
W.E.F.: 15.05.2019

1.) PURPOSE:
The purpose of this survey technique used for assessing the effectiveness of
corrosion protection on buried steel structures.

2.) SCOPE:
The scope of this SOP is to carry out Direct Current Voltage Gradient Survey for verification
of the Coating defects identified during Close Interval Potential Logging survey.

3.) SAFETY REQUIREMENTS:

A. Ensure that all the safety requirements while doing the job are met as per OISD
guidelines
B. PPE Required:
a. Helmet
b. Goggles
c. Safety Shoes
d. Hand Gloves (Normal Electrical)
e. Boiler Suits

4.) MANPOWER:

A. Surveyor - 1 No.
B. Technician - 2 No.
C. Helper- 1 No.
D. Labour - As reqd...
5.) EQUIPMENTS, TOOLS & TACKLES:

Sr. No. Material Description Quantity Make

1. DCVG Meter along with the
Equipment Set DCVG
reference cell sticks
2. Current interrupters with
synchronized timer circuits and One per team DCVG or other Suitable
adjustable time settings
3. Digital Multimeter One per team Rish 18S

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4. Portable Cu/Cu SO4 Reference

One per team MC Miller
Cells
5. Field marking wooden pegs,
As required
Paint, Hammer etc.

6.) PRINCIPLE OF DCVG TECHNIQUE

A. In cathodic protection, when current flows through the resistive soil to the bare steel
exposed at defects, in the protective coating, voltage gradient is generated in soil.
B. Larger the defect greater the current flow & hence the voltage gradient.
C. This is utilised in the technique to give priority to the defects for repair.
D. When the two electrodes are placed 1.5 meters apart on the soil in the voltage gradient
from a coating defect, one electrode adopts a more positive potential than the other, which
allows the direction of current flow to be established and defect to be located
E. The voltage gradient is monitored by measuring out of balance between two electrodes
using specially designed milli – voltmeter, called as DCVG survey me

7.) PROCEDURE

Setting up the DCVG signal.

The most important parameter in ensuring an accurate survey and in determining the
survey speed is in the amplitude of DCVG pulsed signal.
A. Connect the red terminal of the interrupter with the cable going to the TR /CPPSM unit.
B. Connect the black terminal of the interrupter with the cable going to the pipeline.

Assembling the DCVG equipment.

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A. Polarity of the connection is important; if connection is wrong the interrupter will not
switch the DC output.
B. The amplitude or signal strength is the difference between ON and OFF potential
measured on the pipe using DCVG meter, while the interrupter is switching ON and OFF
the applied DC source.
C. Keep the nearest TR/CPPSM unit interrupter in Manual/ AVCC mode during survey and
adjust the output signal from T/R unit along with interrupter to achieve the signal
strength to reach at higher distance.
D. In case of survey area at center of two CP units, both may be interrupted with same
setting and synchronized interrupters or one to be switched off for time being.
E. The amplitude of DCVG signal should be at least 250 mV but not more than 1500 mV.
Measure and record the set point signed at each test station by touching one ref. cell
bottom at Test Station terminal and putting the other reference cell on soil above
pipeline.
F. Rapid decay of signal measured at two locations one km apart would be an indicator of
poor coating on pipeline
G. A good coating would show very little attenuation of signal amplitude with distance.
H. Place the DCVG meter around the neck and waist so that the meter fits snugly on
operator.
I. Fit connecting leads into the meter and into the probes to interconnect two probes with
meter.
J. Turn ON the meter switch and adjust the Range switch from 4V to 1000mV.
K. Switch ON the bias to the right – hand probe with the probe tips placed in the soil.
L. The bias to the left – hand probe is not switched on; it is a spare available if needed.
M. Now move to the test point at which the signal is to be measured.

SURVEYING BY USING CENTRE ZERO DEFLECTION VOLTMETER

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A. Fill probes with Copper Sulphate solution.

B. Fit connecting leads into the meter and into the probes to interconnect two probes with
meter.
C. Turn ON the meter switch and adjust the range Switch from 4 V to 1000 mV
D. Switch ON the bias to the right-hand probe with the probe tips placed in the soil,
E. The bias to the left-hand probe is not switched on, it is a spare available if needed.
F. While Surveying the Pipeline, the Operator walks the pipeline route for testing pulsing
voltage gradient at regular intervals.
G. As a defect is approached, the milli voltmeter needle begins to respond to the pulse and
pointing in the direction of current flow, which is toward the defect.
H. By retracing toward defect, find a position of the electrodes where needle shows no
defection in either direction.
I. Repeat the procedure at right angles to the first set of Observation.
J. Where the two midway positions cross each other is the position directly above the coating
defect.
K. Pin point the defect location and draw a line on the ground then place the probes 2 meters
away from the line and perpendicular to the line and move towards the defect. The meter
needle comes to zero when the defect lies in between the two probes and draw a line
between the probes. The point of intersection of both lines is the defect epi center. Place
wooden pegs with defect marker written at the defect location. Measure over the line to
remote earth potential by placing on probe at defect epi center and the other perpendicular
to the line which is approximately 1 to 1.5-meter distance. Read and place the first probe
where the second probe was placed and the second away from that and observe the meter
deflection. Add all the milli volt drops and total is equal to over the line to remote earth
potential (OL/RE).

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L. Calculate the percentage (%) IR drop based on measured reading at fault drop vs. Actual set
point value.
8.) ANALYSIS AND RESULTS

Calculate the pipe to remote earth potential as follows:

P/RE = S1- dx (S1-S2) / d2-d1

Where,
S1 is signal at upstream test post
dx distance between up streams test post and defect
d2 is the distance of downstream test posts
d1 is the distance of upstreams test post
S2 is the signal strength at downstream test post

Calculate the % IR drop as follows:

In short, % IR = OL/RE x 100

P/RE

Where,
OL/RE: Defect epi – center to remote earth potential
P/RE: Calculate the pipe to remote earth

The Classification of severity of the defect will be based on the % IR drop as follows:
Low profile defect < 15%
Moderate profile defect 15 to 35 %
Severe profile defect > 35 %
Put permanent marker at defect location such as painted stone or wooden peg & also make
a sketch showing the defect location and distance from the nearest permanent
identification available (such as T.S, Route marker, Trees, Electric post etc.) available at site.
Also note down the type of defect and the mV readings on both perpendicular directions

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and record it in the format enclosed (Both sides for confirmation only, only one reading to
be recorded).
Prepare a list of all defect location for further verification.

9.) APPENDIX / FORMATS

DCVG Survey Data Template

Owner:
CP Contractor:
Project:
Report No.: Date:
Pipeline Section Code and Name:

Sr. No.
Date of Survey

Chainage (Defect Location)

Location Detail
ID
Ps Off (Upstream TLP)
Ps On (Upstream TLP)

Chainage (Upstream TLP)

Pulse

Signal Strength (Upstream)

Ps Off (Downstream TLP)

Ps On (Downstream TLP)

Chainage (Downstream TLP)

Signal Strength (Downstream)

Easting (X cord)
Northing (Y cord)

Distance between upstream TLP to

defect

Calculated pipe to remote earth

Over the line to remote earth

potential

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10.) RESPONSIBILITY

➢ Project In – Charge
➢ Surveyor
➢ CP Technician/Supervisor

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REVISION:01
SLEEVE WELDING
W.E.F. 15.05.2019

Sanmarg Projects Private Limited

SLEEVE WELDING

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REVISION:01
SLEEVE WELDING
W.E.F. 15.05.2019

1. PURPOSE:

The purpose of this SOP is: To fix the split sleeve for repairing of anomalies
observed during IPS.

2. SCOPE:

The scope of this SOP is: This procedure is applicable to all pipeline sections
during repair of mainlines.

3. SAFETY REQUIREMENTS:

a) Ensure that all the safety requirements while doing the job are met as per
OISD guidelines

b) PPE Required:
➢ Safety Helmet
➢ Goggles
➢ Safety Shoes
➢ Hand Gloves (Normal, Welding)
➢ Boiler Suits
➢ Ear Muffs/Ear Plugs.
➢ Fire Extinguishers

4. MANPOWER:

➢ Sleeve Welder- 1 No.

➢ Normal Welder-1 No.

➢ Insulator-1 No.

➢ Fitter cum grinder-1 No.

➢ Labour -As reqd...

5. EUIPMENTS, TOOLS & TACKLES:

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Sr.
Materials Description Quantity Make
No.
As per the
Full encircled split sleeve
As per the details
1. Notched with baking strip
requirement mentioned by
client
As per the
As per the details
2. Coating Materials-Cold tape
requirement mentioned by
client

3. Holiday Detector 1 No. Reputed

4. Pipeline Locator 1 No. Reputed

5. Portable GPS Instrument 1 No. Reputed

6. Grinding Machine-AG4 1 No. Reputed

7. Grinding Machine-AG7 1 No. Reputed

Welding Generator Set-150

8. 1 No. Reputed
Amp(portable)/400 amp
9. Grinding Wheel-for AG4 As required Reputed
10. Grinding Wheel-for AG7 As required Reputed
Welding electrodes-7018,
11. As required Reputed
6010
Gas cutting set(regulator,
spark arrestor, hose
12. 1 No. Reputed
cutting/welding torch)
IS:6901, IS:7653, IS:11006
13. Ultrasonic Thickness Gauge 1 No. Reputed
14. Tool Box 1 set Reputed
15. JCB As reqd. Reputed
16. Pit Depth measurement 1 No. Reputed
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gauge
17. Chisel 1 No. Reputed
18. Brass hammer 1 No. Reputed
Measuring tape
19. 1 No. Reputed

6. PROCEDURE:

➢ Get the job order and obtain the work permit from operating department.
➢ Clear the ROW.
➢ Take all the permissions from the concern authorities.
➢ Identification of the exact location of the anomaly.
➢ Excavate the identified point carefully without any damage to the mainline,
its coating and also without disturbing or damaging neighboring utilities.
➢ Maximum unsupported length will not exceed 8 m.
➢ Visual Inspection of the exposed mainline.
➢ Old coating will be removed manually carefully with the help of scrappers
and small brass hammers, so that outer surface of the pipe is not damaged.
After coating is removed, the pipe surface shall be thoroughly cleaned of old
primer, scales, rust, oil, grease, dust particles etc.
➢ Inspection of the pit with respect to the data from IPS.
➢ All the dust, debris, old primer, scales & rust if any should be thoroughly
cleaned from the pipe surface with Emery paper, wire brush or with buffing
wheel without damaging the mainline.
➢ Pipe wall thickness of pipe length exposed will be measure by standard
(digital) ultrasonic thickness gauge duly calibrated. Actual pipe wall
thickness of pipe would be measured at 4 locations (12’ o clock, 3’ o clock, 6’
o clock & 9’ o clock).
➢ Split Type sleeve is welded as per following procedure and WPS:
o Two half of sleeves piece already beveled at the ends and sides are
fitted directly on carrier pipe at corroded area.
o The end of sleeves will be circumferentially welded (Fillet weld) to the
carrier pipe and two half sleeves will be butt welded longitudinally at
both sides.
➢ Inspection & NDT test of the welding of the sleeve to be done.
➢ Mastic putty shall be applied at seam, welds or dents of carrier pipe surface
to get smooth surface to avoid formation of air pockets between pipe &
inner tape.
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➢ The time gap between the pipe cleaning and application of primer should
not be more than 3 hours. The cleaned surface should not be left overnight.
The surface must be cleaned and dried before application of primer.
➢ There shall be an overlap of 500mm between existing 3LPE coating and new
old tape.
➢ A thin, one coat even and uniform primer coat of Densolen Primer MT25
shall be applied over steel pipe by a good quality paintbrush to achieve 50
microns DFT.
➢ An inner layer of DENSOLEN-Tape AS39P, 3-ply(100mmx30mtr) tape with

stabilized polyethylene backing and butyl rubber adhesive layers on both

sides for corrosion protection to be applied with 50% overlap manually.

➢ Return permit to control room.

7. RESPONSIBILTY:

➢ Supervisor

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REVISION:01
Clock Spring Installation
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Installation of Clock Spring

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Clock Spring Installation
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for installation of Clock Spring for providing a permanent
repair for external defects. It can also be used to provide temporary reinforcement for
internal corrosion defects.

2. SCOPE:

This standard covers the guidelines on installing the Clock Spring.

3. DEFINITION:
Clock Spring Pipe Supports typically consist of two concentric wraps of the Clock Spring®
composite shell. The shell is in the form of a split sleeve, with a circumference slightly
smaller (0.063-inches (1.5 mm) than the pipe being protected. Each shell will fit around the
pipe leaving a slight longitudinal gap. Each layer of the Pipe Support will be applied such that
the longitudinal seams are staggered from the longitudinal seams of the preceding layer.
The system operates by restricting bulging in the pipe at the defect location. The hoop stress
is transferred through high compressive strength filler, to the composite sleeve (Clock
Spring®) wrapped around, and bonded to, the pipe.

4. SAFETY REQUIREMENTS:
Rubber hand gloves, safety shoes and safety helmet

5. PROCEDURES:
➢ Obtain the work permit from operating department.
➢ Clean the pipe surface to be protected, removing all scale, loose debris, products of
corrosion, and residual pipe coating. The surface should contain a slight anchor pattern as
specified in the NACE #3 Surface Finish standard. Sand blasting the pipe surface is
recommended. Wire brushing alone is not an acceptable surface preparation. If wire
brushing is used to clean the pipe surface, an anchor pattern should be applied using an
appropriate sanding disk.

➢ Carefully inspect the pipe dents, gouges, scrapes and corrosion. Any damaged areas will be
evaluated using appropriate NDE techniques.

➢ The filler material is a Methacrylate adhesive consisting of a paste and an activator. The
filler and activator will be mixed according to the pipe temperature. Refer to the chart on
the Filler tube for the proper mix ratio. Table 2 below is provided for reference only. Mix the
filler and activator for 3 minutes until the mixture is uniform in color and completely mixed.

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➢ Apply filler material to all voids under the repair.

➢ The adhesive is a Methacrylate consisting of an adhesive and activator. The mix ratio will
depend on the application temperature. Refer to the chart on the Adhesive container for
the proper mix ratio. Table 1 is provided below for reference only. The mix ratio, ambient air
temperature and pipe temperature will all affect the working time available before the
adhesive cures.

➢ Determine the correct mix ratio. Mix adhesive and activator according to standard Clock
Spring procedures.

➢ Liberally apply the mixed adhesive to the filler material and pipe surface to be protected.

➢ Apply the first concentric sleeve over the filler and adhesive.

➢ Apply filler material to the longitudinal seam of the first wrap and adhesive to the surface of
the first wrap.

➢ Applying adhesive between each layer, apply subsequent layers of composite sleeves with
the longitudinal seam positioned away from the longitudinal seams on the underlying layer.

➢ Continue the installation process until the entire support is complete and all layers are in
place.

➢ Using the band clamps supplied, tighten the repair onto the pipe. The band clamps are
spaced evenly along the repair and tightened from the center out to each end. Clean excess
adhesive and filler material.

➢ When the adhesive has fully cured, remove the clamps and coat the support area with a
protective coating.

➢ Return work permit to control room.

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6. RESPONSIBILTY:
Site In-Charge
Technician

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REVISION: 01
Excavation and Backfilling
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Excavation and Backfilling

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REVISION: 01
Excavation and Backfilling
W.E.F.: 04.02.2018

1. PURPOSE:

Purpose of this method statement is to provide guidelines to concerned personnel

regarding minimum requirements for Excavation and Backfilling on pipelines at defect
locations.

2. SCOPE:

The scope of this method statement is limited to activities involved in working near live
lines such as Excavation and Backfilling.

3. SAFETY REQUIREMENTS:

1. A responsible competent supervisor shall monitor the related activities.

2. PTW system will be followed strictly for excavation near live lines.
3. The permit applicant shall ensure that as-built information is considered while applying
for permit especially for the buried cables / facilities.
4. Scanning, trial holes shall be prepared for surveying of existing facility.
5. Toolbox talks shall be conducted prior to starting any activities.
6. Crew supervisor shall ensure all personnel involved in the operation are fully aware of
their individual duties and the possible hazard.
7. All crew members must have proper PPE.
8. Orderliness should be in place during work and after completion of work. Crew
supervisor shall ensure that Proper Housekeeping is maintained at the end of the day
near the work area.

4. PROCEDURE:
EXCAVATION:
1. Reach to the defect location with the help of pipeline locator & GPS meter.
Excavate soil over & around underground pipeline very carefully by mechanical
means (Hydraulic excavator) or manual means as per excavation vicinity to
pipeline.
2. Approximate excavation at each location will be 8-meter length, 1.75-meter width
(1-meter clearance from both side of P/L), 3.5-meter depth (1-meter clearance from
P/L bottom).
3. Photos are to be taken. One Upstream view of site, one Downstream view of site
and One Bottom of the pipe showing clearance of 1 meter with a measuring tape
4. At each investigative site, the terrain conditions are to be recorded as the pipeline is
excavated.

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5. The documentation of terrain conditions includes the identification of soil type,

drainage and topography parameters. Pictures with labelling of the identified terrain
must be taken.
6. Photographs to be provided from within the ditch of surrounding soils to the pipe –
(2 nos.), one from upstream end of the dig site looking downstream and one from
downstream end of the dig site looking upstream.
7. Determination, measurement and documentation of external pipe body damage
found during the examination of the pipe. Scan the coating surface of for the entire
exposed pipeline within the ditch for following:
a. Coating holidays: to mark/ outline the coating holiday using a solid paint
marker (red/yellow color) and take a photograph (1no.)
b. Deposits on pipe: identify the deposits observed and take a photograph
c. 3rd party damage / gouges / dents: if observed, to mark / outline the
anomaly using a solid paint marker (red/yellow color) and take a photograph
8. Locate weld within the dig site (this becomes the reference point). In case
unavailability of weld within the excavation length, the most upstream ditch wall to
be utilized as the reference point for all further inspection findings.
9. The GPS coordinates to be included with each site investigation report. High
accuracy (+/- 10 cm) GPS point of this reference weld.
10. Locate subject pipelines’ 12:00 (top of pipe) using a leveler tool. Mark the 3:00 and
9:00 respectively on each side (both in clockwise direction as well as counter clock
wise direction)
BACKFILLING:
1. Backfill the excavated area after completion of work.
2. Dewatering is to be done if water is ingressing while excavation/ backfilling
3. Reinstatement of the area shall be as per the normal practices to the satisfaction of
PDO.

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RESPONSIBILTY:

Designation Responsibility
a) Plan the activity & advise concerned authorities.
b) Ensure PTW is applied & Validate prior to start of activity.
c) Conduct the toolbox talk
d) Ensure Proper PPE
Project In - Charge e) Ensure excavation for required dimensions carried out.
f) Identify existing structure & Facilities before the activity
g) Protect the structure & Facilities during & after excavation
h) Supervise/ Monitor the activities closely & ensure compliance
with the procedure.
i) Prepare necessary documentation & submit

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RECOATING USING VISCO ELASTIC REVISION: 01

COATING MATERIAL W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

RECOATING USING VISCO ELASTIC COATING MATERIAL

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REVISION: 01
Excavation and Backfilling
W.E.F.: 15.05.2018

1. PURPOSE:

Purpose of this method statement is to provide work procedures of Coating

Removal, Surface Preparation, Recoating and Holiday Detection.

2. SAFETY REQUIREMENTS:
Coating Removal, Surface Preparation and application of Visco Elastic coating
materials is a hazards job and to complete the work safely the following
precautions should be taken care :
1. PTW is obtained from GAIL prior to start of the work
2. The operator should wear safety shoes and hand gloves.
3. Face shield shall be used while using the Grinding machine for surface
preparation.

3. PROCEDURE:
COATING REMOVAL
1. 3-layer PE coating is to be removed very carefully (Natural gas pipeline)
for full circumference for length of approximately 5 meters for DA
(ECDA, ICDA). For ILI, length will be as per diagnostic report.
2. After coating removal, photograph is to be taken covering all
circumference.
3. The coating and pipe surface underneath the coatings are to be
recorded inspected for indications of coating disbandment, such as
mineral deposits or corrosion products.
SURFACE PREPARATION
1. Surface of the pipe is to be cleaned to the bare, bright metal by Solvent
cleaning/ Hand cleaning with grit paper / cloth or Wire brush / power
brush
2. The surface cleanliness must be minimum ST-2.
3. The surface to be coated must be clean, dry and free of loose parts, oil and
grease.
4. The transition to the existing factory coating must be Bevelled to a 45°
angle.
5. If the coating contains parts of asbestos bitumen, then the applicable
regulations for removal must be followed.
APPLICATION OF VISCOWRAP INNER WRAP
1. The existing factory coating must be bevelled to an angle of 45 degrees (if
applicable). In case of thick coatings, like bitumen or coal tar enamel, a

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Excavation and Backfilling
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bridge should be made on the bare steel onto the coating transition with a
first straight circumference wrap. This will facilitate to proper wrap over
the 45 degrees angle.
2. Start with a first straight on the existing factory coating on a 12 o’ clock
position. The overlap onto the existing factory coating should be minimal
100 MM.
3. The first circumference wrap must be straight. Then start wrapping as a
cigar wrap.
4. Wrap the VISCOWRAP with tension with a minimum 1 cm overlap.
5. End on the other coating side with a straight wrap. The overlap on the
other coating side should also be minimal 100.
APPLICATION OF THE PVC/PE OUTER WRAP
1. PVC/PE Outer Wrap shall be wrapped with a 50% minimum overlap.
2. The first wrap should be straight and then followed by a cigar wrap.
3. The last section should end on a 4 o’clock position and be applied onto
the pipe without tension.
4. A 5 mm/ ¼” section of VISCOWRAP material should still be visible after
the PVC/PE Outer Wrap had been applied.
5. In case the PVC/PE Outer Wrap is applied in above ground situations, the
last section of the Outer Wrap should be applied without tension and at
the spot where the last sections are applied the surface underneath
should be lightly roughened with a sandpaper and cleaned with
isopropyl alcohol.
6. Test the coating with a holiday detector at minimum 10 kV.
7. Photos before coating repair & after coating repair is to be submitted

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Non – Destructive Test using Ultrasonic Flaw
Detector and Ultrasonic Thickness Meter W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Non – Destructive Test using Ultrasonic Flaw

Detector and Ultrasonic Thickness Meter

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Non – Destructive Test using Ultrasonic Flaw
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1. PURPOSE:
To provide written operating procedure Ultrasonic flaw detector and Ultrasonic Thickness
Meter. Ultrasonic testing (UT) uses high frequency sound energy to conduct examinations
and make measurements. Ultrasonic inspection can be used for flaw detection/evaluation,
dimensional measurement material characterization, and more.

2. MATERIAL REQUIREMENT

1. 0.5” x 0.5” mesh grid

2. White color spray paint
3. Couplant (50:50 Engine oil + Grease)
4. Paint Brush
5. MODSONIC da Vinci delta Ultrasonic (UT) based flaw detector with D – Meter with
required accessories
a. Testing range: 2.5mm to 10m.
b. Velocity range: 1000 m/s to 15000 m/s
c. Frequency range: 0.5MHz to 15MHz
6. Ultrasonic Thickness Measurement

3. SAFETY REQUIREMENTS:
Safety precaution should be taken while operating the instrument. The safety precautions
are as follows:
1. The operator should wear safety shoes and hand gloves.
2. While operating, no person should get in contact with the probe and job.
The job material should be placed on wooden log and should not get in contact with any
water-logged place

4. PROCEDURE:
FOR ULTRASONIC FLAW DETECTOR
1. Clock Positions
a. Pipeline of diameter less than 10” – 3:00 to 9:00 (180°; bottom half of the
pipeline)
b. Pipeline of diameter greater than 10” – 4:30 to 7:30 (90°)
2. 5 meters length of the pipeline to be tested.
3. Apply a very thin (non – significant thickness) layer of white color spray paint
over a 0.5” x 0.5” mesh grid on the bottom half of the pipe
4. Label grid on the pipe
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a. Columns – A, B, C ……., Z from left to right towards the flow direction

b. Rows – 1, 2, 3 ………, n.
5. Prepare a mix 50:50 Engine oil + grease for the couplant.
6. Apply couplant on the pipe surface. Enough thickness of the couplant is to be
ensured to enable the mapping of internal corrosion.
7. Readings to be taken with Ultrasonic Flaw Detector with following accessories
a. Straight Beam
b. 4MHz and 6MHz probes along with high temperature probes of all required
face sizes
c. B – Scan result recording with time and date function, with download facility
d. Ability to record continuous B – Scan data
8. Spot measurement is to be avoided at all the times
9. Each 0.5” x 0.5” cell of the grid to be inspected
10. Continuous scanning is to be performed in one direction ex: from Column A, Row
1 to Column A, Row 10 (Vertical direction scanning). Repeat by scanning from
Column A, Row 1 to Column Z, Row 1 (Horizontal direction scanning)
11. Photograph screenshots of the machine, along with the probe on pipe to be
taken for measurements where internal corrosion ‘indications’ are visible

FOR ULTRASONIC THICKNESS METER

1. Clock Position – Full circumference for a length of 5 meters
2. Apply a very thin (non – significant thickness) layer of white color spray paint over a
0.5” x 0.5” mesh grid on the bottom half of the pipe
3. Label grid on the pipe.
a. Columns – A, B, C ……., Z from left to right towards the flow direction
b. Rows – 1, 2, 3 ………, n.
4. Prepare a mix 50:50 Engine oil + grease for the couplant.
5. Apply couplant on the pipe surface. Sufficient thickness of the couplant is to be
ensured to enable the mapping of internal corrosion.
6. Readings for wall thickness measurement to be taken with Ultrasonic Thickness
Meter using UT zero degree (normal probe)
7. Spot measurement is to be avoided at all the times. Continuous scanning is to be
performed.
8. Each 0.5” x 0.5” cell of the grid to be inspected
9. Photograph screenshots of the machine, along with the probe on pipe to be taken
for measurements where internal corrosion ‘indications’ are visible

REPORT
1. Minimum 16 (sixteen) number of photographs to be included in the report. The number
of photographs to increase with increase in abnormalities
2. Report to be prepared in continuous excel spreadsheet with proper references to
o’clock position as well as distance from reference point within the dig site.

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3. Following information to be included along with the report

a. Maximum measured wall thickness for each site along with grid cell ID
b. Least measured wall thickness in each site along with grid cell ID
c. In case for any reason, a cell within the grid is not inspected then N/A must be
mentioned for the minimum remaining wall of the cell.
d. B – Scan results from Ultrasonic Flaw Detector

CREDENTIALS OF UT SCANNING INSPECTOR:

1. Experience in the field of detecting internal corrosion for carbon steel pipelines using an
Ultrasonic Flaw Detector/ Ultrasonic Thickness Meter
2. Minimum two years of in – field experience with UFD/UTM and measuring internal
corrosion anomalies
3. Minimum ASN Level – 2 certificate holder for Ultrasonic
4. Must be able to differentiate between internal corrosion and pipe mid – wall defects
5. Must be able to detect and verify presence of pin – holes, if any.

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PIPELINE LEAK REPAIR
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

PIPELINE LEAK REPAIR

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PIPELINE LEAK REPAIR
W.E.F.: 15.05.2019

1. PURPOSE:
The purpose of this SOP is to define a procedure for handling the leakage on
Cross Country Liquid Pipeline due to Sabotage

2. SCOPE:

The scope of this SOP is limited to the pipeline for attending the Leakage
at the Pipeline Locations.

1. CODES AND SPECIFICATIONS:

ASME 31.4 – Liquid Transportation systems for Hazardous Chemicals and

Hydrocarbons.
API 1104 – Welding of pipeline and Related Facilities
API 1107 – Pipeline Maintenance Welding Practices.

2. REFERENCE DOCUMENT:

ERP - Emergency Response Plan of the Organization.

3. SAFETY REQUIREMENTS:

a) Ensure that all the safety requirements while doing the job are met as
per OISD guidelines
b) All Hot Work should be carried out in accordance with the permit system
in consultation with Control Room in charge.
c) PPE Required:
➢ Helmet
➢ Goggles
➢ Safety Shoes
➢ Hand Gloves (Normal, Electrical & Welding)
➢ Cover All
➢ Ear Muffs/Ear Plugs
d) First Aid Emergency Equipment:
➢ SCBA with Spare Cylinder
➢ Approved First Aid Box & Eye Wash, Glucose, Mineral Water, Energy
Drinks, Towel, Soap, Disposable Glass, Tissue Papers etc.
➢ Gas Tester
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➢ Fire Blankets.

4. SAFETY PRECAUTIONS TO BE TAKEN BEFORE/DURING ACTIVITY:

a) Foam Fire tender shall be available at site, round the clock with Fire
Team (Min. Three Members) or 50/75 Kg DCP with Extended hose.
b) Check whether local Govt. Authorities should have been informed.
c) All pipeline control room should be in full contact with the site team.
d) Portable Fire Extinguishers of type DCP (10 Kg) & CO2 (4.5 Kg) are to be
available with Fire Team as per the site requirement.
e) 25 Kg DCP Powder refill shall be kept in spare.
f) Proper PPE for all officers and workers (vis. Helmets, shoes, cover all,
etc)
g) Barricade the leakage/pilferage location and display the required
warning sign boards.
h) Remove all oil-soaked soil from the hot work area, prior to
commencement of hot work.
i) Gas testing should be carried out prior to start the hot work.
j) Stand by Fire Personal should be available during hot work (welding).
k) Spark attesters should be fitted in all running equipment like ERV, Fire
Tender, Hydra, JCB etc.
l) Use Flame proof lights torch for illumination in barricade area.
m) Flame proof mobile should be used for communication in barricade
area.
n) All vehicles should be parked away from the leak site.
o) Empty trays/open barrels should be available prior to start the work for
the collecting the crude oil.
p) Safety coordinator to be designated for monitoring safety aspect.
q) Security should be positioned round the clock till the all activities
completed.

5. LEGAL REQUIREMENTS & COMMUNICATION:

a) If information comes from Control Room and EIC, confirmation to be
ascertained through mail/message.
b) If it comes to SPPL notice inform the control room & Engineer In charge,
Confirmation ascertained to be ascertained through mail message.
c) SPPL will not communicate on the issue to External Agency media or
Statutory Authorities.
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6. INSPECTION AND DOCUMENTATION:

• Obtain the work permit from operating department.
• Inspection and documentation are required for both before and after
repair.

Prior to Repair: -

After excavation and prior to application of the repair, the carrier pipe
shall be completely exposed and cleaned to bare metal to an extent necessary
to reveal all of the anomaly or anomalies. The nature and extent of each
anomaly shall be determined and documented. The actual wall thickness of the
pipe, shall be measured by means of an ultrasonic gauge, and the measured
values shall be recorded. If extensive corrosion-caused metal loss has removed
the original inner or outer surface over a large area, actual thickness shall be
determined at convenient locations by grinding flat areas away from the
deepest pits. These flat spots of known wall thickness shall be used as
reference points to document the amount of metal loss. The relevant date
shall be recorded in the record documents. Grinding shall be performed as
necessary to characterize or repair a stress concentrator or arc burn.

After Repair:

After repair, appropriate inspections shall be performed. These include

but are not necessarily limited to the following.
• Where grinding is the sole means of repair, a check shall be made as
described above to assure removal of the stress concentrator, over all
length, circumferential extent, and depth of the repair shall be recorded.
• All weldments shall be examined visually for workman ship and absence
of obvious flaws.
• 100% inspection of all fillet welds in accordance with NDT Standard.

1 Control Room Operation Log Book

2 Maintenance Log Book
3 Pipeline Elevation Profile
4 Pressure & Temperature details along the pipeline.
5 Welding & Coating records.

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Up on completion of a defect repair, the following data shall be recorded and

Retained in files:

• Defect Dimensions: Maximum axial length, Maximum circumferential

extent, maximum depth, position of defect including the defect depth
profile.
• Adhesive Type.
• Date of installation of Leak clamp
• Pipe Temperature and internal pressure after installations of fixing of
leak clamp
• Records of legal documents.

7. Equipments required:

Sl.No Equipment Quantity Required Remarks

(minimum) No.
1 Leak Clamp As per requirement According to he OD
of Pipeline
28”/30”/48”
2 Fire tender (Water + 01 Nos. Including DCP of
Foam) sufficient qty.
3 ERV (Emergency 02Nos.
Response Vehicle)
4 JCB Hydra 01 No Each
5 MMV(Mobile 01 No.
Maintenance Vehicle)
6 Empty Crude Tanker As per requirement Min 20Kl capacity
7 Welding Machine 02 Nos.
8 Tractor mounted As per requirement.
Pneumatic Hammer

8. PROCEDURE FOR HANDLING LEAKAGE/PILFERAGE:

A. CONSIDERAIONS:

Repair by Mechanical Clamping:

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Any defect or leak in an onshore pipeline may be temporarily repaired by

means of a bolt on mechanical clamp, provided that the effecting sealing
length of the clamp is sufficient to extend beyond the ends of the defect so
that the leak seals can be properly seated. The clamp must be of a esign that is
capable of containing the Maximum Operating Pressure (MOP) of the carrier
Pipe.

The leakage/Pilferage is either due to pipeline failure (pin hole leakage) or due
to tapping (Pilferage)
1. Identify the leakage/pilferage location.
2. Stop pumping
3. Pilferage spot should be isolated by closing nearest
upstream/downstream valve.
4. CP system should be OFF mode of the said location at
upstream/downstream CP station.
5. Mobilization of Manpower/Equipment to pilferage site with all
necessary tools and tackles.
6. Lining up of ERV, MMV, Cordoning of the area, fire tender.

B. STEPS TO BE FOLLOWED INCASE OF LEAKAGE/PILFERAGE:

1. Excavation: Excavation shall be done by JCB up to 0.75 mtr after that

manual excavation should be carried out till pipe surface to find out the
extract location of pilferage on pipeline. OFC Cable should be taken care
during exaction which is lying approx. 300mm distance from the right
side of pipeline in the flow direction.
2. Pit Marking: After identification of the leakage spot on the pipeline &
OFC Cable, suitable pit is to be made by using JCB for collecting oil as
well as pit should be made in feasible manner like stair. Steps making for
easy access, removal of unwanted material, arrangement of ladder etc.
where the leak arrest activity is being carried out.
3. Removal of oil soaked soil: The oil soaked soil should be removed from
the leak point area and fresh soil shall be filled around it. Spray DCP (Dry
Chemical Powder) around the leak point and make the area safe and
workable for carrying out further activity.
4. Depressurization of Pipeline: Depressurize the pipeline as much as
possible (near to zero) to minimize the spillage of crude oil. ERV Can be
used for collection the crude oil for depressurizing the pipeline. For
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smooth suction and discharge of crude oil from ERV, fabrication of valve
from 4” to 2” with 2” hose pipe connected to it. Decanting out of crude
oil from ERV, from SV/Pilferage site and transfer the collected crude oil
to the crude tanker for further dispatch to nearest IPS’s (Sump Tanks).
5. Venting of Pipeline: Venting should be done at both
upstream/downstream at the respective station by 2” hose pipe till the
pressure reaches to the min. level i.e., around 0.5 kg/cm2 or till the
crude starts coming out from the hose pipe.
6. Tapping of the leakage spot: Leakage should be arrested either by
inserting the wooden peg or by the lead into the tapped/leakage sport
for stopping the crude oil leakage.
7. Protection of OFC: OFC Cable should be protected prior to start the
welding by covered it with the plastic hose &after that sand bags are to
be put on the bottom of the OFC Cable to avoid hanging &stress on it.
8. Removal of coating: Removal of coating cold method by chisel and
hammer in case of no leak from the arrested spot after gas test. If still oil
drops area coming out from the spot then we have to use the Brass
Chisel and Hammer. Width of coating will be the width of the leak clamp
+ 50mm on either side/edge of clamp.
9. Surface Preparation: Surface preparation of the removed coating area
either by Rough Emery Cloth in case of leakage from the spot or by the
bugging wheel in case of no leakage from the spot. Surface area of the
pipe should be cleaned in such a manner that there are no traces of
coating/paint/crude oil etc.
10. Ultrasonic Test: UT for pipe lamination check is to be carried out
preferably before placement of leak clamp with the help of UT Thickness
gauge. In case of uncontrolled oil spillage, UT may be done before
welding of clamp. UT is to be done since radiography is made difficult by
the complex geometries and gross thickness changes associated with
these welds. The effectiveness of a UT Procedure depends on the
method used to set test sensitivity, the choice of probe angles and
scanning surfaces and the criteria for evaluating and reporting
discontinuities.
11. Installation of Mechanical Leak Clamp: Fix the leak clamp with fully
safety precautions on the Leakage spot as per the following sequence-
• The line should be depressurized condition
• Necessary marking should be done on the pipeline where clamp is to be
fixed
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• Clean the leak clamp’s nut & bolts with diesel and after that with cotton
waste.
• Place the bottom half of the clamp properly just below the marked area
of the pipeline and hold the clamp with the hydraulic jack.
• The upper half leak clamp (keep two bolts in place in diagonally opposite
director for proper fixing the clamp) shall then be lifted with hydra,
remove the tapping with hacksaw & place it above the marked area of
the pipeline.
• Fully tighten the clamps by torque wrench manually till the maximum
tightening achieved.
• After tighten the nuts with hydraulic torque tensioner by applying
pressure of 6600 N/m2 (>4000 NW), so as to reduce the gap between
flanges of two halves of clamp to <5mm. Tightening of studs/bolts will
be done gradually on diagonally opposite sides. The gap is maintained
between clamps as approx. 2.5mm for welding after full tightening.

12.Ensure the Following during the Installation of Clamp:

❖ Clamp pair have the same serial numbers and all stud holes are
matching.
❖ Seals are not dislodged during, lifting or sliding operation.
❖ Pipe coating is removed completely
❖ The leakage area is covered within the Leak Clamp specified sealing area.

13.Pressure Testing: In order to test the competency of tightened leak

clamp, pressure testing shall be done at least 6 hrs. By pressurizing the
section at required pressure.

C. Welding of Leak Clamp:

Welding with desired electrodes conforming to API 1107 (API-1107-Pipeline

Maintenance Welding Practices) using 2.5mm, 3.15mm, & heated up to 300
degree centigrade in mother oven.

a) Preheat temperature:

Prior to start the welding ensures the preheating temperature should be

maintained minimum 100 degrees centigrade using the propane cylinder with
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the burner. The preheat measurement for in service welding applications

where continuous hearing methods are used should occur in the weld joint,
but consideration should also be given to the temperature in the vicinity of
weld joint. For non-continuous preheating methods, preheat temperature
should also occur in the weld joint, but temperature decay as a function of
time should be considered. This can be accomplished using the re heating
interval technique, where the time allowed for welding is determined by
measuring the time required for the temperature in the preheated area to
drop from some maximum temperature to minimum-required preheat
temperature.

❖ Type of electrodes to be used: E-7018 – Dia: 2.5mm for Root & E-7018 –
Dia: 3.15mm for Filling and capping.
❖ Welders Qualification Test (WQT)/Procedure Qualification Test (PQT):
Two Nos. of Qualified pipeline/piping welders with at least 10 years’
experience with qualified NDT/WPS as per the API-1104.
❖ Type of Welding Process: SMAW process using E-7018, Uphill Type
Welding.
❖ Prevention of rubber from welding heat by putting sealant/insulation
material in between clamp edge and rubber.
❖ Earthling of pipeline before commencement of welding.
❖ Welding Technique:

I. Tack weld the stiffeners, each tack to be approx. 2” to 3” long

II. Start welding circumferentially subsequently. This climates
distortion due to welding heat up. Weld on the both sides of
clamp equally.
III. Weld stiffeners completely.
IV. Weld nuts to stiffeners and weld nut top face to stud.
V. Welding clamp (Longitudinal, Circumference & seal weld at bolts)
should be done as per the approved weld procedure (WPS).
VI. During Welding, (Dye Penetration Test) DPT which consist of
(Cleaner, Penetrant and Developer) will be done on Root run &
final run of weld as per API 1107& API 1104.
VII. AG-5 & AG-7 type grinding machines are to be used during
welding operations.
VIII. 3mm & 5mm grinding wheel should be used during welding
operation.
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IX. The maximum current for 2.5mm electrode (60 to 80 Amps) & for
3.2 mm Electrode (80 to 100 Amps.) during welding operation of
Leak Clamp.

A. Ensure the following during Welding of Clamp:

a) Removal of Oil soaked earth, oil traces.

b) Gas test till suitable safe limit for hot work is obtained as per the
safety guidelines.
c) Isolation of hot work area by proper barricading
d) Placement of extinguishers, firefighting equipment, foam etc.
e) Clearance from safety officer.
f) No leakage should be there after tightening the clamp
g) Crude flow rate should not be more than 500m3/hours in the
pipeline while welding is being carried out. This is to avoid excess
heating on the welded surface.
h) Continuous communication to be maintained between welding site
and pumping stations at Clients Location for intimation on any
stoppage of flow, in such case welding should be stopped
immediately
i) Continuous monitoring is required to check any trapped air at
respective SV/IPS Stations.
j) Root Welding should be done in patches so that the heat generated
during welding gets dissipated.
k) Sealing of Leak Clamp should be protected from the welding heat by
stopping the welding heat by stopping the welding time to time for
few minutes mainly during root pass where the possibility of getting
the seal damage is maximum.
l) Gas Testing should be carried out to check the presence of any
hydrocarbon in pit time to time.
m) Welding & DPT test should be done in presence of Clients QA/QC
Officer.
n) Coating of Leak Clamp: Surface preparation should be done by
buffing then apply R-95 liquid epoxy (wet film thickness >700
microns) at the surface of leak clamp.

B. Ensure the followings at the time of Coating:

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a) Surface Preparation:
▪ Surface should be free from all dust, dirt, moisture, oil, grease or
other contaminations.
▪ If necessary, use a non-contaminating solvent such as Xylene or
MEK to remove the contaminations on the surface.
Clean the surface after removing slag and smoothening of sharp
burns and edges by buffing.

b) COATING APPLICATION:

▪ Mix Part A & Part B in a cup using sticks. This mixing has to be
done thoroughly for 2 to 3 minutes till homogenous mixture is
obtained.
▪ Mix- Ratio of Powercrete R95: By Volume – 3.6:1 Part A to Part B
& By weight – 100:16 Part A to Part B.
▪ Slowly pour mixed epoxy onto cut back area on pipe surface, use
special application pads to apply required minimum thickness of
coating to the field joint.
▪ Cover at least 100mm of the adjacent mainline coating.
▪ Workable pot life after mixing is 14 minutes at 25oC
▪ Measure WFT (Wet film thickness) at randomly selected ares, the
thickness of coating should be more than 700 microns or as per
the manufacturer recommendation.
▪ Care should be taken that the wet coating shall not be
contaminated with particles such as blowing sand, insects or other
foreign material.

c) Inspection and Testing:

▪ Coating system shall be inspected visually for uniformity,

thickness, blister, pinholes etc. all imperfections shall be identified
and marked for repair.
▪ The dry film thickness of the coating should be checked at 5
randomly selected areas.
d) Holiday Testing:

▪ Holiday testing shall be carried out with holiday detector at 25 KV

on pipeline coating surface for ensuring integrity of coating.
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▪ Pinholes, porosity or other defects which are found during the

holiday inspection are to be clearly marked.
▪ Re apply the coating mixture on the repair region
▪ Holiday is to be done again of the repair area.

e) Back filling and Restoration:

When all the activities are completed at leakage/pilferage location,

the manual backfilling or by JCB is to be done as per the site
condition.

f) Return permit to control room.

9. TOOLS, TACKLES & MATERIALS REQUIRED:

S.No Material Description Quantity (Nos.) Remarks

1 Shovels, etc 08
2 Gas Cylinder with two burners 01
3 Chisel with Brass & Iron 02
4 Wire Brush 04
5 Buffing wheel 2”,4” & 6” 02 Each
6 Emery Paper roll/Rough Emery 02 Each
Cloth
7 Hacksaw 02
8 High speed blades for hacksaw 10
9 Grinding Machine (AG-5 & AG- 02 Each
7)
10 Conical wooden peg (of 04
different size ranging from ½”
to 2” or as required)
11 Chocker belt of 6 tom or wire 04
rope
12 D Shackles (2 & 4 tons) 04 Each
13 Wooden Planks 10
14 Grinding Wheel (3mm & 5mm) 10 Each
15 Hydraulic Jack 02
16 Ring & Box spanner (90mm) for 01 Each
30’’
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17 Hydraulic torque tensioner 01

18 Holiday Detector (25KV) 01
19 Tent/umbrella 02
20 Trays 02
21 Oil absorbent roll 02
22 Alluminuim Ladder 02
23 Tarapaulin sheet roll 02
24 Wooden rollers (for coating) 04
25 Thickness Gauge (Size: 0 to 01
12mm)
26 Barricade Tape Roll 04
27 Spark Arrestors (Various size) 04
28 Flame proof torch 02
29 Flame proof mobile 01
30 Open empty barrels 02
31 Coating materials (R-95) As per
requirement
32 Ring & Box spanner (85mm) for 01 each
28”
33 Ring & Box spanner (50mm) for 01 each
48”

10.TOOLS/RESOURCES REQUIRED FOR WELDING OF LEAK CLAMP (AS PER

QA/QC)

1. Welding Consumables: E 7018-1, Dia 2.5mm for root pass & Dia 3.2mm
for further filler and capping. Preferably D&H with Batch test certificate
& electrodes should not be older than their manufacturing date.
2. 2 Nos. – Qualified Pipeline/Piping Welders (SMAW Process using E 7018,
Uphill) with at least 10 years experience. Approved station Piping WPS
may be used.
3. Electrode Mother Oven (300o C) and holding oven (100o C) – 1 Set.
4. DPT Kit -3 set (Red Dye Penetrate Spray 280 ml), Developer spray can
(280ml) & Cleaner/Remover Spray Can (280ml).
5. Welding rectifiers – 2nos. with full accessories like welding cable,
earthing arrangement etc.
6. Temperature scanner: 0oC to 250o C (Laser Type) – 1 No.
7. AG-5 & AG-7 Grinding Machine – 2Nos.
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8. Grinder – 2Nos. with at least 10 years experience.

9. Suitable range measuring instrument for checking the welding current.
10.Necessary Tools & tackles / instrument for checking the welding current.
11.Preheating arrangement – 1No. i.e., propane with suitable hose and
burner.

11.MATERIAL/APPLICATION TOOLS/TESTING EQUIPMENT REQUIRED FOR

LEAK CLAMP COATING:
Coating Material:
▪ Powercrete ® R 95 100% liquefied epoxy Part A & B.
▪ Applicator Pads
▪ Mixing cups and sticks
▪ Measuring cups 25ml, 50ml, 100ml
▪ Weight measure for measuring up to 5 Kg
▪ Applicator pads Kits
▪ Wet film thickness gauge
▪ Dry film thickness gauge

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REVISION:01
Procedure for Replacement of Mechanical
seal W.E.F.:
15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Replacement of Mechanical Seal

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REVISION:01
Procedure for Replacement of Mechanical
seal W.E.F.:
15.05.2019

PURPOSE:
To specify written procedure for replacement of mechanical seal.
SCOPE:
This scope covers the guidelines on replacement of seal during failure, leakage,
periodical maintenance of valve.

STANDARD REQUIREMENTS:
• Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
• Ensure all the safety requirements for doing the job safely are met a per OISD
guidelines.

REFERENCES:
OISD-STD-119, OISD-STD-125, API- 682

PROCEDURE:
• Obtain the valid “HOT” permit as per standard work permit system of pipelines
Deptt. & take clearance from respective control room officer.
• Isolate the pump motor & Lube oil pump motor electrically from the sub-station
pump.
• Isolate the pump by ensuring closure of suction & discharge valves of the pump.
• De-pressurize the isolated section of the pump by draining product into sump take
through Vent / drain.
• Drain the lube oil from bearing housing.
• Remove all necessary piping meant for Mechanical seal flushing and lube oil supply
for bearings.

A) NDE SIDE:
• Loosen the deflector disc and pull it back from housing.
• Remove the dowel pins and bolts holding the main lube oil pump assembly at the
end of bearing housing.
• The thrust pads are split in two halves so that they can be rotated, and each half is
thus lifted out of bottom half of bearing housing.
• Unscrew the grub screws and rotate the lock nut to clockwise direction so that it
comes out. This lock nut looks like shaft only and it is having reverse thread joint.
• Remove the thrust collar by sliding along with its key.
• Remove the upper halve of sleeve by unscrewing the Allen screw.
• Use a suitable lifting arrangement (HOT/EOT can be used) for lifting the pump shaft
so that the lower halve of the sleeve can be removed.
• Remove the lower half of the bearing housing, oil rings, deflector disc and bearing
housing end cover.
• Remove the seal sleeve drive collar sets/screws and remove the drive collar.

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REVISION:01
Procedure for Replacement of Mechanical
seal W.E.F.:
15.05.2019

• Remove the studs holding the seal and remove the seal gland plate.
• Move the seal sleeve inward so that set/screw marks on the shaft can be traced to
prevent damage to the “O” rings under the sleeve when the sleeve is removed.
• Remount the drive collar on the sleeve to aid in pulling the sleeve.
• Pull the seal sleeve with the seal rotating parts mounted on it from the shaft.
• Refit the new/refurbished seal assembly.
• Put the lower half of the bearing housing in place with the help of dowel pins and
then tight the bolts.
• Assemble the bearings in reverse order as they were removed.
• Refit the main tube oil pump back to its position.
• Close the bearing housing with its upper half.
• Paste gasket is to be used between sealing faces.
• Re-fix all the removed piping.
• If only, NDE side mechanical seal is to be replaced, take a trial run of the main
pump for any leak from newly fitted mechanical seal.
•
B) DE SIDE:
• Remove the coupling guard & loosen the coupling bolts & drop the spacer.
• Loosen the lock nut on pump shaft inside the coupling hub.
• Take out the coupling hub with suitable puller.
• Loosen the deflector disc and pull it back from the housing.
• Remove the dowel pins and bolts holding the main Lube oil pump assembly at the
end of bearing housing.
• Removal/Loosen the bolt and remove the top half of the bearing housing.
• Remove the upper half of sleeve by unscrewing the Allen screw.
• Use a suitable lifting arrangement (HOT/EOT can be used) for minor lifting the
pump shaft so that the lower half of the sleeve can be removed.
• Remove the lower half of the bearing housing, oil rings, deflector disc and bearing
housing end cover.
• Remove the seal sleeve drive collar sets/screws and remove the drive collar.
• Remove the studs holding the seal and remove the seal gland plate.
• Move the seal sleeve inwards so that set/screw marks on the shaft can be traced
to prevent damage to the “O” rings under the sleeve when the sleeve is
removed.
• Remount the drive collar on the sleeve to aid in pulling the sleeve.
• Pull the seal sleeve with the seal rotating parts mounted on it from the shaft.
• Refit the new/refurbished seal assembly.
• Put the lower half of the bearing housing in place with the help of dowel pins and
then tight the bolts.
• Assemble the bearings in reverse order as they were removed.
• Close the bearing housing with its upper half.
• Paste gasket is to be used between sealing faces.
• Re-fix all the removed piping.
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REVISION:01
Procedure for Replacement of Mechanical
seal W.E.F.:
15.05.2019

• Mount the coupling hub and lock the nut.

• Mount the spacer & tighten it firmly. Mount the coupling guard.
• Start the auxiliary lube oil pump and check for any lube oil leak/priming of main
lube oil pump coupled with pump shaft (if installed).
• Prime the main line pump & line-up the pump by opening suction & discharge
valves with the assistance of OPS team.
• Take a trial run of the main pump for any leak from the newly fitted mechanical
seal. If only DE mechanical seal is required to be changed. In case both the
mechanical seals are required to be changed, trial run shall be taken after
installing both the mechanical seals.

RESPONSIBILTY:
Site In-charge to check and inspect the proper replacement of mechanical
seal carried out by Mechanical team.

RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/33

Procedure for Cartridge/Basket Filter REVISION:01

Cleaning W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Cartridge/Basket Filter Cleaning

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 STANDARD OPERATING PROCEDURE
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Procedure for Cartridge/Basket Filter REVISION:01

Cleaning W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Cartridge/Basket Filter Cleaning for periodical maintenance of
Valve. The clean is to be taken up for cleaning if the differential pressure across filter is more
than 0.5 Kg/cm2 or the time elapsed is 6 Months from the date of last cleaning.

2. SCOPE:
This scope covers the Cleaning of Cartridge / Basket Filter.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-130, OISD-STD-132, API- 682

5. PROCEDURE:
STEP I: ISOLATE THE SECTION
➢ Isolate the filter by closing upstream & downstream Hand/Motor operated Plug
Valve.
➢ Isolate Differential Pressure Transmitter by closing appropriate valve.
➢ Check the Sump Tank level before draining the filter. If required, empty the sump tank
to accommodate the Product Quantity to be drained from the Filter (Approx. 0.8 KL for
each filter)

STEP II: DEPRESSURISE / DECANT FILTER

➢ Release the pressure in the Filter by slowly opening the vent valve of the Filter.
➢ After the pressure is released, open the Drain Valve and start draining the
product.
➢ During draining operation, keep Vent Valve open.
➢ Ensure that the Filter quantity is fully drained by monitoring the sump tank level.
➢ (Indication: 1. no air suction through Vent line
2. Calculate and compare increase in sump tank quantity)

STEP III: OPENING, CLEANING AND BOXING UP OF FILTER

➢ Ensure depressurization and draining of filter.

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Cleaning W.E.F.: 15.05.2019

➢ Before opening of filter, keep ready all tools, tackles, manpower (skilled/semi-skilled),
collection tray, half cut barrels, gasket etc.
➢ Dismantle vent valve of the filter.
➢ Loosen the nuts of swing bolts of CF, of the filter top cover flange.
➢ After loosening all Nuts & removal of studs, open the top cover using Davit Assembly.
➢ Remove top flange Gasket. Remove the filter/cartridge elements by removing the
holding down nuts and washers. Inspect the element for any damages.
➢ Thoroughly Clean the Elements using brush and washing with water jet. Ensure that all
clogged particles are removed from the filter mesh.
➢ Clean the internals of Cartridge Filter vessel thoroughly and remove the sediments
attached to the walls or collected at the bottom. Ensure the bottom drain line is clear.
➢ Place the Cartridge filter elements in position and tighten the individual Cartridge
Filter element using washer and nuts, CF element holding down ring plate, etc.
➢ Use a new gasket of appropriate size and rating, place it on top cover flange and
tighten the nuts / stud bolts properly.
➢ Apply the small amount of grease in between nut, washer, flange & on the threads of
swing bolt.
➢ Assemble the Vent valve and establish the pipe connection.

STEP IV: CHARGING

➢ Ensure that all nuts are tightened, and connections are restored properly.
➢ Keeping Vent valve open and drain valve closed, slowly and partially open the inlet valve
without largely affecting the line pressure. (It is preferable to charge the filter with HSD
or SKO).
➢ Fill the entire filter with product and observe that the product is flowing to sump tank
through the vent line.
➢ Open and close the drain valve quickly to ensure that the Filter is full of liquid and there
is no air inside and Close the vent valve and inlet valve.
STEP V: TESTING
➢ Pressurize the filter for required pressure using the same product.
➢ Keeping the filter under pressurized condition for at least one hour and observe for
leaks, sweating etc. from the flange joints.
➢ After ensuring that there is no leak, depressurize the filter through vent line.
➢ Now Filter is ready & cleared to be taken on line.

6. RESPONSIBILTY:
Site In-charge to check and inspect the proper cleaning of Cartridge/basket filter
carried out by Mechanical team.

7. RECORD:
LogBook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
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Procedure for Lube Oil replacement of REVISION:01

pumps W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Lube Oil Replacement of Pumps

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/34

Procedure for Lube Oil replacement of REVISION:01

pumps W.E.F.: 15.05.2019

1. PURPOSE:

To specify written Procedure for Lube oil replacement of pumps.

2. SCOPE:

This scope covers the Lube oil replacement of pumps.

3. STANDARD REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-119, OISD-STD-130, API- 682

5. PROCEDURE:
➢ Isolate the Auxiliary lube oil pump.

➢ Drain the existing Lube Oil completely.

➢ Open the lube oil tank manhole.

➢ Clean the lube oil tank for any sludge with cotton waste.

➢ Close the manhole & fill the low viscosity lube oil (UNIVOL 46/CABOL 46(37) mini. 200

lits).

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Procedure for Lube Oil replacement of REVISION:01

pumps W.E.F.: 15.05.2019

➢ Start the lube oil pump. Circulate this low viscosity lube oil for one hour & observe the

temperature rise. If temperature rises by 2 0C, stop the pump & investigate for any

blockage of line/filter.

➢ Drain this lube oil completely through tank & bearing housings.

➢ Add fresh required lube oil after filtering even though it is filled from a new barrel. For

filtering the oil use fine sized strainer for hand operated pump & taking it in another

clean barrel before transferring in to the lube oil tank.

➢ Start and run auxiliary lube oil pump so that lube oil gets filled in the piping & bearings

➢ Prime the main lube oil pumps by opening the appropriate valve & close the same after

5 minutes.

➢ Check the lube oil level after initial starting. If it drops down considerably top up the

same.

➢ The lube oil shall be changed once in six months as recommended by OEM

➢ Filters shall be changed if DPI across the filter is more than 1 kg/sq. cm or once in a year

or as mentioned by OEM.

➢ Clean the lube oil flow indicator.

➢ All leakages from the flanges etc. shall be attended.

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Procedure for Lube Oil replacement of REVISION:01

pumps W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site In-charge to check and inspect the proper cleaning of Cartridge/basket filter
carried out by Mechanical team.

7. RECORD:

Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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REVISION:01
Procedure for CI & Dosing of Pumps
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

CI & Dosing of Pumps

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REVISION:01
Procedure for CI & Dosing of Pumps
W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Lube oil replacement of pumps.

2. SCOPE:
This scope covers the Lube oil replacement of pumps.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-119, OISD-STD-130, API- 682

5. PROCEDURE:
➢ Isolate the Auxiliary lube oil pump.
➢ Drain the existing Lube Oil completely.
➢ Open the lube oil tank manhole.
➢ Clean the lube oil tank for any sludge with cotton waste.
➢ Close the manhole & fill the low viscosity lube oil (UNIVOL 46/CABOL 46(37) mini. 200
lits).
➢ Start the lube oil pump. Circulate this low viscosity lube oil for one hour & observe the
temperature rise. If temperature rises by 2 0C, stop the pump & investigate for any
blockage of line/filter.
➢ Drain this lube oil completely through tank & bearing housings.
➢ Add fresh required lube oil after filtering even though it is filled from a new barrel. For
filtering the oil use fine sized strainer for hand operated pump & taking it in another
clean barrel before transferring in to the lube oil tank.
➢ Start and run auxiliary lube oil pump so that lube oil gets filled in the piping & bearings.

➢ Prime the main lube oil pumps by opening the appropriate valve & close the same after
5 minutes.
➢ Check the lube oil level after initial starting. If it drops down considerably top up the
same.
➢ The lube oil shall be changed once in six months as recommended by OEM
➢ Filters shall be changed if DPI across the filter is more than 1 kg/sq. cm or once in a year
or as mentioned by OEM.
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REVISION:01
Procedure for CI & Dosing of Pumps
W.E.F.: 15.05.2019

➢ Clean the lube oil flow indicator.

➢ All leakages from the flanges etc. shall be attended.

6. RESPONSIBILTY:
Site In-charge to check and inspect the proper cleaning of Cartridge/basket filter
carried out by Mechanical team.

7. RECORD:
Log Book/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/36

Procedure for Painting of above ground REVISION:01

Piping structure W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Painting of above ground Piping structure

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/36

Procedure for Painting of above ground REVISION:01

Piping structure W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Painting of above ground Piping structure.

2. SCOPE:
This scope covers the Procedure for Painting of above ground Piping structure

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-188, OISD-STD-130, API- 1160

5. PROCEDURE:

❖ SURFACE PREPARTION:

1. FACTORS AFFECTING PAINTING LIFE

Residual Oil, Grease, Soil Residues of Chemicals, Salts Rust on the Surface.

2. SURFACE PREPARATION METHOD

Solvent Cleaning: Cleaning can be done with wiping with cloth or rag, Solvent
spray, vapor degreasing, emulsion etc.

Manual Hand Cleaning: Remove loose Mill scale, Rust and Paints using tools like Wire
Brush, Scrapers, Chisel, Knife, and Chipping Hammer.

Power Tool Cleaning: Grinding Wheels, Vibrating Wire Brush, Sand Wheel etc. especially
for weld joints.

❖ PAINT APPLICATION:

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Procedure for Painting of above ground REVISION:01

Piping structure W.E.F.: 15.05.2019

1. MIXING:
Hand Mixing should be avoided as far as possible. If it is inevitable then it
should be restricted to the quantities less than 5 liters. The best method for
mixing the paint is by mechanical stirring. The mixing should be by propeller,
screw or paddle type agitator, driven by compressed air or electric motor.

2. THINNING:
Thinning should be supervised by a Site Engg. Only minimum amount of the
specified thinner should be added to obtain the proper viscosity for the
selected method of application. Please refer data sheet for advice.
Thinning reduces the ‘Volume Solids’ of the paint. Therefore, it is necessary
to apply extra thickness of paint in order to achieve specified dry film
thickness.

❖ METHOD OF APPLICATION

BRUSH APPLICATION:
The brush should not be dipped deep into the paint, as these results in overloading
the bristles and filling the heel with the paint. The paint should be applied in a
uniform film at the specified spreading rate. Do not attempt to cover too large an
area at a time but work in stipes about a foot wide and keep the edges wet.
It is desirable to apply successive coats by cross-brushing, which minimizes brush
marks. Runs, sags and drips may be avoided by applying no more paint than the
surface will support and spreading paint uniformly.
Brushing is used for ‘stripe painting’ of parts which are difficult to protect such as
edges, angular parts and weld seams, when these are given an extra coat of paint.

ROLLING APPLICATION:
Application of paint by rollers is a method that is particularly suitable for treating
large flat surfaces, which for some reason cannot be sprayed.
As with brushing it is difficult to control film thickness and care must always be
taken to ensure the painting is not ‘over rolled’.
The hand roller is dipped into the paint tray and rolled over the sloping bottom to
squeeze out excess paint.
To obtain complete coverage, especially on rough surfaces, the roller must be
worked in several directions back and forth. All final strokes should be made
systematically in one direction. Because the normal roller cannot apply paint right
up to an obstruction or corner, the surface to be painted should be “banded”. Paint
should be applied by brush along all corners and edges before roller coating.

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Procedure for Painting of above ground REVISION:01

Piping structure W.E.F.: 15.05.2019

6. RESPONSIBILTY:
Site In-charge to check and inspect the Painting of above ground Piping structure
carried out by Mechanical/Civil team.

7. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

P a g e | 194
 STANDARD OPERATING PROCEDURE
SPPL/SOP/37

Procedure for Underground Sump Tank REVISION:01

Cleaning W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Underground Sump Tank Cleaning

P a g e | 195
 STANDARD OPERATING PROCEDURE
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Procedure for Underground Sump Tank REVISION:01

Cleaning W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Cleaning of Underground Sump Tank.
2. SCOPE:
This scope covers the Procedure for Cleaning of Underground Sump Tank.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-123, OISD-STD-130, OISD-129,

5. PROCEDURE:
• Close all the TSV isolation valves. Blind the inlet to the sump tank.
• Isolate the sump pump
• Remove all the attachments including vent pipe, level instruments, etc.
• Open the manhole.
• Empty out the sump tank by ERV.
• Transfer the product from ERV to tank lorry.
• Lift out the sump pump with the help of Hydra/Crane.
• Apply the force of water and wash so that the entire debris moves towards the
discharge in the sump tank from which it can be collected by ERV.
• Prior to entering an underground tank, it shall be cleaned internally of its product and
adequate air circulation provided.
• Then fill the sump tank with full of water & keep it for the 24 Hrs. to make it
hydrocarbon and gas free.
• Empty out the water by ERV.
• Again, apply the forced water & collect it by ERV.
• Check the presence of toxic gases by the multi gas detector.
• The man entry should be preceded by ensuring that the tank is Hydrocarbon & gas free.
• If it is in safe limit, allow the workmen to enter & collect the muck.
• All PPE should be used by the workman like Fresh air breather.
• He should carry safety belt with rope.
• He will be there only for 2-3 min.
• Clean the sump tank with wire brush.

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 STANDARD OPERATING PROCEDURE
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Procedure for Underground Sump Tank REVISION:01

Cleaning W.E.F.: 15.05.2019

• The tank shall be visually inspected for general corrosion/ pitting/ deterioration on
internal surfaces.
• Ultrasonic thickness measurements shall be carried out on shell plates, end plates and
nozzles from inside the tank once in ten-year period or to meet industry’s quality control
requirements whichever is less.
• The external inspection of the underground tank shall be performed once in twenty-
year period or to meet industry’s quality control requirements whichever is less. (OISD
129).
• After the repairs, the tank shall be hydrostatically tested of at 0.75-kg/sq.cm-test
pressure and checked for leaks.
• Reinstall the sump pump.
• Re-erect all the accessories.
• Sump Pump trial is taken to check for its performance.
• All the observations, findings and repairs carried out after each inspection should be

recorded.

6. RESPONSIBILTY:
Site In-charge to check and inspect the cleaning of underground sump tank
carried out by Mechanical/Civil team.

7. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
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Procedure for Calibration & inspection REVISION:01

overhauling of TSV'S W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Calibration & inspection overhauling of TSV'S

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 STANDARD OPERATING PROCEDURE
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Procedure for Calibration & inspection REVISION:01

overhauling of TSV'S W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Calibration & inspection overhauling of TSV'S .
2. SCOPE:
This scope covers the Procedure for Calibration & inspection overhauling of TSV'S.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-123, OISD-129

5. PROCEDURE:
❖ ISOLATION:

a. Isolation valve is provided on each TSV line in order to isolate TSV.

b. This isolation valve to be fully closed.

❖ DISMANTLING / TESTING.

c. TSV to be removed from piping system

d. TSV to be stripped.
e. Internal parts cleaning to be done.
f. TSV to be tested using hydro testing unit with calibrated dial gauge.
g. TSV pop-up setting to be adjusted at required set pressure same to be verified
again with hydro testing unit.

6. RESPONSIBILTY:
Site In-charge to check and inspect the Calibration overhauling of TSV’s carried
out by Mechanical.
7. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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Procedure for Prevention Maintenance of REVISION:01

Plug Valves W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Prevention Maintenance of Plug Valves

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SPPL/SOP/39

Procedure for Prevention Maintenance of REVISION:01

Plug Valves W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Prevention Maintenance of Plug Valves.
2. SCOPE:
This scope covers the Procedure for Prevention Maintenance of Plug Valves.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-123, OISD-129

5. PROCEDURE:
❖ VALVE GREASING:

1. SEALANT INJECTION EQUIPMENT:

The sealant injector consists of three main parts

1. Bottom Cap with sealant loading jack
2. Middle barrel for sealant cartridge
3. Head with sealant pump, hose and nipple adaptor

2. SEALANT:

There are two types of sealants normally used:

1. AUDCO 950: This is used for valves in MS/SKO lines.
2. AUDCO 733: This is used for valves in HSD/SKO/MS lines.

3. PROCEDURE FOR GREASING:

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Procedure for Prevention Maintenance of REVISION:01

Plug Valves W.E.F.: 15.05.2019

1. Unscrew the sealant loading jack to the bottom position of the Grease gun barrel.
2. Unscrew and Remove the bottom cap cover along with the jack
3. Unscrew and separate the barrel from the head.
4. Remove the cap of the sealant cartridge & fit it on the head, tight it fully
5. Attach the barrel to the head.
6. Attach the bottom cap to the barrel. Tighten the joints fully.
7. Engage the nipple adaptor at the tip of the hose to the plug sealant injector of the
respective valve and lock the adaptor by sliding.
8. Hold the gun in position and tighten the loading jack. Operate the sealant pumping
handle. The sealant starts flowing in.
9. After few strokes, the handle operation eases. Tighten the jack screw & repeat the same
procedure till hardness of handle is felt. A small quantity of sealant oozes out of the
nipple.
10. Sealant should be injected in fully open or fully close position of valve.
11. Operate the valve 2 to 3 times after charging the sealant.

4. FREQUENCY OF SEALANT INJECTION:

This is dependent on the service conditions and how often the valve is operated. Following are
the recommendation from equipment supplier.

Service Conditions Frequency of Sealant Injection

In non-abrasive gas or liquid service Every 50 operations, minimum once a year

In abrasive gas or liquid service Every 25 operation, minimum 2 times a year

In abrasive slurries Every 10 operations, minimum 4 times a year

5. SEALANT CONSUMPTION (For information Only):

Valve size : >18’’ - ½ Cartridges per valve

10” to 16” - 3 valves per cartridge
<10” - 5 valves per cartridge

❖ STEM SEALING:

The graphite Sticks are used for sealant between stem & the valve body

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Procedure for Prevention Maintenance of REVISION:01

Plug Valves W.E.F.: 15.05.2019

1. PROCEDURE FOR CHARGING STEM SEALANT:

1. Remove the Allen screw from the stem sealing injector of the valve with the help of
correct size Allen key.
2. Place the graphite stick inside the nipple
3. Place the screw in the nipple and tighten with Allen Key
4. Sufficiently tighten the screw and repeat the procedure till no further charging of
graphite is possible.

2. PERIODICITY OF STEM SEALING:

All Plug Valves are fitted with an emergency stem packing fitting. In the unlikely event
of a Valve developing a stem leak, this fitting can be used to inject stem sealant into
the stem area and reseal the valve stem. This can be safely done with the valve under
pressure.

3. STEM SEALANT CONSUMPTION (for Information Only):

>18’’ : 2 to 3 Sticks per valve

10” to 16” : 1½ to 2 Sticks per valve
<10” : 1 to 1½ Sticks per valve

❖ PROCEDURE TO CARRY OUT PURGING OF AUDCO PLUG VALVES

6. REQUIREMENT:

Purging of Valves is done only when the Valve operation becomes hard/difficult even
after carrying out necessary greasing operation.
The Purging Liquid Injector Gun is a high-pressure gun and is also used for injecting
Audco 733-D sealant after the purging operations.

LOADING OF SEALANT:
The 400-D Gun is a hydraulic hand gun capable of developing high pressures. The
following operating instructions should be read and followed closely to assure the safe
and proper use of the equipment.
1. “Crack” the By-pass Valve by turning counter-clockwise less than one full turn. It should
not be tightened against the By-pass stop. Backing out the By-pass Valve too far will
allow air to enter the hydraulic system of the gun.

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Procedure for Prevention Maintenance of REVISION:01

Plug Valves W.E.F.: 15.05.2019

2. Remove the sealant barrel cap, complete with hose assembly, using the Handle with
Grip. The Handle is detachable and has a hole drilled near one end. By unscrewing the
Handle and placing the hole over the protruding pin on the Sealant Barrel Cap, the cap
may be easily removed and replaced.
3. Using the Handle as a push rod, return the Floating Piston to the bottom of the Sealant
Barrel.
4. Clean and replace the Handle.
5. Close the By-Pass Valve. Do not jam the By-Pass Valve in to the seat as this may damage
the sealing member.
6. Insert the sealant into the Sealant Barrel.
7. Operate the gun until the sealant protrudes out.
10. Replace the Sealant Barrel Cap and tighten Snugly using the Handle.
11. Before attaching the Giant Button Head Coupler to the valve sealant fitting, operate the
gun until resistance is felt or the gun begins to build pressure. Continue to pump until
internal relief valve releases and note the pressure at which this occurs.
12. Crack the By-Pass Valve to relieve pressure and close again. The 400-D Hand Gun
can now be used for servicing of valves.

PROCEDURE FOR GREASING:

1. Slide the Giant Button Head Coupler over the button head fitting on the valve to
be injected with sealant.
2. Tighten the By-Pass Valve.
3. Begin sealant injection by pumping the gun handle. It may take several strokes for
the gun to prime itself and inject sealant into the valve.
4. As the valve sealant system becomes full, the gun should become harder to
operate and a pressure drop noted on the gauge. When the valve is full of
sealant, open the By-Pass Valve and disengage the Giant Button Head Coupler.

8. RESPONSIBILTY:
Site In-charge to check and inspect for Prevention Maintenance of Plug Valves
carried out by Mechanical.

9. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/40

REVISION:01
Procedure for Strainer cleaning of a Pump
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Strainer cleaning of a Pump

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REVISION:01
Procedure for Strainer cleaning of a Pump
W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Strainer cleaning of a pump.
2. SCOPE:
This scope covers the Procedure for Strainer cleaning of a pump.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-119, OISD-STD-130, OISD-129

5. PROCEDURE:

The Suction strainer of Main line Pump/Booster Pump is to be taken up for cleaning only when
the differential pressure across is more than 0.5 Kg/cm2 or the time elapsed is 6 Months from
the date of last cleaning.

Cleaning of Suction Strainer Element is done using following procedure:

STEP I: ISOLATE THE SECTION

• Isolate the Pump by closing Suction & Discharge Valves

• Check the Sump Tank level. If required, empty the sump tank to accommodate the
Product Quantity to be drained from the Pump (Approx. 1.0 KL for BP and 1.5KL for MLP)

STEP II: DEPRESSURISE / DECANT ISOLATED SECTION

• Release the pressure in the isolated section by slowly opening the vent valve provided in
the isolated section.
•
• After the pressure is released, open the Drain Valve and start draining the product.
•
• During draining operation, keep Vent Valve open.
• Ensure that the isolated section is fully drained.
•
• Calculate and compare increase in sump tank quantity.

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REVISION:01
Procedure for Strainer cleaning of a Pump
W.E.F.: 15.05.2019

STEP III: OPENING, CLEANING AND BOXING UP OF SUCTION STRIANER

• Before opening of strainer element, keep ready all tools, tackles, manpower
(skilled/semi-skilled), collection tray, half cut barrels etc.
• Dismantle drain valve provided near suction strainer flange.
• Loosen the stud nuts of suction strainer blind flange.
• After loosening all nuts & removal of studs except one in 9’o clock, remove the old
gasket and rotate the blind flange about that stud by use of HOT/EOT crane provided in
pump house.
• Remove the strainer element. Observe the internals of strainer element.
• Thoroughly Clean the Strainer element using brush and washing with water. Ensure that
all clogged particles are removed from the strainer element.
• Clean the internals of pipe where suction strainer is to be fitted back thoroughly and
remove the sediments attached to the walls or collected at the bottom. Ensure the
bottom drain line is clear
• Place the strainer elements in position and use a new SPWD Gasket of appropriate size
and rating.
• Place the Gasket and blind flange in position and tighten the nuts / stud bolts properly

STEP IV: CHARGING

• Ensure that all nuts are tightened, and connections are restored properly.
• Keeping Vent valve open and drain valve closed, slowly and partially open the suction
valve without largely affecting the line pressure. (It is preferable to charge the pump
with HSD or SKO.
• Fill the entire pump and drained section with product and observe for the product
flowing to sump tank through the vent line.
• Open and close the drain valve quickly to ensure that the Pump is filled with product and
there is no air space inside. Close the vent valve and suction be open.
• Pressurize the section to the line pressure.
• Observe for leaks, sweating etc. from the flange joint.

6. RESPONSIBILTY:
Site In-charge to check and inspect for Prevention Cleaning of Strainer of a pump
carried out by Mechanical.

7. RECORD:
Log Book/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/41

Procedure for Flow Meter Removal and REVISION:01

Fitting of Spool Piece W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Flow Meter Removal and Fitting of Spool Piece

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 STANDARD OPERATING PROCEDURE
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Procedure for Flow Meter Removal and REVISION:01

Fitting of Spool Piece W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Flow Meter Removal and Fitting of Spool Piece.

2. SCOPE:
This scope covers the Procedure for Flow Meter Removal and Fitting of Spool Piece.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-119, OISD-STD-130, OISD-129

5. PROCEDURE:
❖ REQUIREMENT: -
• Calibration once in a year.
• If Flow Meter is multifunctioning.

❖ PREPARATOIN: -
• Flow Meter and Flow Straightener needs to be isolated by closing Upstream and
Downstream MOV/HOV Plug Valves of Flow Meter.
• Oil collecting tray to be put up below the flange joint for oil collection.

• According to flange size and rating, Gaskets of appropriate size and rating is to be
checked for availability before start of the job.

❖ EXECUTION: -
• Isolated section is to be drained by opening of appropriate vent and drain valves.
• Once it is confirmed that these sections are completely drained.
• Flange bolting of diagonally opposite ends is to be loosened on one side of Turbine
Meter.
• Once all studs are removed drop the gasket provided between flange joint.
• Wait for a minute or so for product to come out if any.
• Repeat the same procedure for the other flange joint.
• Carefully Remove the Turbine Meter from the system and keep it at a safe distance from
working location.

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 STANDARD OPERATING PROCEDURE
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Procedure for Flow Meter Removal and REVISION:01

Fitting of Spool Piece W.E.F.: 15.05.2019

• Now remove the studs of only flange joint left of flow straightener.
• Shift the Spool Piece from wherever it is kept to the working area.
• The new gasket is to be used in the flange joints.
• Proper alignment of the gasket is to be done.
• Tightening of the flange joint is to be done in a proper sequence by use of studs which
are in good condition.
• Studs on diagonally opposite ends are to be tightened.

❖ PRESSURE TESTING: -

• Pressure testing of the joint is to be carried through nipple or drain point available in the
section.
• Testing is done at the same pressures at which filters are tested.
• Certification of pressure testing to be done and to be witnessed by and duly signed by
site engineer.
• Copy of pressure testing certificate is to be submitted to respective control room and
head quarter at Mumbai.

6. RESPONSIBILTY:
Site In-charge to check and inspect for flow meter removal and fitting of spool
piece carried out by Mechanical.

7. RECORD:
LogBook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/42

Repair of welding joint of Pump Casting REVISION:01

and Vent / Drain Piping W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Repair of welding joint of Pump Casting and Vent / Drain Piping

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/42

Repair of welding joint of Pump Casting REVISION:01

and Vent / Drain Piping W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Repair of welding joint of Pump Casting and Vent / Drain
Piping.
2. SCOPE:
This scope covers the Procedure for Repair of welding joint of Pump Casting and Vent / Drain
Piping.

STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

3. REFERENCES:
OISD-STD-119, OISD-STD-130, OISD-129

4. PROCEDURE:
This procedure is applicable for attending the leak from the weld joint of pump casing
and the vent / drain piping of M/s Bharat Pumps and Compressors.
1. ATTENDING THE LEAK AT WELD JOINT OF PUMP CASING AND VENT PIPING:

• Remove the vent lines. Drop the spool piece after pump drain valve piping.

• Fill the water at least half of casing.

• Keep the vent lines fully open to remove the fumes while welding.

• Carry out visual inspection of the defective zone and mark the defects.

• Gouge to remove defective zone completely.

• Carry out D.P. examination of defect to be repaired to ensure complete

cleaning of the defect.

• Use Electrode AWS E 7018 for weld repair.

• Preheat the weld section to minimum 300° C before starting the welding.

• Inter pass temperature shall be maintained 300° C.

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 STANDARD OPERATING PROCEDURE
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Repair of welding joint of Pump Casting REVISION:01

and Vent / Drain Piping W.E.F.: 15.05.2019

• Carry out air cooling of the job.

• Carry out D.P. check after Root / Final run of welds. Ensure proper air cooling
of the weld portion.

1. Connect the vent piping and spool piece of drain piping. Remove the blinds
provided on the pump suction and discharge piping. Open suction valve and
Charge the pump.
2. Start the pump with SOP and observe for any leak from the repaired weld
portion.

(B) ATTENDING THE LEAK AT WELD JOINT OF PUMP CASING AND DRAIN PIPING:

• Take the Fire Permit from GS11 FZS & clearance from respective control room
for this job.

• Ensure Following material/ tools tackles are arranged at site before starting
the work
• Welding machine, grinding machine, gas cutting machine and proper lighting
arrangement
• Welder, grinder, electrician crew with all the required accessories.
• DP Test material

• Close the pump suction and discharge valves fully. Provide positive isolation by
providing blinds on the suction and discharge side of the pump.

• Drain the pump products and flush the pump with water and ensure to remove
the hydrocarbon vapors,

• Remove the vent and drain piping.

• Carry out visual inspection of the defective zone and mark the defects.
• Gouge to remove defective zone completely.
• Carry out D.P. examination of defect to be repaired to ensure complete
cleaning of the defect,

• Use Electrode AWS E 7018 for weld repair.

• Preheat the weld section to minimum 300° C before starting the welding.
• Inter pass temperature shall be maintained 3000 C.
• Carry out air cooling of the job.

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 STANDARD OPERATING PROCEDURE
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Repair of welding joint of Pump Casting REVISION:01

and Vent / Drain Piping W.E.F.: 15.05.2019

• Carry out D.P. check after Root / Final run of welds. Ensure proper air cooling
of the weld portion.

• Connect the vent piping and spool piece of drain piping. Remove the blinds
provided on the pump suction and discharge piping. Open. suction valve and
Charge the pump.

• Start the pump with SOP and observe for any leak from the repaired weld
portion.

5. RESPONSIBILTY:
Site In-charge to check and inspect Repair of welding joint of Pump Casting and
Vent / Drain Piping.
6. RECORD:
Log Book/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/43

Procedure for Preventive Maintenance of REVISION:01

Pumps W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Prevention Maintenance of Pumps

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/43

Procedure for Preventive Maintenance of REVISION:01

Pumps W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for Preventive maintenance of Pumps.

2. SCOPE:
This scope covers the Procedure for Prevention maintenance of Pumps.

3. STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

4. REFERENCES:
OISD-STD-119, OISD-STD-130, API 610

5. PROCEDURE:

❖ HORIZONTAL CENTRIFUGAL PUMPS (BOTH END SUPPORTED)

CHECKLIST- HORTL CENTFGL

PUMP - FORCED LUBRTN
Sr. No. Checklist Point Type Cycle UOM
10 Vibration analysis Online 1 MON
20 Thoroughness of Mechanical seal pipeline Ofline 6 MON
30 Lube oil analysis Online 6 MON
40 Condition of foundation bolts, supports Online 6 MON
50 Condition of Coupling - fastners/shims Ofline 6 MON
60 Checking/Cleaning of lube oil cooler fan Offline 6 MON
70 Checking the balancing line pressure Online 6 MON
80 Cleaning/Replacing of Lube oil filter Online 1 YR
90 Alignment check Ofline 1 YR

CHECKLIST - HORTL CENTFGL PUMP -SPLASH LUBRTN

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Procedure for Preventive Maintenance of REVISION:01

Pumps W.E.F.: 15.05.2019

Sr. No. Checklist Point Type Cycle UOM

10 - Vibration analysis Online 1 MO
20 Thoroughness of Mechanical seal pipeline Ofline 6 N
MON
30 Lube oil analysis Online 6 MON
40 Condition of foundation bolts, supports Online
Online 6 MON
50 Condition of Coupling - fastners/shims Online
Ofline 6 MON
60 Checking the balancing line pressure Online 6 MON
70 Checking of Oiler ring, Lube oil cup. Offline 1 YY
80 Alignment check Offline 1 YY

CHECKLIST - HORTL CENTFGL PUMP - GREASE LUBRTN

Sr. No. Checklist Point Type Cycle UOM
10 Checking the Gland packing. Online 1 MON
20 Topping up/Replacing the grease. Ofline 6 MON
30 Condition of foundation bolts, supports Online 6 MON
40 Condition of Coupling - fasteners/shims Ofline 6 MON

❖ VERTICAL CENTRIFUGAL PUMPS

CHECKLIST - VERTICAL CENTFGL PUMP - SPLASH LUBRTN

UOM
Sr. No Checklist Point Type Cycle

10 Vibration analysis Online 1 MON

20 Thoroughness of Mechanical seal pipeline Ofline 6 MON
30 Replacing the lube oil of the bearing. Ofline 6 MON
40 Condition of foundation bolts, supports Online 6 MON
50 Condition of Coupling - fastners, shims Ofline 6 MON
60 Greasing of Motor bearings. Ofline 6 MON
70 Alignment check Ofline 1 YR

CHECKLIST - VERTICAL CENTFGL PUMP - GREASE LUBRTN

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Procedure for Preventive Maintenance of REVISION:01

Pumps W.E.F.: 15.05.2019

Sr.No Checklist Point Type Cycle UOM

10 Vibration analysis Online 1 MON
20 Throughness of Mechanical seat pipeline (Mine 6 MON
30 Greasing of pump bearing. Ofline 6 MON
40 Condition of foundation bolts, supports Online 6 MON
50 Condition of Coupling - fastners, shims Ofline 6 MON
60 Greasing of Motor bearings. Mine 6 MON
70 Alignment check Ofline 1 YR

❖ RECIPROCATING / PLUNGER / DIAPHRAGM PUMPS

CHECKLIST - POSITIVE DISPLACEMENT PUMP

Sr.No Checklist Point Type Cycle UOM

10 Crank case/Diaphram oil replacement Ofline 6 MON

20 Gear Box oil replacement Ofline 6 MON
30 Cleaning of pump strainer. Ofline 6 MON
40 Condition of foundation bolts, supports Online , 6 MON
50 Condition of Coupling - fastners, shims Ofline 6 MON
60 Inspection/Replacement of gland packing. Online 6 MON

6. RESPONSIBILTY:
Site In-charge to check and inspect for Procedure for Prevention Maintenance of
Pumps carried out by Mechanical Team.

7. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/44

Procedure for Replacement of Pipeline REVISION:01

Section W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Replacement of Pipeline Section

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/44

Procedure for Replacement of Pipeline REVISION:01

Section W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for replacement of pipeline section.

2. SCOPE:
This scope covers the Procedure for replacement of pipeline section.

STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

3. REFERENCES:
OISD-STD-138, OISD-STD-130, OISD-129

4. PROCEDURE:
This procedure is applicable for replacement of pipeline section of carrier pipe in case it is
decided to be replaced due to mechanical damages to the pipeline or to be replaced as per the
standards.
1. Job to be carried out after obtaining clearance from the ROU,

2. Following material/ tools tackles to be arranged at site before starting the work
a. Hydrotested pipeline section of length more than the pipeline to be replaced at site.
b. Excavators, Hydra, Generators, welding machines, grinding machines, gas cutting
machines and lighting arrangement.
c. Coating material with Holiday test machine.
d. 2 nos. of Foam Pigs of carrier pipe diameter size.
e. Unskilled labours with excavation tools tackles. Welders, grinders electricians,
riggers, shot blasting crew with all the required accessories.
f. Welding clamps of carrier pipeline diameter size
g. NDT crews
h. Inspection Team, Operation Teem, ERV and Maintenance Team at site.

3. Take the Fire Permit from GSI/ FZS & clearance from respective control room for this job.

4. Excavate the pipeline trench as per following dimensions,

I. Length: Proposed length of carrier pipe to be replaced + necessary length on the

either side of the pipeline to be replaced.

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Procedure for Replacement of Pipeline REVISION:01

Section W.E.F.: 15.05.2019

H. Width: Carrier pipe diameter + 2 meter (1 meter on the either side of the carrier
pipe)

iii. Depth: 500 mm below the existing carrier pipe along the length of the pipeline.

5. Mark the pipeline planned to cut.

6. Remove the pipeline coating 200 mm on the either side of the pipeline to be cut on both
sides.
7. Support the pipeline section with gunny bags and lock the pipeline section with wooden
logs, gunny bags filled with soil to restrict the pipeline section after cutting.

8. Carry out UT and ensure the pipeline thickness at the cut location. Initially carry
out complete circumferential groove on the pipeline upto the wall thickness
equal to total pipe wall thickness-2.5 mm.

9. Put the half-cut drums below the cutting locations

10. Carry out cold cutting with hack saw for cutting of the pipeline. Ensure continuous
cooling of hacksaw blade.
11. After cutting the pipeline section on one side ensure proper removal and transfer
of product in the ERV. Carry out similar procedure on the other end.

12. Remove the pipeline cut section with hydra

13. Seal both ends of the pipeline with insertion of foam pigs and provide adequate
mud plugs.

14. Lay and spread dry soil in the trench at hot work locations. Ensure no wet section
in the trench.

15. Carry out edge preparation of both the pipe ends for making it ready for welding.

16. Carry out Dye Penetration test of the beveled edges of the pipeline to ensure no
hairline cracks at weld location and UT all along the circumference upto 50 mm
from bevel end to ensure no flaws on the pipeline.

17. Carry out continuous preheating upto 300° C of the beveled end upto 200 mm to
remove stresses if any and to remove any trapped hydrogen at the heat affected
zone. The preheating temperatures to be ensured with laser temperature gun or
temperature sticks.
18. One side of the pre hydrotested section bevel end to be checked for DP test and
UT test and ensure no defects.

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19. Lower the hydrotested section and align checked bevel section with the pipeline
one end. Alignment to be carried out with clamps. Ensure proper gap 2.5 mtr all
around the pipes to be welded and their longitudinal alignment.
20. Root welding to be carried out with E 6010 electrodes. (uphill welding)

21. Hot pass, filler and capping to be carried out with E 8010 electrodes. (Downhill
welding).

22. After completion of one side weld align the pipe, cut the excess pipe, carry out end
bevel preparation, carry out DP test and UT test.

23. Align the pipe, ensure proper equal gap between the pipe ends.

24. Welding procedure to be repeated as per the clause no. 20 and 21'.

25. Allow the weld Joints for cooling and take 100 % x-ray.
26. The x- ray films to be analyzed. If any defect found same to be repaired,
radiographed and analyzed.

5. RESPONSIBILTY:
Site In-charge to check and inspect for Pipeline Coating Refurbishment carried out
by Mechanical.

6. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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Sanmarg Projects Private Limited

COATING DEFECTS SURVEY

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1. PURPOSE:

To provide written operating procedure of Holiday detector.

2. SCOPE:

This standard is applicable to detect the pinhole or crack in the pipeline

coating.

Instrument used: Holiday detector

3. SAFETY REQUIREMENTS:

The Holiday Detector is a high voltage instrument; precaution should be

taken while operating. The safety precautions are as follows:

1. The operator should wear safety shoes and hand gloves.

2. While operating no person should get in contact with the probe and job.
3. The job material should be placed on wooden log and should not get in
touch with any water logged place.

4. REFERENCES:

Manufacturer’s (Caltech Engineering Services) Operation Manual of Holiday

Detector model HD-830

5. PROCEDURE:

Operating Procedure

(1) Obtain the work permit from operating department.

(2) Keep “ON/OFF” switch to “OFF” position.
(3) Connect the Battery (12v, 2.3 AH) in back panel.
(4) Connect the earth probe to Holiday detector then keep the spring on the
ground to get earthing to instrument.
(5) Connect the H.T. Probe suitable attachment (Either ring or Bush).
(6) Connect the job (pipe) bare part to earth with the help of earth clip.
(7) Return permit to control room.

Switch on the instrument with the help of “ON/OFF” switch keeping the
output voltage selection switch to desired position. Move the H.T probe along
the job (pipe).
Whenever the pinhole or crack is detected in coating the audio/visual
indication is given by the instrument.
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NOTE:

1) Whenever 8 to 10 hours of operation, recharge the battery for 10 hours

Charging cycle with the help of battery charger supplied along with the
Holiday Detector.
2) If the instrument is not used for the long time, recharge the battery at
Intervals of once in a month.
3) To charge the battery, connect battery charger pin battery socket, Red
Indication display that the battery is under charging procedure. Then
Connect the mains plug to main outlet of 230 V AC. Then switch “ON”
To charge the battery.

6. RESPONSIBILTY:

Electrical team & engineers responsible for the proper functioning of holiday
detector.

7. RECORD:

Maintain Log Book/ register to record monthly battery voltage of instrument.

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Sanmarg Projects Private Limited

Maintenance of PSP Monitoring Operation Procedure

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1. PURPOSE:

To provide written procedure for monitoring of Pipe to soil potential.

Measurement of metal to soil potential is a widely used technique to maintain the
buried steel pipeline. This is the case that electro-chemical theory is applied to
industry field. Measurement and evaluation of the potential are effective
inspection method which could find out the possibility of corrosion for steel pipe
under cathodic protection.

2. SCOPE:

This standard covers the guidelines on quarterly checking of PSP as well as

Metering and Controls of Automatic Cathodic Protection Rectifier Unit as per
checklist and maintenance of Automatic Cathodic Protection Rectifier Unit
(TRANSFORMER RECTIFIER UNIT) Rating 50V, 50 A DC.
Frequency of inspection & checking: Weekly/Quarterly

3. SAFETY REQUIREMENTS:

➢ Electric shock - When transformer rectifier cabinet is open, ensure that no live
parts are exposed during testing in the use of that ladder. The ladder should be
used on firm ground and secured to procedures.

➢ Risk of falling - If a transformer rectifier is installed in a location that requires the

use of a ladder, care should be exercised prevent slipping.

➢ Working in confined spaces - Personnel should not enter confined spaces without
the authority and direct supervision of qualified personnel. Site owners/operators
should have their own procedures for entry into confined spaces and these
should always be followed.

➢ Always ensure the correct permit has been issued and that all correct procedures
have been carried out before continuing.

Under no circumstances should a person working alone enter a confined

space. There must always be someone outside the confined space to raise
the alarm in case of emergency.

Use of PPEs:

1. Hand Gloves & Helmet

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2. Safety Shoes & Multimeter

3 Insulating Mat & Tools

4. PROCEDURES:

• Obtain the work permit from operating department.

• Checking & maintenance of TR Units, CP Units
• Insulating the internal or external surfaces of a structure from the electrolyte by
the installation of paint, wax, coal, tar, asphalt, plastic tape, epoxy resin, or other
coating or lining material.
• Installing the structure in a high resistant or well-drained environment, such as in
or on sand, crushed rock, etc.
• Cladding, lining, dipping, electroplating, or metalizing to coat a metallic surface
with a metal, alloy, or material of superior resistance.
• The addition of selected chemical inhibitors, passivators, or desiccants.
• The removal of oxygen, carbon dioxide, or other gasses from, or the addition of
inert gasses, such as nitrogen, to the environment.
• The careful consideration and selection off metals, alloys, plastics, ceramics, or
other materials, to be used in conjunction with a necessary metal.
• Control of the environment to lower temperatures.
• The reduction of velocities and/or throughput at the face of the corroding material.
• The installation of in-line insulating materials.
• Type of coating.
• The presence of laterals, valves, and other structures which may influence the
Readings.
• Location or existence of insulating fittings or other deliberate or inadvertent
Discontinuities in the piping.
• The existence of outside sources of stray D.C. current or adjacent protected
Structures.
• Soil resistivity along the route of the pipe.
• Return work permit to control room.

5. DEFINITION:

Main Objective behind Inspection & maintenance is to ensure that we should

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Protect the under laid pipeline from corrosion.

The pipe-to-soil potential test has been established by corrosion engineers as

a standard measurement technique in the evaluation of corrosion control and the
degree of cathodic protection applied to buried metallic structures.

The copper sulphate half cell reference electrode is most commonly used to
contact the soil. Normally, the natural static potentials of unprotected buried steel
will vary from -0.30 to -0.80 volts, with reference to the copper sulphate electrode.
Such differences in the pipe-to-soil potentials observed at various intervals along
a pipeline indicate the voltage drops in the soil between the test points. This
means that galvanic currents will flow through the soil between the anodic and
the cathodic points, the magnitude of current flow depending on the resistivity of
the soil (electrolyte) and the voltage drop in the galvanic cells.

If the static pipe-to-soil potentials along a pipeline were of equal values, galvanic
currents could not flow, and there would be no corrosion.

When enough external counter-current is provided to a corroding section of a

pipeline to exactly cancel out the galvanic currents, the pipe-to-soil potentials at the
anodic points will be equal to the pipe-to-soil potentials of the cathodic points, and
the voltage drop between the points would be zero. That point of theoretical potential
equalization is usually at or near the open circuit potential of the anodic point.

For example, if the open circuit pipe-to-soil potential of an anodic point is -0.65 volt,
then corrosion will be stopped if the potential of the cathodic point(s) is made more
negative and equal to this value. This is a basic criterion for the cathodic protection
of a buried structure. However, it would be impractical and almost impossible to
determine the open circuit potential values and points of potential equalization along
a pipeline, so corrosion engineers have established a second and more practical
criterion for adequate cathodic protection.
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It is generally accepted by the corrosion engineers that a structure will be under

complete cathodic protection if the pipe-to-soil potential at all points on that structure
is maintained at a minimum level of -0.85 volt. This value represents over-protection
in most instances, since the points of potential equalization, as pointed out above, is
usually less negative than -0.80 volt. This is the most practical and economical
criterion to consider in testing for the existence of corrosion on any buried and
coated pipeline.

Structure-to-soil potentials should be observed using a potentiometer, which draws

no current, or a high resistance voltmeter, which draws only a very small current. A
copper-copper sulphate electrode is used for the reference contact with the
electrolyte (soil), and there must be direct contact with the structure (pipe).

To make a pipe-to-soil test observation, the lead wire attached to the copper
sulphate electrode is attached to the positive (+) post of the meter. A wire attached to
the negative (-) post of the meter is attached solidly to the pipe at any convenient
point. This contact can be made by clipping directly to an above-ground valve, fitting,
riser, or even by attaching to a probe bar pushed into the ground to contact the pipe.

The plug end of the copper sulphate electrode is then placed firmly against the moist
soil at a position relative to the top of the buried pipe. If the soil is dry, it will be
necessary to spill just a little water onto the ground (1/2 cupful) in order to ensure
good contact between the soil and the electrode. The pointer on the voltmeter will
then indicate the pipe-to-soil potential at that particular point on the pipeline.

Continuing and using the same direct contact to the pipe, but then using a very long
wire between the meter and the copper sulphate electrode, it will be possible to
move the electrode about and take many pipe-to-soil test observations at any
number of intervals for hundreds of feet along the length of a pipeline.

If all test observations over the entire structure are found to be -0.85 volt or greater, it
can be concluded that the entire structure is cathodic with respect to the sacrificial
anodes (or with respect to the rectifier groundbed) and that there is no active
corrosion taking place. This value of -0.85 volt considers a "built-in" constant of -0.52
volt as the solution potential between copper and copper sulphate in the reference
electrode.

Pipe-to-soil observations should be made whenever there is any question or any

doubt that the structure may not be under full cathodic protection. It is desirable to
practice the re-observation of pipe-to-soil potentials at regular, say, six-month
intervals to have assurance that no physical changes had previously been made that
would upset the balance of the cathodic protection circuit.

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This is for confirmation purposes, and to discover any changed condition which could
result in corrosion damage to the structure. The period of retesting pipe-to-soil
potentials should never exceed one year.

Whenever any work is performed directly on the structure which may affect the
cathodic protection balance, it would then be prudent to retest the pipe-to-soil
potential at the completion of that work. Such work would include any activity which
might affect the insulation or the shorting of any portion of the structure to another
structure, any work on or addition to insulating fittings, any addition or removal of
pipe to the length of the system, any pollution of the soil which my lower the
resistivity of the soil environment, any indirect contact to the structure by a different
metallic structure, any nearby construction and subsequent operation of a cathodic
rectifier by others, any other new source of stray DC into the earth, etc. Any changes
which do occur to reduce the pipe-to-soil potential on the structure under cathodic
protection below a level of -0.85 volt should be removed or corrected to restore the
structure to a protective level.

6. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the
inspection & maintenance of Electrical Panel at IPS & SV Stations.

7. EQUIPMENTS DETAILS:

• Multimeter with test leads

• Copper/Copper Sulphate portable reference electrode
• Earth Tester
• Clamp Meter
• Hand tools

8. RECORDS:

QUARTERLY PSP SURVEY REPORT

P.S.P. Survey for the quarter of __________

Report No _________________________ Base ____________

Sl. Chainage in Kms Date Location of TLP PSP (Volts) Remarks

NO. Carrier Casing

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Remarks__________________________________________________________________
__

Note: 1. The PSP values for both ON and OFF condition shall be taken and recorded.
2. One copy of the report along with detailed analysis/ action plan & target date for
rectification to be forwarded to HMPL

Signature : ………………….
Name : ………………….
Designation :
Date : ………………….

Note : Use additional sheet wherever necessary

Strike out whichever is not applicable
Details in appropriate format
Countersigned : …………………………

Distribution : (1)
(2)

Tapping
Date CP Circuit PSP Volts Energy
DC DC settings AC AC
Sl. No. & Station Resist- meter REMARKS
volts amps ON OFF Coarse Fine volts Amps
Time location ance reading

1
SV-10

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2
SV-11

3
SV-12

4
SV-13

SV-14

6
SV-15

Power availability hours during the week: ……………………………..

Details of other works done if any: ……………………………..

Remarks:

Signature : ………………….
Name : ………………….
Designation :
Date : ………………….

Note: Use additional sheet wherever necessary

Strike out whichever is not applicable
Details in appropriate format
Countersigned: …………………………
Distribution: (1)
(2)

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its System Operation Procedure

Sanmarg Project Private Limited

Inspection & Maintenance of CP Panel & its System Operation

Procedure

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its System Operation Procedure

1. PURPOSE:

To provide written procedure for maintaining of Cathodic Protection System, Inspection and
Checking of Automatic Cathodic Protection Rectifier Unit to ascertain & ensure/obtain
optimum level of protection of underground pipeline section under varying condition at all
the time.

2. SCOPE:

This standard covers the guidelines on quarterly checking of PSP as well as Metering and
Controls of Automatic Cathodic Protection Rectifier Unit as per checklist and Maintenance
of Automatic Cathodic Protection Rectifier Unit (TRANSFORMER RECTIFIER UNIT) Rating
50V, 50 A DC.

Frequency of inspection & checking: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:

Correct pipe to soil potential data in scheduled time to assess health of p/l & take corrective
action based on surveys.

CRITERIA OF PROTECTION:

• A negative cathodic voltage of at least 750 mv between pipe surface and cu-cuso4 half-cell
in contact with earth and measurement at the surface directly over the pipe line.

• Polarisation negative voltage shift of 100 mv measured with respect to reference electrode.
This is done by switching 'off' c.p. and observing polarisation decay. The difference between
negative voltage and natural potential (depolarised after 72 hrs.) is the voltage shift.

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• 300 mv minimum negative potential in 'c.p.' in 'on' condition is called shift because of c.p.
'on' range of protection is between (-) 0.85 v to -1.5v for 3 lpe.
• Monitoring / maintenance, weekly inspection is done including other equipments (battery
charger etc.) Quarterly, psp report are analysed for any point below protection level.
• Unit para meter of c.p. units, power position, insulating joint effectiveness etc. & analysis is
done for improvement if required.

OTHER INCLUDES ½ YEARLY GROUND BED CONDITION.

• Test lead connection
• Survey as per NACE & OISD - 138 to be followed
• Remedial action by report of ground bed resistance
Value - pour water in anode beds.
• Check disconnection of anodes, anode tail joints.
• Carbonaceous back fill (cpc breez) to be used.
• Header cable joining with m.seal / araldite.
INSULATING JOINT / COUPLING
• PSP of main line & station piping adjacent to each other.
• Switch off c.p. Of station for ½ hrs.
• Keep main line c.p. 'On'.
• Measure c.p. On either side of coupling.
• Now measure instant 'off' on station side by making main line c.p. Off.
• No significant variation should be there.
• Repeat above other way i.e. Main line off & station c.p. On.

a) CPTR unit in SVs

1. Obtain the work permit from operating department.
2. Check for digital displays and meter readings in CPTR panel in case no reading is
displayed, record and report.

3. Recoding of PSP value and CPTR output voltage and current values.

4. Check for alarms if any record and report.

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5. Return permit to control room.

b) Monthly monitoring of pipeline:

1. Standard format for recording monthly CP readings.

2. Ensuring that connection drawing and Pipeline Chainage are there in/on TLPs.

3. Monitor PSP values of Casing Pipes as well in case of cased crossings.

4. Proper guidelines for use of half -cell.

5. SCHEMATIC DIAGRAM:

6. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the inspection &
maintenance of Electrical Panel.

7. DEFINITION:

Main Objective behind Inspection & maintenance is to ensure that we should

Protect the under laid pipeline from corrosion.

8. REFERENCES:

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1 Operating Instructions for Automatic Cathodic Protection Rectifier Unit (TRANSFORMER

RECTIFIER UNIT) Out Put Rating 0-50V DC, 50 A DC (RRL ref. No. CEO496 of Raychem RPG
Ltd. Industrial Electronic Division.

2 Drawings
a) General Assembly Drawing for Rectifier: CEO496/TRA2/GA and
b) Wiring diagram for Rectifier: CAO496/TRA2/WIR

9. RECORDS:

A. Anode Bed Monitoring Report

SV/IP STATION LOCATION………..

ANODE BED MONITORING

S.
No. Anode No. Voltage Drop Across Shunt(mv) Current (Amp.) Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
S.No. Impection Remarks

1 Physical condition of Anode Junction Box

2 Physical condition of Cathode Junction Box

3 Physical condition of Anode Header Cables

4 Physical condition of Cathode cable

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5 Physical condition of Anode bed

6 Anode Bed Resistance

Readings By :- Checked By :-
Signature Signature
Name Name
Designation Designation
Date Date

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Sanmarg Projects Private Limited.

Rectification of Damaged Coating Maintenance Procedure

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1. PURPOSE:

To provide written procedure for rectification of damaged coating.

This installation procedure covers only hand application of Powercrete® R 95 100% solids
high build liquid epoxy coating using Applicator Pads.

2. SCOPE:

This standard covers the minimum requirement of materials, application tools, equipment

required for testing and application of Powercrete® R 95 for field Joints.

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD guidelines.
All necessary precautions shall be taken to protect personnel and property from accidents
due to falls, hazardous materials, fire explosion and other dangers. Applicator or Contractor
who is applying the epoxy liquid coating must read MSDS (material safety data-sheet) and
should be aware of all related safety precautions. All personal protective equipment (PPE)
should be in place when application is carried-out.

1. Rubber Hand Gloves.

2. Safety Shoes.
3. Helmet.

4. PROCEDURES:

➢ Obtain the work permit from operating department.

➢ Coating system shall be inspected visually for uniformity, thickness, blister, pinholes etc. all
imperfections shall be identified and marked for repair.

➢ The Dry film thickness of the coating shall be checked at 5 randomly selected areas. The
nominal thickness of coating shall be 500 µm; no single measurement shall be less than 450
µm.

➢ Holiday Inspection is to be done at 2.5 KV. Pinholes, porosity or other defects which are
found during the holiday inspection are to be clearly marked for repair.

➢ Adhesion Testing is to be done by using cross cut test.

Acceptable value: Rating 1.

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5. SURFACE PREPARATION:

• Surface should be free from all dust, dirt, moisture, oil, grease or other contaminations.

• If necessary, use a non-contaminating solvent such as Xylene or MEK to remove the

contaminations on the surface.

• Before blasting/sweep blasting remove completely slag of the root run of the girth weld, any
sharp burrs. Edges should be smoothened using hand hammer/grinding wheel.

• Clean the surface after removing slag and smoothening of sharp burrs and edges.

• Check the surface temperature prior to blast cleaning. Blast cleaning operation shall not be
done when relative humidity exceeds more than 85% and steel surface temperature shall at
least be 3 ºC above dew point and maximum steel surface temperature shall be 60 ºC

• For coating on bare pipes/field joints blast clean using grit/garnet/sand (only river), to SA 2½
and a roughness profile (anchor pattern) between 70 to 100 microns. Surface profile to be
measured randomly.

• To roughen the adjacent coating surface use sand disc/sweep blasting

• Remove carefully all remaining abrasive dust and loose particles after surface cleaning.

• The coating shall be applied normally within 2 hours of surface preparation to prevent any
rusting. No coating shall be applied if the relative humidity exceeds 85% or the surface
temperature of the pipe drops less than 10ºC. At any case, temperature of steel surface
must be at least 3 ºC higher than the dew point.

MIX – RATIO OF POWERCRETE® R 95:

a) By Volume – 3.6: 1 Part A to Part B

b) By Weight – 100: 16 Part A to Part B

6. COATING PROCEDURE:

• Prior to application of the coating make sure surface is cleaned and removed of all dust and
other contaminants.

• Mix Part A and Part B in a cup using sticks. The mixing has to be done thoroughly for 2 to 3
minutes till homogeneous mass is obtained. No traces of Part B shall be seen.

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• Reconfirm that the surface temperature is above 10ºC & 3ºC above the dew point.

• Slowly pour mixed epoxy onto cut back area on pipe surface, use special applicator pads to
apply required minimum thickness of coating to the field joint.

• Cover at least 100mm of the adjacent mainline coating.

• Workable Pot life after mixing is 14 minutes at 25ºC.

• Measure WFT (wet film thickness) at randomly selected areas the WFT shall be in the range
of 500 µm average

• Care should be taken that the wet coating shall not be contaminated with particles such as
blowing sand, insects or other foreign material.

• Return permit to control room.

7. RESPONSIBILTY:

Shift In-charge, Mechanical team & Company engineers to check rectification of damaged
coating, on routine basis at SV & IPS Stations.

8. DEFINITION:

Main objective is to maintain the 3LPE coating properly to stop corrosion through the crude
oil pipeline.

9. EQUIPMENTS USED:

MATERIAL / APPLICATION TOOLS / TESTING EQUIPMENT REQUIRED

Coating Material
• Powercrete® R 95 100% liquid epoxy Part A & B
• Applicator Pads
• Epoxy Pumps
• Mixing cups and Sticks

Application Tools

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• Measuring cups 25 ml , 50ml, 100 ml

• Weight Measure for measuring up to 5 Kg
• Applicator pads Kits
• Wet film thickness gauge
• Dry Film thickness gauge
• SA 2½ Surface Comparator Plate

Application Tools / Material for Surface Preparation

• Grit / Garnet/Sand (only river) Potable Blasting Unit
• Air Compressor
• Abrasive media of suitable mesh size to ensure surface roughness of
70-100 microns.
Testing Equipment

• Press ‘O’ film with micro meter

• Potable adhesion testing equipment
• Coating thickness gauge
• Holiday Detector with Jeep meter
• Digital thermometer with flat probe
• Stanley Knife

10. RECORDS:

Maintain records as per formats & Logbook/ Register is to be maintained and also
maintenance carried out with parts consumed is maintained.

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Sanmarg Projects Private Limited

MAINTENANCE OF TR UNIT

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1. PURPOSE:

To provide written procedure for maintenance of TR Unit to ascertain & ensure/obtain

optimum level of protection of underground pipeline section under varying condition at all
the time.

2. SCOPE:

This standard covers the guidelines on monthly maintenance of TR Unit.

Frequency of maintenance: Monthly

3. SAFETY REQUIREMENTS:

Rubber Hand Gloves, Safety shoes, Safety helmet and proper insulating tools.

4. PROCEDURES:

1. Obtain permit from control room.

2. Arrange vehicle, manpower & material.
3. Perform Journey.
4. Inform to MCR/CR on reaching site.
5. Do physical inspection of TRU.
6. Note parameters of TRU.
7. Check for digital displays and meter readings in CPTR panel in case no reading is
displayed, record and report.
8. Recoding of PSP value and CPTR output voltage and current values.
9. Check for alarms if any record and report.
10. Analyze parameters of TRU.
11. Confirm with C/R all OK.
12. Perform return journey.

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5. RESPONSIBILTY:

Mechanical/Electrical team & engineers responsible for the proper maintenance of TR Unit.

6. REFERENCES:

Wiring Drawing of T/R Unit.

7. RECORDS:

Log Book/ Register is to be maintained for and maintenance carried out with parts
consumed is maintained.

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Sanmarg Projects Private Limited

CIPS SURVEY

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1. PURPOSE:

The purpose of this SOP is:

A. To know the effectiveness of the system
B. To identify Anodic & Cathodic regions of the Pipeline, as existing.
C. To study whether the pipeline is cathodically protected
D. To study the interference effect due to Tractions/Transmission lines and to provide
mitigation measures for the same.

2. SCOPE:

The scope of this SOP is:

A. To carry out CIPS survey by using Computerized potential logging survey method.
B. To find out Pipe to Soil Potentials at desired locations along the pipeline (excluding River
crossing & Road crossing) and to identify the under protected / Over protected area &
Coating damage locations on the pipeline.
C. Any over/under protection area and current drainage locations observed during this survey
shall be provided with necessary mitigation measures to bring the pipeline with in
protection criteria range.
D. ON/OFF CIPS survey shall be carried out at every 1m interval along the pipeline.

3.) SAFETY REQUIREMENTS:

A. Ensure that all the safety requirements while doing the job are met as per OISD guidelines

B. PPE Required:

a. Helmet
b. Goggles
c. Safety Shoes
d. Hand Gloves (Normal Electrical)
e. Boiler Suits
f. Earmuffs/Ear Plugs

4.) MANPOWER:

A. Surveyor - 1 No.

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B. Technician - 2 No.
C. Helper - 1 No.
D. Labour - As reqd...

5.) EQUIPMENTS, TOOLS & TACKLES:

Sr. No. Materials Description Quantity Make

Data Collector- along with two nos of
1. reference cell sticks & multiple reference One set per Mc. Miller
cell connector team

Current interrupters with synchronized GPS based Inbuilt Current

2. 3Nos
timer circuits and adjustable time settings Interrupter
3. Rodometer One per team Reputed
4. Measuring Tape One per team Reputed
5. Flexible cable/ Copper wire As required Reputed
Computer loaded with COMPANION
6. One Reputed
SOFTWARE
7. Digital Multi meter One per team Rish 18S
8. Portable Cu/CuSO4 Reference Cell One per team MC Miller

6.) PROCEDURE:

A. Carry out CIPS survey after commissioning of pipeline and after minimum 48 (Initial) hrs. Polarization
of pipeline CP system, if in-between CP system, is switched-off then restart same process again and
start survey after re-polarization for min 24 hrs.

B. Before commencing the survey, confirm that the cathodic protection system is operating normally.
Check the DC feeders, drain points, insulating joints with commissioning results. Identify TRU/
CPPSM; Grounding cells provided at IJ/ IF, Sacrificial Anode. Bonding location of the pipeline section
to be considered for the CIPS Survey.

C. Disconnect foreign pipelines, if any, grounding cell of IJ/ IF, valve earthing (in protected section) and
sacrificial anode. However, do not disconnect bonding of client pipeline running in same ROU. Do
not disconnect grounding anodes/ Earthing provided through polarization cells, provided healthiness
of the Polarization Cell is intact.

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D. Check the cathodic protection commissioning results to identify areas requiring special attention
during the CIPS survey.
E. Install current interrupter with synchronized GPS in the DC negative output of the D.C. power source
(CP system) at all the CP stations in which electrical continuous section of the CIPS survey is to be
carried out. (-ve terminal of CP unit to be connected to -ve terminal of interrupter and +ve terminal
of interrupter to pipeline)
F. Operate CP unit in AVCC mode with set PSP as commissioning setup for output voltage, current and
PSP, Set the interrupter switching cycle at a ratio of 4:1 ON: OFF (4 seconds “On”: 1 Second “OFF”)
G. The OFF PSP at the CP Unit Location not to be more negative than (-) 1200 mV and at far end
location and not to be less negative than (-) 850 mV. In case of multiple CP units in same section, PSP
at mid location not to be less negative than (-) 850 mV.
H. Note a set of ON & OFF PSP record of the pipeline as compliance of the above and if required re –
adjust CP Unit to get the OFF PSP within (-) 850 to (-) 1200 mV.
I. Calibrate the portable reference electrode before start of the survey w.r.t calibrated (master)
portable reference cell.
J. Locate the route of the pipeline using a pipeline locator and provide temporary markers on the route
to enable the surveyor to walk on the route of the pipeline for carrying out the CIPS survey.
K. Set the mode of the data logger in logging mode for programmed Interval as per interrupter cycle.
L. Connect the data logger Black terminal to pipeline through copper reel cable and Red terminal to
reference cell stick.
M. With the equipment connected and the pipeline located, move along the pipeline carrying the
mobile data logger and Cu/CuSo4 reference cell sticks to measure and store the pipe to soil
potentials at every 1meter interval by pressing the button on stick/ logger for storing.
N. Restore all disconnected CP bonding and anodes to original condition.
O. Record distance travelled and physical features like roads which will be useful as descriptors to assist
in locating specific areas after taking reading at location.

P. Transfer the data from the Sincorder to a computer for producing data print outs and plots of the
PSP potential profiles against distance travelled.

Q. Collect following data during survey:

a. Monitoring results of the sectional T/R units.

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b. Data (PSP values).

c. Distance location details (TS/ Road/ Rail/ foreign line/ HT line etc.) as descriptors.

d. Energized Potentials “ON”.

e. Polarized potentials “instantaneous OFF”.

R. Prepare report with chainage locations to represent the readings in tubular and graphical manner.

7.) APPENDIX / FORMATS

CPPSM/ TR Unit Data Template for CIPS Survey

Owner:
CP Contractor:
Project:
Report No.: Date:
Pipeline Section Code and Name:
CP Unit CP Unit
Interrupter
Sr. Date of Location Output Output
Chainage Pulse working in
No. Recording Name Voltage Current
sync. (Y/N)
(V) (A)

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CIPS Survey Data Template

Owner:
CP Contractor:
Project:
Report No.: Date:

Pipeline Section Code and Name:

ON Later
Terrai Date OFF Northin Later
Sr. PSP Eastin Diff. in al
Chainag n of PSP g al ON Remar
No (- g (X ON/OF OFF
e Featur Surve (- (Y PSP ks
. mV Cord) F PSP PSP
e y mV) Cord) (-mV)
) (mV) (-mV)

8.) RESPONSIBILTY:

A. Project In- Charge

B. Surveyor
C. CP Technician/Supervisor

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REVISION:01
CAT SURVEY
W.E.F.:15.05.2019

Sanmarg Projects Private Limited

CURRENT ATTENUATION TEST SURVEY

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1. PURPOSE:

The purpose of this SOP is:

A. To know the effectiveness of the cathodic protection system.

B. To measure current loss along the main pipeline and locating the exact position of the buried
pipeline.

2. SCOPE:
The scope of this SOP is:

A. To carry out Current Attenuation Test Survey at 50 Meters interval & measuring current loss along
the mainline pipe including locating the exact position of the buried pipeline.
B. Based on the results of CAT Survey, Coat & wrap condition shall be indicated showing the defect
severity & priority for Coat & wrap refurbishment.
C. CAT survey shall be conducted at closer interval in case of high dB/loss or as per instruction EIC/ Site
Engineer, If Required.

3.) SAFETY REQUIREMENTS:

A. Ensure that all the safety requirements while doing the job are met as per OISD
guidelines

B. PPE Required:

a. Helmet
b. Goggles
c. Safety Shoes
d. Hand Gloves (Normal, Electrical & Welding)
e. Boiler Suits
f. Ear Muffs/Ear Plugs

4.) MANPOWER:

A. Surveyor - 1 No.
B. Technician - 2 No.
C. Helper - 1 No.
D. Labour - As reqd...

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5.) EQUIPMENTS, TOOLS & TACKLES:

Sr. No. Materials Description Quantity Make

1. CAT instrument with ‘A’ frame One kit per Vivax/ Radio Detection
team

Current interrupters with synchronized GPS based Inbuilt Current

2. 3Nos
timer circuits and adjustable time settings Interrupter
3. Measuring Tape One per team Reputed
4. Flexible cable/ Copper wire As required Reputed
Computer loaded with COMPANION
5. One Reputed
SOFTWARE
6. Digital Multi meter One per team Rish 18S
7. Portable Cu/CuSO4 Reference Cell One per team MC Miller

6.) PROCEDURE:

A. The concept of Current Attenuation Test is to measure the impressed signal leakage from the buried
pipeline. The signal leakage will depend directly on the health of the coating wrapping.

B. The basic equipment consists of a Transmitter and Receiver. The Transmitter, which can inject a low
frequency AC Signal, is connected to the pipeline. The receiver, when held just above the pipeline,
reads the current remaining in the pipeline, irrespective of the height at which the receiver is held
above the ground.

C. Switch off the CP system for pipeline section (from one Insulation Joint to next Insulation Joint) for
the survey.

D. First locate the exact alignment of the pipeline within the ROW (Right of Way) and then inject the
Transmitter frequency into the pipeline through the existing Test Points.

E. Measure current at an interval of 50 meters on both sides of signal point. Prepare a current gradient
profile and rate of loss of signal profile against distance traversed along the pipeline chainage after
completion of each span. Hot spots/Poor coating locations are to be adequately illustrated in
relation to permanent bench marks viz. Boundary wall, Test Point, Kilometer Post etc. to facilitate
easy identification of the said locations at a subsequent stage during coating refurbishment.

F. Tabulate current attenuation values after completion of test (refer Appendix)

G. The performance of the instrument to be checked before starting the actual field survey by
measuring the field strength / dB loss per Km for the same defect when the transmitter is kept in
one case ascending and in second case descending location. The dB loss measured at these two
locations shall be compared and should be within permissible limit of 10%.

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H. Necessary analysis of the test data to be furnished to indicate coating condition for each span
tested. Recommendations for coating refurbishment in a priority wise manner to be recorded along
with these data.

I. Field Data (from the CAT instrument) and plots of Pipeline Map current v/s Distance on graph sheets,
for analysis and identification of places of high current attenuation.

J. Present results in Graphical form in a way that areas of poor coating are readily identifies from it.

PRECAUTIONS
A. Exact pipeline route is required to be identified for the survey.

B. During CAT survey all grounding cells for IJ etc. pipeline bonding etc. should be removed and
restoration should be done after completion of survey.

C. The survey shall be performed in such way that ROW crops damage is minimum.

7.) APPENDIX / FORMATS FOR SITE INSPECTION REPORT

CAT Survey Data Template

Owner:
CP Contractor:
Project:
Report No.: Date:
Pipeline Section Code and Name:
Date Easting
Terrain Current Current Current Northing
Sr. Chainage of Depth Direction Measure (X Remarks
Feature (mA) (dB) loss (Y cord)
Survey Interval cord)

8.) RESPONSIBILTY:

➢ Project In- Charge

➢ Surveyor
➢ CP Technician/Supervisor

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POLARISATION COUPON INSTALLATION REVISION:01

&MEASUREMENT W.E.F.:15.05.2019

Sanmarg Projects Private Limited

POLARISATION COUPON INSTALLATION & MEASUREMENT

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Purpose: Standard operating procedure for polarization coupon

installation & measurement.
SCOPE:

This procedure covers the Installation & Measurement Technique of

Polarization Coupons in Cathodic Protection System.

SAFETY REQUIREMENTS:

a. Elementary safety practices are to be observed and use of PPEs

Hand Gloves & Helmet

1. Safety Shoes

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a.

Polarisation Coupon:
• A CP coupon is a small piece of Metal that is electrically connected to the
structure at a Test station. Polarisation Coupons of Pipeline material shall
be provided along the pipeline to monitor the adequacy of the CP System to
Polarize /Protect coating Holidays.

Coupon Design Considerations:

• The information obtained with the coupons depends on the geometry &
size of the coupon. As a consequence, attention should be paid to these
influencing Parameters. The fundamental concept of the coupon is the
mimicking of a coating defect in the pipeline. These coating Defects can
have various shapes & Sizes .Therefore the coupon Geometry should be
adapted to assume coating defects geometry present on the pipeline.
• Connecting Cable Details: 02 no’s cable connection Required.01 no for
connection to pipeline for protection .01no for potential measurement.
Coupon Preparation:

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• Coupon size of 100mm dia shall be cut from a coated pipe. The cut out
coupon shall be grinded on all its edge to strip the loose material. One side
of the coupon shall be coated with coating material and other side shall be
fully exposed.02 nos unarmored cable of Required Size shall be thermit
welded/Pin brazed and to be sealed with epoxy for encapsulation.
• (Coupon size & holiday Size may vary as per the clients Requirement)

Materials Required

Sr.No Material/Tool Application/Purpose

01 Pipe Material Coupon base material

02 Thermit Mould & Sparking Cable connection with

Gun /Pin Brazing Equipment Coupon
03 Cad Weld Powder, CA15 & Welding
CA32
04 Cables Connection to Coupon
(Cable will be terminated
in TLP)
05 Epoxy Dobefil-60 For sealing of Cable
joints in COUPON

06 Hardner-758
07 PVC Pipe/ Funnel
08 M seal / Mastic Sealing for PVC funnel
09 Cu Sleeves/Lugs For Cable Connections
10 Multimeter Coupon On/Off PSP
11 Portable Half cell measurement
12 Magnet (if Req)

Installation Procedure:

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• Polarisation coupon shall be installed at bottom 1/3 portion of the pipeline

and 250 mm away from the pipe surface.
• Reference cell shall be installed adjacent to the coupon facing the coupon
exposed surface.
• Bcos of the coupon should be located close to the pipeline to assure that
the soil conditions are similar in the coupon and in the nearby pipeline
coating defects.
• If the coupon fulfills the protection criteria under these conditions, it can be
concluded that all corresponding coating defects on the pipeline with
similar (or) smaller surfaces are protected as well.
Any voltage drop occurring in the electrolyte in the distance between the
Reference Electrode and the coupon surface will still be incorporated into

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measurements. So Placing the Permanent cell 100 mm distance from the facing
bare surface of the coupon can minimize this voltage drop Error.

Measurement Procedure:
Magnetic Read
Switch (P)

• One no magnetic Read Switch is available in between Coupon & Pipeline cables
in Test Station.
• As per the Fig.4, Consider the “P” as a Magnet Read switch.
• First Keep the Multi meter in “ DC mode” and check the ON PSP(-VDC) of
coupon (Red Probe= Coupon ,Black Probe= Reference cell )
• Record the “ON” PSP.
• Then touch the magnet above the Magnet Read Switch (P). And take the PSP
of coupon. It is called as Instant off Reading of Coupon. (Red Probe= Coupon,
Black Probe= Reference cell).
• In the Same Manner Coupon On/Off reading to be taken with Portable half-cell
to monitor the permanent Reference cell performance.
• Then in the same manner Coupon AC pickup values with Reference cell &
Portable half-cell to be checked & Recorded for AC study.

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• Some Magnetic Read Switch are like inbuilt along with the Magnet. In such
type of Magnetic Read Switch, Magnets are available in Read Switches. For OFF
readings, have to remove the magnet from the switch.
• Record this “OFF “PSP of the coupon.
• The ON/OFF PSP readings of coupon are to be in the limit of “ -0.850 V to -
1.500 V”

Possibilities of the Low /High PSP values above or below the limit of “-
0.850 V to -1.500 V”
• There are a number of problems with the off-potential method, although, it
continues to be the best method available and has proven to be a very useful
measurement when all current is interrupted. The problems include:
(a) current from multiple rectifiers must be interrupted simultaneously (or a
non-synchronous interruption method like the wave-form analyzer or step
wise reduction method must be used),
·(b) often, second party CP systems are present in the area that are either
unknown or cannot be interrupted and these systems can introduce IR-drop
errors in the off-potential measurement,
·(c)fixed sacrificial anodes are often included as hot spot protection for a
variety of reasons that can produce errors in the off-potential measurement,
·(d)long-line currents have been shown to produce errors that interruption
cannot eliminate,
· (e)stray current situations can cause significant errors in the off-potential
measurement,
·(f)rapid IR transients (spikes), immediately following interruption, can cause

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errors in the off- potential measurement,

·(g)simple averaging over some area of pipe, due to p/s measurements made
at grade, can cause local potential fluctuations to be under estimated, and

(f) multiple pipelines in the same right-of-way can produce averaging of the
multiple lines preventing an accurate measure of any given line.

Need a complete study /Analysis on the points shown above to minimize the
voltage drop/pick up error during Instant off PSP reading. .
Health, Safety & Environment
Hazard Identification and risk assessment will be carried out & shall be
adopted for Coupon installation Activities.
Necessary PPE to be utilized
Only trained personnel to be deployed for this activity.

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Procedure for Pipeline Coating REVISION:01

Refurbishment W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Pipeline Coating Refurbishment

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Procedure for Pipeline Coating REVISION:01

Refurbishment W.E.F.: 15.05.2019

1. PURPOSE:
To specify written Procedure for pipeline coating refurbishment.
2. SCOPE:
This scope covers the Procedure for pipeline coating refurbishment.

STANDARD REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

• Rubber Hand Gloves.

• Safety Shoes.
• Helmet.

3. REFERENCES:
OISD-STD-138, OISD-STD-130, OISD-129

4. PROCEDURE:
This procedure is applicable for pipeline coating refurbishment: -

1. Take the Hot permit & clearance from respective control room to start the job,
2. Excavate the pipeline & prepare the pit for carrying out refurbishment work.
3. Removal of the Existing Coating Material: The existing coating material shall be
removed from the pipeline surface properly and surface shall be cleaned. it shall be
ensured that while removing the coating pipe surface shall not be hit by any sharp
cutter.
4. Cleaning & Surface preparation of Pipeline:
The pipeline shall be cleaned by following methods:

a. Cleaning by water/Kerosene:
The pipeline surface shall be cleaned by water properly in order to remove all the
water dissolvable particles that include mud and dust. Use kerosene to
clean/dissolve the greasy material.
b. Drying:
The water-wet surface shall be dried using the cloth.
c. Cloth cleaning:
The pipeline surface shall be cleaned using the fresh cloth.
d. Wire brush Cleaning:

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The pipeline shall be cleaned by wire brush in order to remove the rust and all the
physically attached particles to the surface.
e. Emery Paper Cleaning:
The pipeline surface shall be cleaned using Emery paper in order to remove all the
coating particles.
f. Sand blasting 1 Shot blasting / Power Brushing:
In case the surface is found corroded with pitting or the pipeline surface is not
rough then shot blasting or power brushing to be carried out to obtain surface
roughness about SA 2& 1/2 grade.

5. PIPELINE COATING:
Ensuring Cleanliness of Pipeline:
Once it is ensured that the pipeline surface is free of the dust. The
following steps as mentioned shall be taken:

a. Primer application:
The primer shall be applied on the surface judiciously and left for drying
as per the specification.
b. Drying of Dense Primer:
The primer must be dried before application of either coating or filler on
the pipeline. The primer shall be properly hardened.
c. Application of Filler material on girth weld, L - seam and small pit area:
Filter material shall be applied on weld, L-seam, uneven surface as to
smoothen the surface.
d. Cold applied tape application:
The cold tape shall be wrapped over the pipeline with 66 %
overlapping using only the machine wrap. The hand wrap shall
be done only where machine wrap is not possible. Second
layer of cold tape to be wrapped on the pipeline with 50%
overlap for providing the mechanical strength.

6. Holiday Testing: Once the coating is applied on the pipeline Holiday Testing has to
be carried out at 15-20 KV based on the coating type.
5. RESPONSIBILTY:
Site In-charge to check and inspect for Pipeline Coating Refurbishment carried
out by Mechanical.
6. RECORD:
Logbook/ Register are to be maintained and record along with the parts
consumed during maintenance.

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REVISION:01
MONTHLY MAINTENANCE OF ACDB PANEL
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MONTHLY MAINTENANCE OF ACDB PANEL

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MONTHLY MAINTENANCE OF ACDB PANEL
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for monthly maintenance of ACDB panel to ensure its
optimum performance.

2. SCOPE:

This standard covers the guidelines on monthly maintenance of ACDB panel as per the
maintenance schedule.

Frequency of inspection & checking: Monthly as per schedule.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools are
required.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Isolate all power supply.
• Fix safety board on the panel.
• General cleaning.
• Check weather protection.
• Check external damage.
• Check control supply availability.
• Check corrosion effect (external).
• Check functioning of meters.
• Check functioning of lamps.
• Check trip circuit healthiness.
• Do cleaning of site.
• Normalize the system.
• Remove safety board fixed on the panel.
• Return the permit to control room.

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5. RESPONSIBILTY:

Site In-charge to check & inspect of maintenance of ACDB panel by electrical team.

6. REFERENCES:

• Maintenance / Inspection schedule.

• As built drawings of ACDB panel.

• Concerned register.

7. RECORDS:

Maintain records as per formats & log book / register is to be maintained and also
maintenance carried out with parts consumed is to be maintained.

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YEARLY MAINTENANCE OF ACDB PANEL
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

YEARLY MAINTENANCE OF ACDB PANEL

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REVISION:01
YEARLY MAINTENANCE OF ACDB PANEL
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for major maintenance of ACDB panel to ensure its optimum
performance.

2. SCOPE:

This standard covers the guidelines on major maintenance of ACDB panel as per the
maintenance schedule.

Frequency of inspection & checking: Monthly as per schedule.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools are
required.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Isolate all power supply.
• Provide safety tag on the panel.
• General cleaning.
• Check weather protection.
• Change the gasket if required.
• Check dust and verify proof ness.
• Seal all openings and holes in the panel.
• Check external damage.
• Check insulation resistance of cable.
• Check gland tightness and termination.
• Replace the lugs if found overheated.
• Check control supply availability.
• Check corrosion effect (external).
• Check functioning of meters.
• Repair / Replace if required.
• Check functioning of lamps.
• Check trip circuit healthiness.
• Do cleaning of site.
• Normalize the system.
• Remove safety tag from the panel.
• Return the permit to control room.

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5. RESPONSIBILTY:

Site In-charge to check & inspect the annual maintenance of ACDB panel by electrical team.

6. REFERENCES:

• Maintenance / Inspection schedule.

• As built drawings of ACDB panel.

• Concerned register.

7. RECORDS:

Maintain records as per formats & log book / register is to be maintained and also
maintenance carried out with parts consumed is to be maintained.

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Sanmarg Projects Private Limited

MAINTENANCE OF SWITCH GEAR

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1. PURPOSE:

To provide written maintenance procedure of switch gear. The main purpose of switch gear is
switching the operations in electrical circuits. They are used to de-energize equipment to allow
work to be done and, to clear faults downstream.

2. SCOPE:

This standard covers the guidelines on maintenance procedure of switch gear.

Frequency of inspection & checking: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

Electrical Drawing.

5. PROCEDURE:
• Obtain clearance from control room
• Isolate required section of the switchgear
• Fix tag on the panel to be isolated
• Rack out the circuit breakers
• Switch off control and ac supply
• Check contactor and relay panel for connection tightness
• Check all control relays and fuses
• Replace the relay or fuse, if required
• Check safety interlocks
• Check circuit breaker operation in manual mode
• Provide grease on moving joints of circuit breaker.
• Carry out major maintenance if required
• Check IR value of circuit breaker
• Check panel earthing.
• Close all the doors and panels
• Return the work permit to operation
• Normalize the system

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6. RESPONSIBILTY:

Site In charge, Electrical team & engineers responsible for maintenance of switch gear.

7. RECORD:

Log Book/ Register is to be maintained and also maintenance carried out with parts
consumed is maintained

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Sanmarg Projects Private Limited

Battery Bank Inspection & Maintenance Operation Procedure

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1. PURPOSE:

o Maintenance& inspection of battery bank.

o Maintenance and Upkeep of Battery Charger for 48 V / 250 AH L.A. BATTERY to ensure
optimum performance and life of Battery Charger (Dual Float cum Booster Charger) and
associated Battery Bank.
o Maintenance and Upkeep of Battery Charger for 48 V / 400 AH L.A. BATTERY to ensure
optimum performance and life of Battery Charger (Dual Float cum Booster Charger) and
associated Battery Bank.
o Maintenance and Upkeep of 18 V / 70 A, CELL BOOSTER to ensure optimum performance
and life of Cell Booster and associated Battery Bank.

2. SCOPE:

This section covers the maintenance activities of Battery, Float cum boost Chargers & Cell
Booster.
Frequency: Daily
Frequency: Weekly
Frequency: Monthly
Frequency: Yearly

3. SAFETY REQUIREMENTS:

Elementary safety practices are to be observed and use of PPEs

1. Safety Shoes & Helmets

2. Cautions Tags

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3. Use of proper insulating tools.

4. Before doing anything in battery bank room use proper safety glove, eye Washer, eye
glass and apron.

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Do’s & Don’ts With battery:

• Always use insulated tools while working and avoid metal objects rest on battery
terminals.
• Does not touch inter cell connectors or terminal of the battery without wearing gloves.
• Isolate the battery from charger/ Load while working on the battery to avoid sparks.
• Use only insulated tools for maintenance of battery to avoid any accidental shorting.
• Remove metal wristbands, chains, and loose coins from shirts/ pockets while working on
the battery to avoid any accidental shorting.
• Do not allow metal objects to rest on the battery or fall across the terminals.
• Do not expose the battery to open flame or sparks.
• Do not tamper with cell vent plug.
• Ensure that the connections are made as per the General arrangement enclosed.
• Do not attempt to move the installed batteries without removing inter cell/module
connector.
• Keep the battery clean and dry.
• In case of accidental contact with acid, wash the affected area with continuous flow of
water for 15 minutes and consult doctor immediately.

4. PROCEDURES:
a. Maintenance & inspection of battery bank
• Obtain the work permit from operating department
• Remove the cells from the battery stand and bring them to battery shop for attention.
• Clean the acid traces if any on outside surface of the cells after fittings the plug.

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• Follow special maintenance instruction for revival of cells/ batteries suffering from
undercharging due to frequent deep discharges, improper charging and not giving equalizing
charge as and when required.
• Test for capacity at 10 hr. discharge rate. If capacity of any cells / battery is observed to be
less than 80% of rated value, then subject them to revival exercise. Even after revival, if
capacity is observed to be less than 80% of the rated value, replace them.
• Clean all the vent plugs in warm DI water to remove the dust accumulated on vent plugs.
• Check the electrolyte level in all the battery banks it should be on maximum level (see
physically on battery glass container).
• Use distiller water to maintain the level in normal operation (ACID in special case).
• Check all battery connections to ensure they are clean and tight and apply proper Jelly to
avoid rust and voltage drop.
• Check Specific Gravity of the entire cell using hydrometer weekly it should be 1.200 + .0005.
If found specific gravity below level, add little electrolyte (ACID) in battery water carefully
and charge battery for 24 hours if still found below level. Replace the battery from battery
bank. (Don’t add water in ACID).
• Check the Voltage of all the battery banks by the digital multimeter from first battery
terminal to last battery terminal (Check Positive and Negative terminal of first & last
battery), it should be above 48V in fully charged.
• Check voltage of all the battery individually it should be 2.2V in fully charged. If any cell is
below the 1.85V that cell should be charged by removing from the battery bank with Cell
Booster.
• Before connecting and disconnecting battery from the battery bank charger should be OFF
then remove the battery carefully.
• Equalize batteries to fully charge (on requirement) the battery for increasing performance.
• Ventilation in battery bank room should be proper to avoid casualty.
• Keep Clean the dust and dirt at vent plug cover, terminals and surrounding area with clean
and dry cotton/ cloth.
b. Maintenance& inspection of Float Cum booster Charger

The Battery Charging Equipment comprising of Dual Float cum Booster Charger Housed in a
common cubicle. It Consists of AC I/P terminal for Battery and Load. Control Switches,
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potentiometers, analogue meters Indicating Lamps and Annunciation are provided on front
panel of battery charger. Operational details for Battery Charger (2x100% Float cum Booster
charger with 2x100% battery banks and 1x100% load).

Normally, both float cum booster chargers will operate in float mode & will trickle charge
the batteries at 2.16 V per cell with a stabilisation of +/-1% of the floating voltage. The
Charger will supply the trickle charging current required for the batteries as well as feed the
DC continuous load as required. During this time, the charger and the battery are across the
DC load terminals.

Both the chargers will be sharing load almost equally in float mode. The battery current will
be limited to Battery charging current through SMPS circuit (14% of Battery AH).

A) Routine Maintenance of Battery charger

1. Cleaning of Panel from inside & outside by using blower; - weekly

2. Healthiness of indicating lamps; - weekly
3. Tightness & healthiness of Fuse links; - quarterly
4. Electrical performance, tightness of all connections, noise observation & complete
cleaning of equipment: Half yearly
5. Calibration of meters: yearly

B) In addition to above Log Book is to be maintained for recording Meter

Readings & working status of Charger shown by indicating lamps.
C) Any fault occurring and rectification carried out/maintenance carried out to be
recorded in log book.
D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control cards
etc. At least one set each.

c. Maintenance & inspection of Cell booster

• Monthly inspection and cleaning of the equipment will ensure trouble free operation of
the unit.
• In case of no output, check the fuse and replace, if necessary
• If fault is persistent, it can be traced by step-by-step by referring the circuit diagram.
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• In case of reduced output, disconnect and check the diodes individually and replace, if
necessary.
• Ensure that AC input switch is at “OFF” position and variac knob is at zero (0) position. If the
variac is not at minimum position, then turn it at its minimum position so as to pick up the
main contactor (C1).
• Switch “ON” the AC input switch, contactor will get energized. Turn the variac knob
clockwise direction gradually. Maintain the required DC output voltage on voltmeter
DCVM2.
• Turn the variac knob to zero position, switch OFF SW1.
• Connect the water load/ resistive load.
• Switch “ON” the DC output switch & AC input switch. Turn the variac gradually in clockwise
direction to maintain the required DC output voltage at required current.
• Turn the variac at zero position, switch OFF SW1, SW2.
• Complete the initial charging of battery cells as per the instruction given in battery manual.
• While in operation the output current is controlled through variac.
• Return permit to control room.

5. TROUBLE SHOOTING

Special attention and precautions to be observed /taken

While doing maintenance/trouble shooting.
I. Always use HRC fuses of proper rating: use of wire fuses will cease the Guarantee of vendor.
II. While changing the mode i.e. auto Mode to Manual Mode of Controller or vice versa.
Switch off the charger and then change the position of Auto/Manual switch.
III. After meeting an emergency by battery, charge the battery by charger in Boost mode for
the period depending upon the duration of emergency the battery has met. After boost
charging is over, allow the battery across charger in float mode for trickle charging.
IV. Always check the ground (earth) connection before switching ON the Power supply.
V. In case the input fuse blows due to some fault, switch off the power supply before replacing
the input fuse.
VI. The input fuse shall be of same rating and type as previous.

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VII. If U/O LED of module glow, then check the input supply and make sure that supply should
be within range of 180-270V AC.
VIII. If O/L/ LED of module glow, then check the current setting and load current.
IX. High Voltage caution: - Precaution should be taken while handling the SMPS to avoid any
safety hazard.

6. REFERENCES:

1. Manufacturer’s (Chhabhi Electricals Private Limited) Operation & Maintenance Manual

of Float Cum Booster Charger.

2. Installation & Operation Manual of Float Cum Booster Charger.of Chhabi Electricals Pvt.
Ltd.

3. Installation & Operation Manual of Low Maintenance Lead Acid Batteries for NDP, HDP
& SPV Applications of HBL Power Systems Ltd.
4. As-built drawing(s)

7. NECESSARY REQUIREMENTS

Instrument used for testing shall be duly calibrated and shall have the accuracy and least
count specified below:

Instrument Accuracy Least Count

Digital Voltmeter/ Multimeter +/- 0.5% 1mV
Digital Ammeter/ Clamp meter +/- 1.0% 0.1 A
Temperature Indicator/ +/- 1 deg. C 1 deg. C
Thermometer
Hydrometer +/- 0.01 points 0.01

Specific gravity correction Factor:

For every 10 deg. C above 27 deg. C add the value recorded in the hydrometer. For every 10
deg. C below 27 deg. C, 0.007 should be subtracted from the reading i.e 0.0007/ deg. C.

Example:

Temperature Hydrometer Correction Factor Corrected specific

Reading gravity

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37 deg. C 1.25 +0.007 1.2576

25 deg. C 1.25 -0.0014 1.2486
16 deg. C 1.25 -0.0077 1.2423

Acid Mixing Procedure:

Acid Mixing Chart

When Mixing by
volume (Liter) using When mixing by Volume (Liter)
1.800 Acid using 1.400 Acid Desired specific gravity at
Distilled water 27 deg. C
required to one-part Distilled water required to one-
acid part acid
2.80 0.45 1.280
2.90 0.53 1.270
3.00 0.60 1.260
3.09 0.64 1.255
3.17 0.67 1.250
3.35 0.75 1.240
3.55 0.82 1.230
3.68 0.86 1.224
3.80 0.90 1.220
4.30 1.10 1.200
5.00 1.41 1.180

Note: Battery grade sulphuric acid is usually available in 1.800 or 1.400 Sp. Gr.
Concentration. To change the sp. Gr. To another value, it is necessary to mix it slowly with
distilled water, to obtain the desired sp. Gr.

8. RESPONSIBILTY:

Shift In-charge, Electrical team & Company engineers responsible for the inspection &
maintenance of Electrical Panel at IPS & SV Stations.

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9. DEFINITION:

Main Objective behind Inspection & maintenance is to ensure that we should

Be provided Un-interrupted power supply to the system.

10. RECORDS:

Batteries

400 AH BANK-1 400 AH BANK-2 250 AH BANK-1 250 AH BANK-2

Cell. Sp. DC Cell. Sp. DC Cell. Sp. DC Cell. Sp. DC
No. Gr. Volts Gr. Volts Gr. Volts Gr. Volts
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20
21 21 21 21

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22 22 22 22
23 23 23 23
24 24 24 24

Total Battery DC voltage in charger off condition Volts

Remarks: Distilled water added/ not added
Note: Charger switched ON: Yes/No

CELL BOOSTER

1. UPS-1, UPS-2 AND AVS PHYSICAL APPEARANCE OK/NOT OK

2. UPS-1, UPS-2 AND AVS INPUT/OUTPUT VOLTAGE OK/NOT OK

INPUT OUTPUT

UPS 1 : VOLTAGE UPS 1: VOLTAGE

UPS 2: VOLTAGE UPS 2: VOLTAGE
AVS: VOLTAGE AVS: VOLTAGE

3. IN THE EVENT OF INPUT MAINS FAILURE OK/NOT OK

(UPS1 & UPS2 WILL WORK ON BATTERY)

4. INVERTER FAIL TRANSFER TEST OK/NO OK

a) IN THE EVENT OF UPS1 FAILS, SYSTEM OUTPUT SHOULD TRANSFER TO UPS-2

b) IN THE EVENT OF UPS-2 FAILS, SYSTEM SHOULD TRANSFER TO AVS.

5. MANUAL BYPASS TRNSFER OK/NOT OK

a) UPS-1 OUTPUT SHOULD TRANSFER TO UPS-2

b) UPS-1 OUTPUT SHOULD TRANSFER TO AVS

6. UPS 1 & UPS 2 ON AVAILABLE LOAD OK/NOT OK

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7. AVS ON AVAILABLE LOAD OK/NOT OK

On load:

1. Total Battery voltage : vdc

2. DC input voltage : vdc
3. AC output voltage : vac
4. Frequency output : Hz
5. Charger output voltage :

Checking discharge cycle: Battery load Test on Actual Load condition:

a) Time (in hours) of UPS battery put on load _________________

b) Total Battery voltage & master cell gravity after 2 hours _______________
c) Average battery current drawn by actual load __________________

Miscellaneous:

1. Physical checking of each battery : Yes/No

(overheating/bulging)
2. Temperature on the surface of UPS is abnormally high : Yes/No
3. Connecting wires and terminals are heated : Yes/No
4. Cooling fan in running condition : Yes/No
5. Abnormal sound heard : Yes/No
6. Cleaning/dusting done : Yes/No
7. Indication lamps/Warning lamps : OK/Not OK

Maintain Records as per formats prescribed by M/s HMPL.

Log Book/ Register is to be maintained in monthly maintenance record and note down the
battery voltage and specific gravity which will be charged by this cell booster.

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MAINTENANCE OF LEAD ACID BATTERIES

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1. PURPOSE:

To provide written maintenance procedure of Lead Acid Batteries to ensures its optimum
performance.

2. SCOPE:

This standard covers the annual maintenance guidelines on Lead Acid Batteries.
Frequency of inspection & checking: Annually as per schedule.

3. SAFETY REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD guidelines

1. Does not touch inter cell connectors or terminal of the battery without wearing gloves.
2. Isolate the battery from charger/ Load while working on the battery to avoid sparks.
3. Use only insulated tools for maintenance of battery to avoid any accidental shorting.
4. Remove metal wristbands, chains, and loose coins from shirts/ pockets while working on
the battery to avoid any accidental shorting.
5. Do not allow metal objects to rest on the battery or fall across the terminals.
6. Do not expose the battery to open flame or sparks.
7. Do not tamper with cell vent plug.
8. Ensure that the connections are made as per the General arrangement enclosed.
9. Do not attempt to move the installed batteries without removing inter cell/module
connector.
10. Keep the battery clean and dry.

In case of accidental contact with acid, wash the affected area with continuous flow of
water for 15 minutes and consult doctor immediately.

Use of PPEs:
1. Rubber Hand Gloves.
2. Safety Shoes.
3. Helmet.
4. Use of proper Insulating tools.

4. PROCEDURES:

• Obtain Work permit from operating Department.

• Remove the cells from the battery stand and bring them to battery shop for attention.
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• Clean the acid traces if any on outside surface of the cells after fittings the plug.
• Follow special maintenance instruction for revival of cells/ batteries suffering from
undercharging due to frequent deep discharges, improper charging and not giving
equalizing charge as and when required.
• Test for capacity at 10 hr. discharge rate. If capacity of any cells / battery is observed
to be less than 80% of rated value, then subject them to revival exercise. Even after
revival, if capacity is observed to be less than 80% of the rated value, replace them.
• Clean all the vent plugs in warm DI water to remove the dust accumulated on vent.
• Return permit to control room.

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect of maintenance of Lead Acid Batteries
at all SV and IPS.

6. REFERENCES:

1. Manufacturer’s (Chhabi Electricals Private Limited) Operation & Maintenance Manual.

2. Installation & Operation Manual of Low Maintenance Lead Acid Batteries for NDP, HDP
& SPV Applications of HBL Power Systems Ltd.

7. RECORDS:

Maintain records & Log Book/ Register Maintain Log Book/ register to record annual
performance of the battery banks.

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Sanmarg Projects Private Limited

MOTOR OPERATING VALVE (ACTUATOR)

Maintenance Procedure

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1. PURPOSE:

To provide written procedure for MOV actuator.

2. SCOPE:

This standard covers the maintenance guidelines of MOV Actuator system.

Frequency of inspection & Checking: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

Rotork controls installation and maintenance instructions.

5. PROCEDURE:

➢ Obtain the work permit from operating department.

➢ All electrical power supplies to the actuator must be isolated before any maintenance or
inspection is carried out, except replacement of battery.
➢ Electrical supplies must be isolated before actuator covers are removed refer to battery
replacement instruction.
➢ Check actuator to valve fixing bolts for tightness.
➢ Ensure valve stems and drive nits are clean and properly lubricated.
➢ If the motorized valve is rarely operated, a routine inspection schedule should be set up.
➢ Replace actuator battery every 5 years.

Note: Removal of the battery with the main electrical power switches off will result in stored
data logger records time reference being lost for duration when there is no mains and
battery power. It is therefore recommended that the battery is replaced with the main
electrical supply to the actuator switch on.
➢ Check the actuator enclosure for damage, lose or missing fasteners.
➢ Ensure there is not an excessive buildup of dust or contaminant on the actuator.
➢ Check for any loss of lubricant.
➢ Return permit to control room.

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6. RESPONSIBILTY:
Shift In-charge and Mechanical team responsible for the inspection &
Maintenance of MOV at SV & IPS Stations.

7. RECORDS:

Maintain Logbook/ register to record the time, pressure and temperature of before valve
opening and after valve opening.

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Sanmarg Projects Private Limited

MOTOR OPERATING VALVE (ACTUATOR)

Operation Procedure

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1. PURPOSE:

The main purpose of MOV is to control flow or pressure rate regulations in all SV/IPS.

2. SCOPE:

This section covers the operation of actuator Systems at SV and IPS locations.

Frequency: Weekly/ monthly

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

1. Rubber Hand Gloves.

2. Safety Shoes.
3. Helmet.
4. While operating no person should get in contact with the probe and job.

4. REFERENCES:

Rotork controls installation and maintenance instructions.

5. PROCEDURE:

(A) Obtain the work permit from operating department.

(B) OPERATING ACTUATOR BY HAND:

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• Keep clear of the hand wheel when engaging hand operation.

• Actuators driving valves via extension shafts may be subject to retained shaft torsion
which can cause the hand wheel to rotate when hand operation is engaged.
• To engage hand wheel drive, depress the Hand / Auto lever into “Hand” position and
turn the hand wheel to engage the clutch.
• The lever can now be released where it will return to its original position.
• The hand wheel will remain engaged until the actuator is operated electrically when it
will automatically disengage and return to motor drive.
• If required, the Hand / Auto lever can be locked in either position using a pad lock with
6.5mm hasp.

(C) OPERATING ACTUATOR ELECTRICALLY:

• Check that power supply voltage agrees with that on the actuator name plate. Switch
on power supply. It is not necessary to check phase rotation.
• Do not operate the actuator electrically without first checking; using the infrared Setting
Tool, that at least the Basic Settings have been made.

SELECTING LOCAL / STOP / REMOTE OPERATION

• The red selector enables either Local or Remote control, lockable in each position using
a pad lock with a 6.5mm hasp.
• When the selector is locked in the Local or Remote positions the stop facility is still
available. The selector can also be locked in the Stop position to prevent electrical
operation by Local or Remote control.

LOCAL CONTROL

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With the red selector positioned at Local (anti - clockwise) the adjacent black knob can be
turned to select open or close. For stop, turn red knob clockwise.

REMOTE CONTROL

Rotate the red selector to the Remote position (clock wise), this allows remote control
signals to operate the actuator. Local Stop can still be used by turning the red knob anti
clock wise.

(D) Return permit to control room.

6. RESPONSIBILTY:
Shift In-charge, Mechanical team & engineers responsible for the operation of MOV at SV &
IP Stations.

7. RECORDS:
Maintain records as per formats given by M/s HMPL. Maintain Logbooks/ register to record
the activities which are carried out.

Before Valve Opening After Valve Opening

TT-A PT-A TT-B PT-B TT-A PT-A TT-B PT-B

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Sanmarg Projects Private Limited

MAINTENANCE OF LEAD ACID BATTERIES

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1. PURPOSE:

To provide written maintenance procedure of Lead Acid Batteries to ensures its

optimum performance.

2. SCOPE:

This standard covers the Half- Yearly maintenance guidelines on Lead Acid Batteries.
Frequency of inspection & checking: Half- Yearly as per schedule.

3. SAFETY REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD guidelines

1. Does not touch inter cell connectors or terminal of the battery without wearing
gloves.
2. Isolate the battery from charger/ Load while working on the battery to avoid sparks.
3. Use only insulated tools for maintenance of battery to avoid any accidental shorting.
4. Remove metal wristbands, chains, and loose coins from shirts/ pockets while
working on the battery to avoid any accidental shorting.
5. Do not allow metal objects to rest on the battery or fall across the terminals.
6. Do not expose the battery to open flame or sparks.
7. Do not tamper with cell vent plug.
8. Ensure that the connections are made as per the General arrangement enclosed.
9. Do not attempt to move the installed batteries without removing inter cell/module
connector.
10. Keep the battery clean and dry.

In case of accidental contact with acid, wash the affected area with continuous flow of
water for 15 minutes and consult doctor immediately.

Use of PPEs:
1. Rubber Hand Gloves.
2. Safety Shoes.
3. Helmet.
4. Use of proper Insulating tools.

4. PROCEDURES:
• Obtain the work permit from operating department.
• Verify the monthly inspection report.

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REVISION:01
HALF- YEARLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

• Check the level of electrolyte of each cell in the system, if any call showing the float level
above RED MARK or less, top up with distilled water up to green mark. Record the
quantity of water topped up to each cell.
• Check the condition of vent plug. Replace if it is broken.
• Check for the proper functioning and accuracy of measuring instrument. Replace with
calibrated instruments if not satisfactory.
• Give equalizing charge.
• Return permit to control room.
Note: For adjusting the electrolyte levels, distilled water shall only be added to the cells/
batteries but not the normal water/ packaged drinking water.

5. RESPONSIBILTY:

Site In-charge, Electrical team & Company engineers to check & inspect of
Maintenance of Lead Acid Batteries at all SV and IPS.

6. REFERENCES:

1. Manufacturer’s (Chhabi Electricals Private Limited) Operation & Maintenance

Manual.
2. Installation & Operation Manual of Low Maintenance Lead Acid Batteries for
NDP, HDP & SPV Applications of HBL Power Systems Ltd.

7. RECORDS:

• Maintain records of all parameters monitored at various intervals using the service
record formats.
• Maintain Log Book to record performance of the battery banks.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/62

REVISION:01
IPS POWER TRANSFORMER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

IPS POWER TRANSFORMER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/62

REVISION:01
IPS POWER TRANSFORMER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for Quarterly maintenance of IPS transformer.

2. SCOPE:

This standard covers the entire maintenance activities of transformer which includes
checking of all the.
Frequency of inspection & checking: Quarterly as per schedule.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, eye goggle and use of proper insulating
tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Wiring diagram of controller system of transformer.

5. PROCEDURE:

• Obtain clearance from Control room

• Switch off the Transformer
• Rack out Input/output Circuit Breaker(CB)
• Lock the Breakers in isolated position
• Switch Off Control & OLTC Supply
• Discharge the TR using Earthing Trolley
• Open the Primary & Secondary Terminal Box Cover
• Check tightness of Busbar connection
• Check the sealing/ condition of Bus duct
• Check the Bushing for defect
• Check Oil leakage
• If required, take corrective action
• Take Oil sample bottom Main Tank
• Take sample bottom of OLTC Tank
• Test the Oil Sample for BDV
• Clean the radiator cooling fins
• Check IR Value between PRI/SEC/Earth
• Check PI Value for TR Winding
• Check IR Value of OLTC Winding
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 STANDARD OPERATING PROCEDURE
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REVISION:01
IPS POWER TRANSFORMER
W.E.F.: 15.05.2019

• Check OLTC LC/Remote Panel

• Check Oil Level in the Conservator Tank
• If required, Add tested Oil in C-Tank
• Check B'HOLZ Relay for Trap Gases
• If require, Release the gases
• Check intactness of safety Diaphragm
• Check Earthing of TR and its Neutral
• Check Silica Gel Condition in Breather
• If required, Replace the Silica Gel
• Check the Oil in Oil Cup of Breather
• If Required, fill the Oil Cup
• Check all Prot-Relay for Flag Operation
• Fix Terminal Box Cover on Primary side
• Fix Terminal Box Cover on Sec. side
• Check all Drain/Vent point and fix Plug
• Remove earthing Trolley
• Then Close Panel Doors and Covers
• Give clearance to C/R, return the permit
• Switch-on Control Supply
• Switch-on Power Supply
• Check for normal operation
• Clearance to C/R for taking TR in Line

6. RESPONSIBILTY:

Site In-charge, Electrical team and Mechanical team are responsible for the maintenance
of IPS Power Transformer at IPS Stations.

7. RECORD:

Logbook/ Register to be maintained for quarterly maintenance record and also

maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/63

MAINTENANCE OF POWER TRANSFORMER REVISION:01

W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF POWER TRANSFORMER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/63

MAINTENANCE OF POWER TRANSFORMER REVISION:01

W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for yearly maintenance of IPS Power transformer.

2. SCOPE:
This standard covers the entire maintenance activities of IPS transformer which includes
checking of all the parameters.
Frequency of inspection & checking: Yearly.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, eye goggles and use of proper
insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Wiring diagram of controller system of transformer.

5. PROCEDURE:

• Obtain clearance from Control room

• Switch off the Transformer
• Rack out Input/output Circuit Breaker(CB)
• Lock the Breakers in isolated position
• Switch Off Control & OLTC Supply
• Discharge the TR using Earthing Trolley
• Open the Primary & Secondary Terminal Box Cover
• Check tightness of Bus bar connection
• Check the sealing/ condition of Bus duct
• Check the Bushing for defect
• Replace the bushing if required
• If required, tighten the bolts
• If required, replace gasket
• Check Oil leakage
• Take Oil sample bottom Main Tank
• Take sample bottom of OLTC Tank
• Test the Oil Sample for BDV
• If required filter/ replace the oil
• Check Voltage Ratio of Trans. winding
• Check IR Value of Transformer winding
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MAINTENANCE OF POWER TRANSFORMER REVISION:01

W.E.F.: 15.05.2019

• Check PI Value for Transformer Winding

• Heat Transf. Winding at low volt.
• If required send the transformer for rewinding
• Check IR Value of OLTC Winding
• Check OLTC LC/Remote Panel
• Check Oil Level in the Conservator Tank
• If required, Add tested Oil in C-Tank
• Check B'HOLZ Relay for Trap Gases
• If require, Release the gases
• Check intactness of safety Diaphragm
• Check Earthing of TR and its Neutral
• Check Silica Gel Condition in Breather
• If required, Replace the Silica Gel
• Check the Oil in Oil Cup of Breather
• If Required, fill the Oil Cup
• Check all Prot-Relay for Flag Operation
• Fix Terminal Box Cover on Primary side
• Fix Terminal Box Cover on Sec. side
• Check all Drain/Vent point and fix Plug
• Remove Earthing Trolley
• Then Close Panel Doors and Covers
• Give clearance to C/R, return the permit
• Switch-on Control Supply
• Switch-on Power Supply
• Check for normal operation
• Clearance to C/R for taking TR in Line

6. RESPONSIBILTY:

Site In-charge, Electrical and Mechanical team are responsible for the maintenance of
Power Transformer at IPS Stations.

7. RECORD:

Log Book/ Register is to be maintained for the major maintenance along with the parts
consumed.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/64

REVISION:01
MONTHLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF LEAD ACID BATTERIES

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/64

REVISION:01
MONTHLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

1. PURPOSE:
To provide written maintenance procedure of Lead Acid Batteries to ensures its
optimum performance.

2. SCOPE:
This standard covers the monthly maintenance guidelines on Lead Acid Batteries
Frequency of inspection & checking: Monthly as per schedule.
3. SAFETY REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD guidelines
1. Obtain the work permit from operating department.
2. Does not touch inter cell connectors or terminal of the battery without wearing gloves.
3. Do not attempt to move the installed batteries without removing inter cell/module
connector.
4. Keep the battery clean and dry.
5. Return permit to control room.
In case of accidental contact with acid, wash the affected area with continuous flow of
water for 15 minutes and consult doctor immediately.

Use of PPEs:
1. Rubber Hand Gloves.
2. Safety Shoes.
3. Helmet.
4. Use of proper Insulating tools.

4. PROCEDURES:
• Check the voltage and current setting on charger, correct if any deviations are observed.
• Check for any dust accumulation on cell cover, vent plug if observed, clean it thoroughly.
• Check for any broken container or cover. Remove and replace with good one, as it will
damage the battery stand.

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect of maintenance of Lead Acid
Batteries at all SV and IPS.

6. RECORDS:

Maintain Log Book/ register to record monthly performance of the battery banks.

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STANDARD OPERATING PROCEDURE
SPPL/SOP/65

REVISION:01
WEEKLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF LEAD ACID BATTERIES

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/65

REVISION:01
WEEKLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

1. PURPOSE:

To provide written maintenance procedure of Lead Acid Batteries to ensures its

optimum performance.

2. SCOPE:

This standard covers the Weekly maintenance guidelines on Lead Acid Batteries.
Frequency of inspection & checking: Weekly as per schedule.

3. SAFETY REQUIREMENTS:
Ensure all the safety requirements for doing the job safety are met a per OISD guidelines

1. Does not touch inter cell connectors or terminal of the battery without wearing gloves.
2. Isolate the battery from charger/ Load while working on the battery to avoid sparks.
3. Use only insulated tools for maintenance of battery to avoid any accidental shorting.
4. Remove metal wristbands, chains, and loose coins from shirts/ pockets while working on
the battery to avoid any accidental shorting.
5. Do not allow metal objects to rest on the battery or fall across the terminals.
6. Do not expose the battery to open flame or sparks.
7. Do not tamper with cell vent plug.
8. Ensure that the connections are made as per the General arrangement enclosed.
9. Do not attempt to move the installed batteries without removing inter cell/module
connector.
10. Keep the battery clean and dry.

In case of accidental contact with acid, wash the affected area with continuous flow of
water for 15 minutes and consult doctor immediately.

Use of PPEs:
1. Rubber Hand Gloves.
2. Safety Shoes.
3. Helmet.
4. Use of proper Insulating tools.

4. PROCEDURES:

• Obtain the work permit from operating department.

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REVISION:01
WEEKLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

• Before doing anything in battery bank room use proper safety glove, eye glass and
apron.
• Always use insulated tools while working and avoid metal objects rest on battery
terminals.
• Check the electrolyte level in all the battery banks it should be on maximum level (see
physically on battery glass container).
• Use distiller water to maintain the level in normal operation (ACID in special case).
• Check all battery connections to ensure they are clean and tight and apply proper Jelly
to avoid rust and voltage drop.
• Check Specific Gravity of the entire cell using hydrometer weekly it should be 1.200 +
.0005. If found specific gravity below level, add little electrolyte (ACID) in battery water
carefully and charge battery for 24 hours if still found below level. Replace the battery
from battery bank. (Don’t add water in ACID).
• Check the Voltage of all the battery banks by the digital multimeter from first battery
terminal to last battery terminal (Check Positive and Negative terminal of first & last
battery), it should be above 48V in fully charged.
• Check voltage of all the battery individually it should be 2.2V in fully charged. If any cell
is below the 1.85V that cell should be charged by removing from the battery bank with
Cell Booster.
• Before connecting and disconnecting battery from the battery bank charger should be
OFF then remove the battery carefully.
• Equalize batteries to fully charge (on requirement) the battery for increasing
performance.
• Ventilation in battery bank room should be proper to avoid casualty.
• Keep Clean the dust and dirt at vent plug cover, terminals and surrounding area with
clean and dry cotton/ cloth.
• Maintain Log Book to record performance of the battery banks.
• Return permit to control room.

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect of maintenance of Lead Acid
Batteries at all SV and IPS.

6. REFERENCES:

1. Manufacturer’s (Chhabi Electricals Private Limited) Operation & Maintenance Manual.

2. Installation & Operation Manual of Low Maintenance Lead Acid Batteries for NDP, HDP
& SPV Applications of HBL Power Systems Ltd.

7. RECORDS:

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REVISION:01
WEEKLY MAINTENANCE OF LEAD ACID
BATTERIES W.E.F.: 15.05.2019

• Maintain records of all parameters (float voltages, on load voltages, electrolyte S.G, etc.)
monitored at various intervals using the service record formats.
• Maintain Log Book to record performance of the battery banks.
Batteries

400 AH BANK-1 400 AH BANK-2 250 AH BANK-1 250 AH BANK-2

Cell. Sp. DC Cell. Sp. DC Cell. Sp. DC Cell. Sp. DC
No. Gr. Volts Gr. Volts Gr. Volts Gr. Volts
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
8 8 8 8
9 9 9 9
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20
21 21 21 21
22 22 22 22
23 23 23 23
24 24 24 24

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/66

REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

DIESEL GENERATOR MAINTENENCE

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/66

REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

1. PURPOSE:

To specify general maintenance instructions for a DG set to ensures its

Proper functioning in case of failure of State Electricity Board Supply.

2. SCOPE:

This standard covers the guidelines on weekly maintenance of D.G. sets.

Frequency: 300 Hrs.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Check oil level
• Change lubrication oil.
• Change lube oil filter.
• Check coolant level, if required fill premix coolant.
• Check belt condition.
• Check fan hub and fan drive arrangement.
• Check fuel strainer
• Check breather on fuel tank.
• Drain sediments from fuel water separator.
• Clean air filter in reverse direction, using dry air with max 0.5Kg/sqcm pressure.
• Check leaks & rectify if required
• Check battery condition.
• Clean battery leads
• Secure all connectors in engine electrical system.
• Run the engine and record the observations
• Return permit to control room.

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REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

5. RESPONSIBILTY:

Site In-charge & Mechanical team to ensure the proper maintenance of Diesel Generator
at all SV and IPS.

6. REFERENCES:

Manufacturer’s Operation & Maintenance Manual of DG.

7. RECORDS:

Maintain Log Book and note down the Working Hours and Status of Diesel
Engine set and maintained the register with parts consumed during
Maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/67

REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

DIESEL GENERATOR MAINTENENCE

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/67

REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

1. PURPOSE:

To specify general maintenance instructions for a DG set to ensures its

Proper functioning in case of failure of State Electricity Board Supply.

2. SCOPE:

This section covers the guidelines on maintenance of D.G.

Frequency: 600 Hrs.

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:
• Obtain the work permit from operating department.
• Check oil level
• Change lubrication oil.
• Change lube oil filter.
• Check breather.
• Check coolant condition.
• Check recovery bottle and seal.
• Check connections and sealing of radiator.
• Clean radiator, externally.
• Check coolant level, if required fill premix coolant.
• Check belt condition.
• Check fan hub and fan drive arrangement.
• Check fuel strainer
• Check breather on fuel tank.
• Drain sediments from fuel water separator.
• Check all joints in fuel lines & tighten.
• Clean air filter in reverse direction, using dry air with max 0.5Kg/sqcm pressure.
• Check leaks & rectify if required.
• Check battery condition.
• Clean battery leads
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REVISION:01
MAINTENANCE OF DIESEL GENERATOR
W.E.F.: 15.05.2019

• Secure all connectors in engine electrical system.

• Run the engine and record the observations.
• Return permit to control room.

5. RESPONSIBILTY:

Site In-charge & Mechanical team to ensure the proper maintenance of Diesel Generator
at all SV and IPS.

6. REFERENCES:

Manufacturer’s Operation & Maintenance Manual of DG.

7. RECORDS:

Log Book/ Register are to be maintained for Quarterly inspection

Record along with the parts consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/68

REVISION:01
WEEKLY MAINTENANCE OF DIESEL
GENERATOR W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

DIESEL GENERATOR MAINTENENCE

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/68

REVISION:01
WEEKLY MAINTENANCE OF DIESEL
GENERATOR W.E.F.: 15.05.2019

1. PURPOSE:

To provide written maintenance procedure for diesel generator to ensures its

Optimum performance in case of failure of electricity.

.
2. SCOPE:

This standard covers the guidelines on Weekly maintenance of D.G.

Frequency: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating
tools.

Ensure all the safety requirements for doing the job safely are met a per OISD
guidelines.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Check Battery Voltage of the D.G Set, it should be 10 to 12 volts

• Check Suction air filter.

• Check Lube oil by Gauge Stick it should be on maximum level.

• Check Water Level in Radiator, V-Belt and Coolant level, it should be on

maximum level.

• Check Diesel level in Diesel Tank & check shut off valve, it should be open.

• Check physically the status of any leakage and Loose connections.

• Check the Selector switch it should be in Local mode before start.

• After checking all the checklist then start the D.G set by using Key from the D.G
Control Panel.
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REVISION:01
WEEKLY MAINTENANCE OF DIESEL
GENERATOR W.E.F.: 15.05.2019

• After starting the Diesel Engine set check noise and vibration if coming and stops
D.G set, Resolve Problem if possible then start the D.G set.

• After started the D.G set check the speed on control panel (LCD) it should be
1500 rpm.

• Check Output Current and Voltage of Alternator on Control Panel.

• Check Frequency on Control panel, it should be 49.5 to 50.5 Hz.

• Stop the D.G set by using key.

• Return permit to control room.

.

5. RESPONSIBILTY:

Site In-charge and Electrical team/Mechanical team to ensure the proper

maintenance of Diesel Generator at all SV and IPS.

6. REFERENCES:

Manufacturer’s Operation & Maintenance Manual of DG.

7. RECORDS:

Maintain Logbook and note down the Working Hours and Status of Diesel
Engine set.

DG Set
**Keep tracking the D.G log, for diesel consumption and service checks.
**Don’t forget to drain the bottom sediments weekly, from the diesel tank and refill
after sedimentation.

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 STANDARD OPERATING PROCEDURE
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REVISION:01
WEEKLY MAINTENANCE OF DIESEL
GENERATOR W.E.F.: 15.05.2019

1) Diesel Level
2) Lube Oil Level
3) Battery Voltage DC Volts
4) Battery Sp. Gravity
5) Last Maintenance. at ___ hrs, Type
6) Trial Run
7) Auto Operation
8) Any leakage
9) Hour Meter Reading Hrs.
10) Next due on _____, Type _____

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/69

REVISION:01
MAINTENANCE OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF 48V/70A BATTERY CHARGER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/69

REVISION:01
MAINTENANCE OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for maintenance and Upkeep of Battery Charger for 48 V /
400 AH L.A. BATTERY to ensure optimum performance and life of Battery Charger (Dual
Float cum Booster Charger) and associated Battery Bank.

2. SCOPE:

This standard covers the guidelines on Weekly checks as per checklist and Maintenance
of Battery Charger (Dual Float cum Booster Charger) for 48 V / 400 AH L.A. Battery.

Frequency of maintenance: Weekly, Quarterly, half- Yearly, Yearly.

3. SAFETY REQUIREMENTS:

Safety shoes, Safety helmet, insulating mat and use of proper insulating tools.

4. PROCEDURES:

Description: -The Battery Charging Equipment comprising of Dual Float cum Booster
Charger Housed in a common cubicle. It Consists of AC I/P terminal, DC O/P terminal for
Battery and Load. Control Switches, potentiometers, analogue meters, Indicating Lamps
and Annunciation are provided on front panel of battery charger.

A) Obtain the work permit from operating department.

B) Routine Maintenance of Battery charger

• Cleaning of Panel from inside & outside by using blower: - weekly

• Healthiness of indicating lamps: - weekly
• Tightness & healthiness of Fuse links: Quarterly
• Electrical performance, tightness of all connections, noise observation
• and complete cleaning of equipment: Half Yearly

• Calibration of meters: Yearly

C) In addition to Logbook is to be maintained for recording Meter

Readings & working status of Charger shown by indicating lamps.

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REVISION:01
MAINTENANCE OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control
cards etc. at least one set each.

E) Return permit to control room.

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect of maintenance of Battery charger
at all SV and IPS.

6. REFERENCES:

• Manufacturer’s (Chhabhi Electricals Private Limited) Operation & Maintenance Manual

of Float Cum Booster Charger.

• Installation & Operation Manual of Float cum Booster Charger of Chhabi Electricals Pvt.
Ltd.

• As built drawing(s)

7. RECORDS:

Any fault occurring and rectification carried out/maintenance carried out to be recorded
in log book.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/70

REVISION:01
OPERATION OF 18V/70A CELL BOOSTER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Operation of 18V/70A CELL BOOSTER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/70

REVISION:01
OPERATION OF 18V/70A CELL BOOSTER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written operating procedure of 18 V / 70 A, CELL BOOSTER to ensure

optimum performance of associated Battery Bank.

2. SCOPE:

This standard covers the guidelines on operating procedure of 18 V / 70 A, Cell Booster

for 250AH & 400AH, L.A. battery.

Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, insulating mats and use of proper
insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:

OPERATING INSTRUCTION:
• Obtain the work permit from operating department.
• Ensure that AC input switch is at “OFF” position and variac knob is at zero (0) position. If
the variac is not at minimum position, then turn it at its minimum position so as to pick
up the main contactor (C1).
• Switch “ON” the AC input switch, contactor will get energized. Turn the variac knob
clockwise direction gradually. Maintain the required DC output voltage on voltmeter
DCVM2.
• Turn the variac knob to zero position, switch OFF SW1.
• Connect the water load/ resistive load.
• Switch “ON” the DC output switch & AC input switch. Turn the variac gradually in
clockwise direction to maintain the required DC output voltage at required current.
• Turn the variac at zero position, switch OFF SW1, SW2.
• Complete the initial charging of battery cells as per the instruction given in battery
manual.
• While in operation the output current is controlled through variac.
• Return the permit to control room.

5. RESPONSIBILTY:

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/70

REVISION:01
OPERATION OF 18V/70A CELL BOOSTER
W.E.F.: 15.05.2019

Site In-charge and Electrical team to ensure the proper operation of cell Booster at all SV
and IPS.

6. REFERENCES:

Manufacturer’s (Chhabi Electricals Private Limited) Operation & Maintenance

Manual of 18V/70A Cell Booster charger.

7. RECORDS:

Logbook/ Register is to be maintained in monthly operation record and note

down the battery voltage and specific gravity which was charged by this
cell booster.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/71

REVISION:01
MAINTENANCE 18V/70A CELL BOOSTER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Maintenance of 18V/70A CELL BOOSTER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/71

REVISION:01
MAINTENANCE 18V/70A CELL BOOSTER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for maintenance and Upkeep of 18 V / 70 A, CELL

BOOSTER to ensure optimum performance and life of Cell Booster.

2. SCOPE:

This standard covers the guidelines on monthly checks as per checklist and maintenance
of 18 V / 70 A cell Booster for 250AH and 400AH L.A. battery installed.

Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, insulating mats and use of proper
insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURES:

• Obtain the work permit from operating department.

• Monthly inspection and cleaning of the equipment will ensure trouble free operation of
the unit.
• In case of no output, check the fuse and replace, if necessary.
• If fault is persistent, it can be traced by step-by-step by referring the circuit diagram.
• In case of reduced output, disconnect and check the diodes individually and replace, if
necessary.
• Return the permit to control room.

5. RESPONSIBILTY:

Site In-charge and Electrical team to ensure the proper maintenance of cell Booster at all
SV and IPS.

6. REFERENCES:

Manufacturer’s (Chhabi Electricals Private Limited) Operation & maintenance

Manual of 18V/70A Cell Booster charger.

7. RECORDS:
Log Book/ Register is to be maintained for monthly maintenance record.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/72

REVISION:01
OPERATION OF 48V/45A BATTERY
CHARGER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

OPERATION OF 48V/45A BATTERY CHARGER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/72

REVISION:01
OPERATION OF 48V/45A BATTERY
CHARGER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for operation of Float cum Booster Charger for 48 V / 400
AH L.A.

Type: 48V / 45A

2. SCOPE:

This standard covers the guidelines on the operating procedure of Battery Charger (Dual
Float cum Booster Charger) for 48 V / 400 AH L.A. Battery.

3. SAFETY REQUIREMENTS:

Use of Safety shoes, Safety helmet, insulating mat and proper insulating tools.

4. PROCEDURES:

OPERATING PROCEDURE

Operational details for Battery Charger (2x100% Float cum Booster charger with 2x100%
battery banks and 1x100% load).
Normally, both float cum booster chargers will operate in float mode & will trickle
charge the batteries at 2.16 V per cell with a stabilisation of +/-1% of the floating
voltage. The Charger will supply the trickle charging current required for the batteries as
well as feed the DC continuous load as required. During this time, the charger and the
battery are across the DC load terminals.
Both the chargers will be sharing load almost equally in float mode. The battery current
will be limited to Battery charging current through SMPS circuit (14% of Battery AH).
a) The voltage range shall be between 48V – 52V. Normally it operate on float mode, in
case of voltage drop down to 48V it will automatically comes in boost mode.

5. RESPONSIBILTY:

Site In-charge and Electrical team to ensure the proper operation of battery charger.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/72

REVISION:01
OPERATION OF 48V/45A BATTERY
CHARGER
W.E.F.: 15.05.2019

6. REFERENCES:

• Manufacturer’s Operation & Maintenance Manual of Float Cum Booster Charger.

• Installation & Operation Manual of Float cum Booster Charger.

• As built drawing(s).

7. RECORDS:

Any fault occurring and rectification carried out to be recorded in log book.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/73

REVISION:01
BATTERY CHARGER FOR 48V/250 AH L.A.
BATTERY W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

BATTERY CHARGER FOR 48V/250 AH L.A.BATTERY

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/73

REVISION:01
BATTERY CHARGER FOR 48V/250 AH L.A.
BATTERY W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for maintenance and Upkeep of Battery Charger for 48
V / 250 AH L.A. BATTERY to ensure optimum performance and life of Battery Charger
(Dual Float cum Booster Charger) and associated Battery Bank.

Type: 48V/45A

2. SCOPE:

This standard covers the guidelines on Weekly checks as per checklist and
Maintenance of Battery Charger (Dual Float cum Booster Charger) for 48 V / 250 AH
L.A.Battery
Frequency of maintenance: Weekly, Quarterly, half- Yearly, Yearly.

3. SAFETY REQUIREMENTS:

Safety shoes, Safety helmet, insulating mat and use of proper insulating tools.

4. PROCEDURES:

Description: -The Battery Charging Equipment comprising of Dual Float cum Booster
Charger Housed in a common cubicle. It Consists of AC I/P terminal for Battery and
Load. Control Switches, potentiometers, analogue meters Indicating Lamps and
Annunciation are provided on front panel of battery charger.

A) Obtain the work permit from operating department.

B) Routine Maintenance of Battery charger

1. Cleaning of Panel from inside & outside by using blower; - weekly

2. Healthiness of indicating lamps; - weekly
3. Tightness & healthiness of Fuse links; - quarterly
4. Electrical performance, tightness of all connections, noise observation
& complete cleaning of equipment: Half yearly
5. Calibration of meters: yearly

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/73

REVISION:01
BATTERY CHARGER FOR 48V/250 AH L.A.
BATTERY W.E.F.: 15.05.2019

C) Any fault occurring and rectification carried out/maintenance carried out to

be recorded in log book.
D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes,
control cards etc. At least one set each.
E) Return the permit to control room.

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect of maintenance of Battery
charger at all SV and IPS.

6. REFERENCES:

• Manufacturer’s (Chhabhi Electricals Private Limited) Operation & Maintenance

Manual of Float Cum Booster Charger.

• Installation & Operation Manual of Float Cum Booster Charger.of Chhabi Electricals
Pvt. Ltd.

• As built drawing(s)

7. RECORDS:

A) In addition to above Logbook is to be maintained for recording Meter Readings &

working status of Charger shown by indicating lamps

(B) Logbook/ Register in the format given below is to be maintained for weekly
maintenance record and for the monthly/quarterly/half Yearly/yearly maintenance
carried out with parts consumed is Maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/74

REVISION:01
OPERATION OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

OPERATION OF 48V/70A BATTERY CHARGER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/74

REVISION:01
OPERATION OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for operation of Float cum Booster Charger for 48 V / 400
AH L.A. Battery to ensure its optimum performance.

2. SCOPE:

This standard covers the guidelines on the operating procedure of Battery Charger (Dual
Float cum Booster Charger) for 48 V / 400 AH L.A. Battery.

Frequency: Monthly

3. SAFETY REQUIREMENTS:

Safety shoes, Safety helmet, insulating mat and use of proper insulating tools.

4. PROCEDURES:
OPERATING PROCEDURE

Operational details for Battery Charger (2x100% Float cum Booster charger with 2x100%
battery banks and 1x100% load).
Normally, both float cum booster chargers will operate in float mode & will trickle
charge the batteries at 2.16 V per cell with a stabilisation of +/-1% of the floating
voltage. The Charger will supply the trickle charging current required for the batteries as
well as feed the DC continuous load as required. During this time, the charger and the
battery are across the DC load terminals.
Both the chargers will be sharing load almost equally in float mode. The battery current
will be limited to Battery charging current through SMPS circuit (14% of Battery AH).

5. RESPONSIBILTY:

Site In-charge and Electrical team to check & inspect the proper operation of 48V/70A
Battery charger at all SV and IPS.

6. REFERENCES:

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/74

REVISION:01
OPERATION OF 48V/70A BATTERY
CHARGER
W.E.F.: 15.05.2019

• Manufacturer’s (Chhabhi Electricals Private Limited) Operation & Maintenance Manual

of Float Cum Booster Charger.

• Installation & Operation Manual of Float cum Booster Charger of Chhabi Electricals Pvt.
Ltd.

• As built drawing(s)

7. RECORDS:

Any fault occurring and rectification carried out to be recorded in log book.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/75

REVISION:01
MAJOR MAINTENANCE OF MOV MOTOR W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAJOR MAINTENENCE OF MOV MOTOR

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/75

REVISION:01
MAJOR MAINTENANCE OF MOV MOTOR W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for major maintenance of MOV motor to ensure its
optimum performance.

2. SCOPE:

This standard covers the guidelines on the major maintenance of MOV motor.

3. SAFETY REQUIREMENTS:

Use of hand gloves, safety shoes, safety helmet and proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Rotork control installation and maintenance instructions.

• Wiring diagram of motor.

5. PROCEDURES:

• Obtain work permit from control room.

• Isolate from PMCC panel.
• Fix danger tag on the feeder panel.
• Check for external damage.
• Check terminations for overheating.
• Check the condition of battery.
• Check the winding resistance.
• Check and replace faulty items if any.
• Replace the faulty motor if required.
• Checking of earthing.
• Do cleaning of site.
• Check remote operation if required.
• Return the permit to control room.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/75

REVISION:01
MAJOR MAINTENANCE OF MOV MOTOR W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site In-charge to check and inspect the proper maintenance of MOV motor carried out
by electrical team.

7. RECORDS:

Log Book/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/76

REVISION:01
YEARLY MAINTENANCE OF MOV MOTOR W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

YEARLY MAINTENENCE OF MOV MOTOR

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/76

REVISION:01
YEARLY MAINTENANCE OF MOV MOTOR W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for yearly maintenance of MOV motor to ensure its
optimum performance.

2. SCOPE:

This standard covers the guidelines on the yearly maintenance of MOV motor.

3. SAFETY REQUIREMENTS:

Use of rubber hand gloves, safety shoes, safety helmet and proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Rotork control installation and maintenance instructions.

• Wiring diagram of motor.

5. PROCEDURES:

• Obtain work permit from control room.

• Isolate from PMCC panel.
• Check the cable termination tightness.
• Earthing check and tightness.
• Check the push button operation.
• Check the position limit switch.
• Check position of torque limit switch.
• Check condition of foundation bolt.
• Check cable IR value if required.
• Normalize the system.
• Check remote operation of required.
• Return the permit to control room.

6. RESPONSIBILTY:
Site In-charge to check and inspect the proper yearly maintenance of MOV motor
carried out by electrical team.
7. RECORDS:
Log Book/ Register are to be maintained and record along with the parts
consumed during maintenance.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/77
WEEKLY MAINTENANCE OF INDOOR REVISION:01
LIGHTING
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

WEEKLY MAINTENANCE OF INDOOR LIGHTING

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/77
WEEKLY MAINTENANCE OF INDOOR REVISION:01
LIGHTING
W.E.F.: 15.05.2019

1. PURPOSE:

To specify guidelines for weekly maintenance of Indoor lighting, to ensure its proper
functioning.

2. SCOPE:

This standard covers the guidelines on weekly maintenance of Indoor lighting.

Frequency: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, safety belt and use of proper
insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD
guidelines.

4. REFERENCES:

• Wiring diagram of Indoor lighting system.

5. PROCEDURE:

• Mark the defective lights

• Obtain permit from operating Department.
• Switch off from the switch board
• Fix danger tag on panel
• Wear PPE for working at height
• Check the ladder to be used
• Clean the fixture
• Replace the defective or damaged part
• Clean the fixture
• Check Cable terminations
• Checking of earthing of fixture
• Clean the site
• Return the permit to control room

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/77
WEEKLY MAINTENANCE OF INDOOR REVISION:01
LIGHTING
W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site In-charge and Electrical team is responsible for the maintenance of Indoor
lighting system at SV & IP Stations.

7. RECORD:

Log Book/ Register is to be maintained for weekly maintenance record and also
maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/78
MAJOR MAINTENANCE OF INDOOR REVISION:01
LIGHTING
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAJOR MAINTENANCE OF INDOOR LIGHTING

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/78
MAJOR MAINTENANCE OF INDOOR REVISION:01
LIGHTING
W.E.F.: 15.05.2019

1. PURPOSE:
To specify written procedure for major maintenance of Indoor lighting, to ensure its
optimum performance.
2. SCOPE:
This standard covers the guidelines on the maintenance of Indoor lighting.
Frequency: Yearly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, safety belt and use of proper
insulating tools.

4. REFERENCES:

• Wiring diagram of Indoor lighting system.

5. PROCEDURE:

• Mark the defective lights

• Obtain permit from operating Department
• Isolate from PMCC panel
• Fix danger tag on panel
• Wear PPE for working at height
• Check the ladder to be used
• Check Cable terminations
• Regland/ reterminate if required.
• Checking of Earthing of fixture
• Clean the site
• Normalize the system
• Return the permit to control room

6. RESPONSIBILTY:

Site In-charge and Electrical team is responsible for the maintenance of Indoor
lighting motor at SV & IPS Stations.

7. RECORD:

Log Book/ Register is to be maintained for major maintenance record and also
maintenance carried out with parts consumed is maintained

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/79

WEEKLY MAINTENANCE OF PLANT LIGHTING REVISION:01

W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

WEEKLY MAINTENANCE OF PLANT LIGHTING

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/79

WEEKLY MAINTENANCE OF PLANT LIGHTING REVISION:01

W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for weekly maintenance of plant lighting, to ensure its
proper functioning.

2. SCOPE:

This standard covers the guidelines on weekly maintenance of plant lighting.

Frequency: Weekly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, safety belts and use of proper
insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Wiring diagram of plant lighting system.

5. PROCEDURE:
• Mark the defective lights
• Obtain permit from operation Department.
• Isolate from PMCC panel
• Fix danger tag on panel
• Wear PPE for working at height
• Check the ladder to be used
• Check PDB/LDB for MCB/ELCB defect
• Clean the site
• Normalize the system
• Return the permit to control room

6. RESPONSIBILTY:
Site In-charge and Electrical team is responsible for the maintenance of plant lighting
system at SV & IPS Stations.

7. RECORD:
Log Book/ Register is to be maintained for weekly maintenance record and also
maintenance carried out with parts consumed is maintained.
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 STANDARD OPERATING PROCEDURE
SPPL/SOP/80
MONTHLY MAINTENANCE OF PLANT REVISION:01
LIGHTING
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MONTHLY MAINTENANCE OF PLANT LIGHTING

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/80
MONTHLY MAINTENANCE OF PLANT REVISION:01
LIGHTING
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for monthly maintenance of plant lighting, to ensure its
optimum performance.

2. SCOPE:

This standard covers the guidelines on the maintenance of plant lighting.

Frequency: monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, safety belt and use of proper insulating
tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

5. PROCEDURE:
• Obtain permit from operating Department.
• Fix danger tag on panel
• Wear PPE for working at height
• Check the ladder to be used
• Check the condition of Junction boxes
• Check the light fixture for damage
• Clean the fixture
• Replace the defective or damaged part
• Check Cable terminations
• Check of earthing of pole/panel/fixture
• Check PDB/LDB for MCB/ELCB defect
• Replace the defective or damaged part
• Clean the site

6. RESPONSIBILTY:
Site In-charge, Electrical team/ Mechanical team & engineers responsible for the
maintenance of plant lighting system at SV & IPS Stations.

7. RECORD:
Log Book/ Register is to be maintained for monthly maintenance record and also
maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/81
MONHTLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF UPS

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/81
MONHTLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for Inspection & Checking of UPS Batteries to ascertain the
condition and capacity of Battery Bank to ensure optimum performance and life.

2. SCOPE:
This standard covers the entire maintenance activities of UPS.
Frequency of inspection & checking: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• UPS manual.

5. PROCEDURE:

• Obtain the work permit from operating Department.

• Check for alarms
• Physical inspection of UPS
• Check operation of protective devices
• Check tightness of all connections
• Check DC & AC Bus voltages
• Check functioning of static switch
• Check all the wave forms at Test points
• Check the battery backup duration
• Check changeover operation
• Clean the UPS
• Check heating of components and cable
• Check the earthing system
• Clean the site
• Normalize the system
• Return the permit to control room

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/81
MONHTLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site In-charge, Electrical/ Mechanical team & engineers responsible for the
maintenance of UPS.

7. RECORD:

Log Book/ Register are to be maintained for monthly maintenance record and also
maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/82

YEARLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF UPS

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/82

YEARLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for Yearly maintenance of UPS to ensure its optimum
performance.

2. SCOPE:

This standard covers the entire maintenance activities of UPS which includes checking of
all the parameters.
Frequency of inspection & checking: Yearly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• UPS manual.

5. PROCEDURE:

• Obtain the work permit from operating Department.

• Check for alarms
• Physical inspection of UPS
• Check operation of protective devices
• Check DC & AC Bus voltages
• Check the DC/ AC Capacitors
• Replace the capacitors if required
• Replace defective card or component
• Check tightness of all connections
• Check function of static switch
• Check all the wave forms at Test points
• Check the battery backup duration
• Carry out change over tests
• Clean the UPS
• Check heating of components and cable
• Check the earthing system
• Clean the site
• Normalize the system
• Return the permit to control room
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 STANDARD OPERATING PROCEDURE
SPPL/SOP/82

YEARLY MAINTENANCE OF UPS REVISION:01

W.E.F.: 15.05.2019

• Clean the site

• Normalize the system

6. RESPONSIBILTY:

Site In-charge and Electrical/ Mechanical team responsible for the maintenance of
UPS at IPS Stations.

7. RECORD:

Log Book/ Register is to be maintained for Yearly maintenance record and also
maintenance carried out with parts consumed is maintained.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/83

REVISION:01
MAINTENANCE OF ELECTRICAL CABLE
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF ELECTRICAL CABLE

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/83

REVISION:01
MAINTENANCE OF ELECTRICAL CABLE
W.E.F.: 15.05.2019

1. PURPOSE:

To specify written procedure for monthly maintenance of electrical cable.

2. SCOPE:
This standard covers the guidelines on the maintenance of electrical cable.
Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. PROCEDURE:

• Obtain clearance from Control room

• Isolate & rack out the breaker
• Fix Tag on the panel
• Disconnect the cable from both sides
• Meggar the cable
• If required locate the fault
• Repair the fault
• Meggar after repair
• Restore the site
• Connect the cable on both sides
• Do Cleaning of site
• Normalize the system
• Return the permit to control room

5. RESPONSIBILTY:

SITE In-charge and Electrical team are responsible for the maintenance of electrical
cable at all SV Stations.

6. RECORD:

Log Book/ Register is to be maintained for the maintenance of electrical cable.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/84
MAINTENANCE OF CIRCUIT BREAKER REVISION:01

W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

MAINTENANCE OF CIRCUIT BREAKER

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/84
MAINTENANCE OF CIRCUIT BREAKER REVISION:01

W.E.F.: 15.05.2019

1. PURPOSE:

To provide written procedure for monthly maintenance of circuit breaker, to ensure its
optimum performance.

2. SCOPE:

This standard covers the guidelines on the monthly maintenance of circuit breaker.
Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.

Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Electrical Drawing of breaker.

5. PROCEDURE:

• Obtain clearance from Control room

• Isolate & rack out the breaker
• Fix Tag on the panel
• General Cleaning of Breaker
• Checking for Loose Connections
• Checking for any corrosion effect
• Check Closing & Tripping Coil
• Check Condition of Springs
• Check condition of Contact blocks
• Measure contact resistance
• Check Functioning of micro switches
• Check Trip Circuit Healthy
• Do Cleaning of site
• Normalize the system
• Return the permit to control room

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/84
MAINTENANCE OF CIRCUIT BREAKER REVISION:01

W.E.F.: 15.05.2019

6. RESPONSIBILTY:

Site In-charge and Electrical team responsible for the maintenance of circuit breaker
at all SV Stations.

7. RECORD:

Log Book/ Register is to be maintained for the maintenance of circuit breaker along
with the parts consumed.

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/85

REVISION:01
FAULT FINDING IN ELECTRICAL SYSTEM
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

FAULT FINDING IN ELECTRICAL SYSTEM

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 STANDARD OPERATING PROCEDURE
SPPL/SOP/85

REVISION:01
FAULT FINDING IN ELECTRICAL SYSTEM
W.E.F.: 15.05.2019

1. PURPOSE:

To specify work Procedure on fault finding in electrical system.

2. SCOPE:

This standard covers the guidelines on fault finding in electrical system.

Frequency: Weekly

3. SAFETY REQUIREMENTS:

Rubber Hand Gloves, Safety shoes, Safety helmet and proper insulating tools.

4. PROCEDURES:

• Obtain clearance from control room.

• Isolate the circuit.
• Fix tag on the panel.
• Disconnect the circuit from both sides.
• Meggar the cable/wiring.
• If required locate the fault.
• Repair the fault.
• Meggar after repair.
• Restore the site.
• Connect the cable on both sides.
• Clean the site.
• Normalize the system.
• Return the permit to control room.

5. RESPONSIBILTY:

Site In charge and Electrical team responsible for fault finding in electrical system.

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6. REFERENCES:

Electrical Drawing

7. RECORD:

Log Book/ Register are to be maintained for the maintenance of fault finding in electrical
system along with parts consumed.

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RELAY TESTING AND CALLIBRATION REVISION:01

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Sanmarg Projects Private Limited

RELAY TESTING AND CALLIBRATION

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1. PURPOSE:

To specify guidelines for monthly maintenance of relay testing and calibration, to

ensures the optimum performance.

2. SCOPE:

This standard covers the guidelines on the relay testing and calibration.
Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet, insulating mats and use of proper
insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Electrical Drawing.
• Reference equipment.

5. PROCEDURE:
• Obtain clearance from Control room
• Isolate the required feeder
• Fix Tag on the panel
• Record initial settings of relay
• Take out the relay for testing
• Carry out testing
• Fill up the details in formats
• Fix the relay back in panel
• Defective relay to be identified
• Replace defective relay
• Return the permit
• Energize the feeder

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6. RESPONSIBILTY:

Electrical team & engineers responsible for relay testing and calibration.

7. RECORD:

Log Book/ Register is to be maintained and also maintenance carried out with parts
consumed is maintained

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MAINTENANCE OF 3PH/1PH (SVR) REVISION:01

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Sanmarg Projects Private Limited

MAINTENANCE OF 3PH/1PH (SVR)

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1. PURPOSE:

To specify guidelines for monthly maintenance of 3PH/1PH (SVR) to ensures its optimum
performance.

2. SCOPE:
This standard covers the guidelines on maintenance procedure of 3PH/ 1PH (SVR) outlet.

Frequency: Monthly

3. SAFETY REQUIREMENTS:

Rubber hand gloves, safety shoes, safety helmet and use of proper insulating tools.
Ensure all the safety requirements for doing the job safely are met a per OISD guidelines.

4. REFERENCES:

• Wiring diagram of SVR feeder.

5. PROCEDURE:

• Obtain permit from operation department

• Isolate the power supply
• Fix Tag on the panel
• Check the condition of OUTLET
• Check all connection
• Check the condition of outlet
• Check for IR value for cable/wire
• Checking of Earthing of all power point
• Do Cleaning of site
• Normalize the system
• Return the permit to control room

6. RESPONSIBILTY:

Shift In-charge, Electrical team & engineers responsible for the maintenance of SVR
at all SV Stations.

7. RECORD:

Log Book/ Register is to be maintained for the maintenance of SVR along with the
parts consumed
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REVISION:01
TRANSFORMER OIL TESTING
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Sanmarg Projects Private Limited

TRANSFORMER OIL TESTING

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1. PURPOSE:

The main purpose of testing of transformer oil ensures the optimum performance of the
transformer.

2. SCOPE:

This section covers the guidelines on the testing of transformer oil.

Frequency: Annually

3. SAFETY REQUIREMENTS:

Ensure all the safety requirements for doing the job safety are met a per OISD
guidelines.
Elementary safety precautions & practices are to be observed and use of PPEs

1. Rubber Hand Gloves.

2. Safety Shoes.
3. Helmet.
4. Insulating Mat
5. Insulating tools

4. REFERENCES:

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• Drawing specifications.

5. PROCEDURE:
• Obtain clearance from Control room
• Mark identification on sample bottles
• Clean the Oil sampling valve
• Collect Oil sample from Top and Bottom
• Shut the valve and Plug it
• Return the permit
• Send the sample to Laboratory

6. RESPONSIBILTY:

Site Incharge, Mechanical team & engineers responsible for maintenance of switch
gear.

7. RECORD:

Log Book/ Register is to be maintained and also maintenance carried out with parts
consumed is maintained

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REVISION:01
OUT SOURCE PROCESS
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

OUT SOURCE PROCESS

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1. PURPOSE:

The Purpose of this Standard operating procedure is how to outsource a process

which is provided by an external organization.

2. SCOPE:

The scope of this Standard operating procedure is to control the outsource process.

3. DEFINITION:

An outsource process is a process that is provided by an external organization i.e.,

a. Purchased from an independent supplier
b. Provided by the another part of the larger organization
c. Provided at your facility or at an independent site

4. PROCEDURE:

• Control of Outsource Process: The organization must demonstrate it exercise

sufficient control to ensure that outsourced processes are performed
according to:
• ISO 9001: 2008 Standard
• Customer Requirements
• Regulatory & Statutory Requirements
• The type and extent of control depend on what is outsources and the potential
risks involved. Examples may include:
− Contractual agreement with provider along with a clear specification
− Validation requirements for the process
− Quality Management System requirements
− Onsite inspections or verifications

An outsourcing Strategy & seven gate process:

• Gather and Validate Data:

• Establish true costs of doing business
• Gather Performance data on existing processes
• Determine the stability of existing processes
• Ensure that clear criteria for acceptance of both products is in place
• Identify fixed costs that may remain regardless of outsourcing activities
• Establish Indicators:
• Define critical control points
• Place weights to scoring criteria
• Understand financial indicators
• Define specific performance metrics

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1. Prepare for Quotation:

• Define the criteria to be used when evaluating potential
contractors
• The more specific contract scope, the more accurate the proposal
• Consider establishing and interface procedure and attach it to the RFQ
• Communicate any requirements upfront
• Seek at least three potential contractors

2. Select Contractor:
• Create a multi-disciplinary review team
• Ask each contractor to formally present their proposal plan and key project
persons
• Mandate the creation and walk through of a migration plan
• Apply the previously defined scoring system
• Witness first-hand the contractor’s operations to ensure capabilities

3. Migration Plan:
• Consider temporarily posting personnel at the contractor’s operation to ease
the transition
• Ensure the pan includes aspects such as resources, infrastructures, performance
measures, etc
• The plan should cover up to 18 months
• Continue parallel operations until the contractor’s capability is confirmed

4. Post turnover Maintenance:

• Limit contract to three-year renewable cycles
• Allow for a competitive assessment at renewal
• Establish systematic meetings to review performance
• Initiate formal corrective actions to resolve issues
• Include the contractor as part of the internal audit schedule

5. Re – Validation:
• Annually conduct an in depth re validation of the contractor’s processes
• Update the contractor of pending changes so that inputs can be provided
upfront
• Perform a cost assessment on the outsourcing relationship
• Evaluate your working relation ship
• Assess potential risk exposure by contractor

Risks of Outsource Process:

• The Unknown
• Vulnerability
• Loss of reliability
• Competitive pricing pressures, Quality Issues
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Gains of outsources Process:

• Cost savings
• Focus on core products
• Divestment of risk
• Technological advancements
• Effective use of resources

5. RESPONSIBILTY:

MR/Operation/Process Owner

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W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure For

Procurement

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1. PURPOSE:
• The purpose of this procedure is to define the responsibilities and activities of personnel to
ensure that purchase requisitions for goods and services, received in the Procurement
Material Management Department, are promptly performed and the Purchase Orders for
the same are efficiently processed.
• To provide written instructions for procuring right material in right quantity at lowest price
to be delivered at right time to support operations / user department.
• To make an integrated approach to the improvement in total Materials Management with
active involvement of all concerned at the grass root level.
• Planning by avoiding over stocking, locking up of capital and reducing material cycle.
• Developing new source of supply & Good suppliers’ relations and Vendor Development.
• Proper planning and programming of materials to avoid emergency purchases as far as
possible.

2. SCOPE:
• Materials as per SOR Specification
• Consumable, Stores & Spares
• Safety Accessories, PPF etc.
• Fixed Assets including tools, tackles, furniture, computers, laptop, equipments etc.
• Sub Contractors
• Survey Work / Calibration Work
• Hiring of Plants & Equipment
• Logistic of Material
• Local Site Purchases for more than Rs.5000/-

Note:
• Respective Departments like Admin, IT etc shall follow the SOP against purchase directly
concerned with their departments.
• Operation Department shall follow the SOP in case of Hiring of Sub Contractors / Surveys
etc.
• Hiring of Vehicle shall be in the scope of Admin Department including liaison with RTO &
Insurance of Owned Vehicles.

3. STANDARD REQUIREMENTS:
• Approved list of materials/ CAPEX.
• Approved Indent from Operations Dept.
• Timeframe to supply the material.
• Clear identifying of material, SOR item / Reimbursable or Asset.
• Technical specifications if available.
• Budgeted rates for comparisons.

4. REFERENCES:

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• LOA, SOR, Budget & Contract documents.

• Stock levels for inventory control items.
• Processing schedule as per Procurement Procedure.

5. PROCEDURE:

1. Operation department shall prepare a list of materials / capex required for execution of
project immediately after award of the contract.

2. Operation department shall raise an indent keeping reasonable time for procurement
process and delivery as per the approved indent format to procurement department duly
approved by project head / incharge.

3. On receipt of any Purchase requisition, the assigned Buyer shall check that all the
information is complete and accurate. If the details are inadequate, the Buyer shall resolve
the same with the originating department.

4. Procurement department to check the availability of material within the company / on any
of the projects. If required material is available in the stock which can be economically
transferred to concerned project, then with due written permission from the project
incharge where material is available, logistic shall be arrange for transfer of material.

5. In case of Capex requirement, its long term usage and option of hiring shall also be
checked before processing of comparative.

6. The Buyer shall issue a RFQ to the selected vendors, by letter / emails. However, for
certain branded material having exclusive dealership. It may not be required to float
multiple RFQs. All the clarifications to the quotation shall be confirmed in writing with
vendor.

7. If the required material is to be purchased, then rate enquiry shall be called from atleast
three vendors and a comparative statement shall be prepared for all purchases exceeding
Rs.5000.

8. Comparative statement shall be recommended by the head procurement keeping in view

all the aspects like rates, vendor credentials, payment terms, taxes and input credit,
delivery period, transportations, quality, sales after service etc.

Comparative Statement shall be done on following parameters:

• Items must be comparable in specifications (like items shall be compared)
• Final accepted rates shall be compared with Estimates / Budgets, if final rates are
more than the rates in estimates / budgets; procurement departments shall take

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the responsibility and estimation department shall have to justify the rates
showing documentary proof of rates taken in costing.
• Vendor’s assessment, track records, his experience etc must be considered while
accepting any vendor.

9. Duly recommended comparative statement shall be further approved by VP Operation,

Head Finance and finally approved by Head Operations. Any deviation from Estimates /
Budget shall be approved from COO explaining the justification of such differences by
procurement department.

10. Purchase Indent of CAPEX item exceeding Rs.10000/- shall be pre approved by COO.

11. Following comparatives shall be approved by COO after approval from Head Operations:
• CAPEX Purchases exceeding Rs.10,000/-
• Purchases which are having loss as compared to the rates as per SOR / Budget.
• Purchases in excess of Rs.50,000 single item.
• Orders with more than 25% unsecured advance.

12. After approval of the comparative, formal purchase order shall be prepared and signed by
procurement department and head of operation shall countersign the purchase order to
ensure the procurement of material. All purchase orders shall be accepted by the vendor.

13. Approved and accepted PO shall be forwarded to Operations and Finance Department for
their reference.

14. If amendment is needed because of delays or and users request, the amendment of a
Purchase order needs to be justified by the assigned Purchasing Authority / Buyer stating
why an approved purchase order needs to be amended.

15. Procurement department shall coordinate with the vendor for timely supply of material at
project including arrangement & management of logistic.

16. The assigned Purchasing Authority shall bring out an Expediting and Follow-up Report to
identify the Purchase Orders that have not met the scheduled delivery date and take
action as necessary. It is to be ensured that Quality / Test Certificates / Factory acceptance
test / TPI report are available for the supplied material.

17. Procurement department shall maintain a set of records like copy of Invoices, Test
Certificates, Inspection Reports, and Warranty Certificates (original) etc and ensure to
coordinate and arrange for sales after service etc on timely basis whenever required.

18. In case of procurement of material which require inspection before dispatch shall be
ensured in-house / or by third party.

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19. Project Incharge shall ensure and confirm the receipt of quality and quantity of material
and shall immediately prepare MIIR and send the same along with certified invoice to
Head Office for further processing, there should not be any time lag in receipt of material
and issue of MIIR, any discrepancies should be brought out to the Purchasing Authority to
resolve the issue.

20. Purchase of specific materials, supplies, equipment or services may be made in the open
market for immediate delivery only to meet the bona fide emergencies arising from any
unforeseen cause and emergency requirement in line with Finance department
procedures and with justification explaining the emergency of the subject.

21. Procurement department shall ensure to enter the receipt of material as per MIIR in the
stock register immediately after receipt of material at site / office in coordination with
Project Incharge and put a mark on bill for confirmation of entry into the stock register.

22. Procurement department shall ensure to take adequate insurance coverage to insure the
company inventory / assets at different location and take proactive action updation of
same for any additions.

23. Accounts department shall process the bills after verification of:
• Original Certified Invoice
• MIIR
• Verification of entry in Stock Register.

24. Procurement department shall ensure physical verification of stores at site jointly with
operation and finance department at periodical interval (Sept & March). Stock Register
shall be considered at basis for conducting physical verification.

25. Loss/damages report, fixing responsibility to be generated by respective Project IC on the

given ISO Form MSSR and sent to HO for competent authority approval for penalizing
/Waiver/condoning/replenishment of store.

26. Any deviation in physical Vs Actual stock shall be considered as loss and respective
incharge / store head shall be held responsible and will have to bear the loss.

27. Any movement of material from one project to other must be duly documented through a
Challan (store transfer note) and reported to Head Office Procurement / Operations &
Finance. Procurement department shall ensure to make stock transfer entry in the stock
register of transferor and transferee project / site.

6. RESPONSIBILTY:

1. Operations Department

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• Timely Raising of Indent with Specification

• Comparison of rates with SOR, Budgets & Estimates
• MIIR Certification
• Invoice Certification
• Control over inventory / assets

2. Procurement Department
• Indent Processing
• Negotiation with vendor
• Vendor Selection and Assessment / Development
• Purchase Orders and its acceptance
• Supply / Logistic Coordination
• Invoice Certification
• Inventory Control & Records Keeping
• Sales After Service
• Insurance of Stock in Hand / Transit

3. Finance & Accounts Department

• Verification of Comparative & PO
• Comparison of rates with budgets, SOR & Estimates
• Vetting Payment Conditions & Taxes
• Bills verifications and accounts reconciliations

FORMATS ENCLOSED:
• PR (Indent) Purchase Requisition
• RFQ –Request for quote
• Comparative Statement
• PO –Purchase Order
• MIIR –Material Incoming Inspection Report
• Material Short Stock Report (MSSR)
• Stock Transfer Challan

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REVISION:02
CLIENT INVOICING
W.E.F.: 15.05.2019

Sanmarg Projects Private Limited

Standard Operating Procedure for

Client Invoicing

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1. PURPOSE:

The purpose of this SOP is to provide written instructions for preparing invoices,
documents to be attached and its timely submission to client after meeting their
requirement for raising Invoice.

2. SCOPE:
To cover Invoicing for all the projects.

3. STANDARD REQUIREMENTS:

• Invoice No.
• Invoice Date
• Service Period
• Service Order No. / Work Order No.
• Service Order Date/ Work Order Date
• Service Provided at…
• Service Tax No.
• Service Tax Category
• VAT (if Required)

4. REFERENCES:

Refer LOA, SOR & Contract documents of the respective Projects for the purpose of rated
items.

5. PROCEDURE:

• Site Incharge shall collect the data of work done at sites during the billing period and

prepare measurement sheet according to client’s requirement. JMS / Time Sheet Duly

certified by client shall be submitted to Project Incharge to prepare invoice as per the

format prescribed and forward to the Operation Department in Head Office for their

vetting.

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• Operation Department shall verify the Invoice in respect of its quantities, rates,

measurement, man-hour, overtime etc with SOR and applicable contract conditions. If

they found any observation regarding the quantity claimed, rates or man-hour or

expected penalty etc, immediate explanation shall be call from concerned and if they

found the explanations are convincing and justified, then recommended copy of invoice

shall be forwarded to Accounts Department for examination.

• Accounts will check the invoice in respect of accounting, calculations, statutory

parameters and generate an invoice number and forward the invoice to Project Incharge

(with copy to operation Department) to submit the bill to concerned department / office

of respective client along with all relevant documents .

• Operation Dept./ Project Incharge will ensure compliance of statutory requirements w.r.t

Labour laws as per LOA.

• Operation Dept. / Project Incharge will submit Soft Copy and Hard Copy of Final Invoice

to the finance department for their records.

• Project Incharge shall ensure the follow up for certification and payment of the invoice

on time.

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• The invoice shall be considered final after getting clearance (i.e. Invoiced Passed and

processed) for payment from concern dept. of respective client.

6. RESPONSIBILTY:
• All persons / Department concerned with invoicing process must comply with this SOP
with no exceptions.

• Company persons must aim to raise invoice within the target date set for each project
and get the invoice certified with minimum process time from client.

• The Absence due to leave or otherwise of concerned officials should not affect
continuous processing of invoices at any level.

7. FORMATS ENCLOSED:
• Joint Measurement sheet / Time Sheet
• Abstract of Measurement
• Memorandum of Payment
• Invoice

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Sanmarg Projects Private Limited

Standard Operating Procedure For

Fixed Assets Management

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1. Objective
The objective of this SOP is to set forth the guidelines for the physical and reporting control
of the company’s fixed assets, including accountability over the fixed assets, meeting
financial reporting needs, and generating Asset Management Information on regular
intervals.

This document is intended to describe the standard operating procedure / policies required
for recording new and existing assets, changes in assets and the methodology of record
keeping.

In addition, it is intended to provide steps to assist Company personnel in the safeguarding,

accounting for and disposing of Company assets. Legal responsibilities require that the
Company accurately record and account for capital assets on a regular basis. Because each
department engages in the acquisition, transfer, disposal, and use of capital equipment, this
policy sets forth the roles and responsibilities regarding capital assets.

2. Scope & Coverage

• Moveable & immovable Assets of the Company
• Temporary Structures / Infrastructure & Porta Cabins
• Computers, IT Assets & Software
• Acquisition / Purchase, Disposal, Transfer, Record keeping etc.

3. Roles and Responsibilities

The major responsibilities each party has in connection with the Capital Assets Policy &
Procedures are as follows:

The Controller of Assets is responsible for the establishment and maintenance of an

adequate fixed asset accounting system that allows for the proper presentation of capital
assets in the financial statements and the overall safeguarding of fixed assets.

The Controller of Assets is responsible for ensuring the fixed asset accounting system is being
properly maintained on regular basis, including the identification of capital assets, accurate
use of codes (if any defined), determination of useful lives, reconciliation to the financial
books of accounts, and financial MIS reports.

A) The Asset Coordinator reports to the Controller of Assets and is responsible for:

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1. Effective administration and maintenance of the documentation and control system of fixed
assets,
2. Providing the Controller of Assets with the necessary documentation to review assets
invoiced as capital assets for final determination as a fixed asset;
3. The proper tagging of all movable equipment;
4. Preparing a monthly listing of all movable assets procured/ transferred / disposed of;
5. Providing department heads with current records of the assets for which they are
responsible;
6. Joint physical inventories taken on a periodical basis, verifying the existence and condition of
all capital assets to ensure the accuracy of Company accounting records;
7. Updating the fixed assets inventory based on inspection reports and notifying the Controller
of Assets regarding any inventory changes;
8. Evaluating loss, damage, destruction, disposal, theft, sale, and /or transfer of Company
assets and providing recommendations with regard to the disposition of these assets;
9. Review and posting of depreciation through the Fixed Asset Module on a monthly basis as
per depreciation policy and rates prescribed;
10. Reconciliation of the fiscal year additions in the Fixed Asset Module to the general ledger
completed in a timely basis;

B) All Functional Department Heads are responsible for:

1. Reading and understanding the Fixed Assets Management Policy by all the users concerned
in the department,
2. Maintaining current inventory records for all in-use fixed assets within their assigned
department and work location i.e. sites / departments;
3. Assuring property / assets is given proper care and protection and is used for official
purposes only;
4. Ensuring that Company property is used only in the conduct of official Company business;
5. Ensuring / notifying the periodical maintenance and upkeep of Fixed Assets,
6. Notifying the Coordinator / assistant whenever any fixed assets are transferred /acquired,
sold, donated, destroyed, stolen, lost or otherwise disposed of,
7. Identifying and reporting to the Coordinator / assistant along any surplus property which is
useable but not needed in his /her area, or which is beyond economic repair and therefore
to be disposed of;
8. Assisting / signing of in taking physical inventories on defined regular intervals,

C) Purchase Department / Accounts Department shall ensure and is responsible for:

1. Correct Accounting heads are used for booking in financial books
2. Proper Purchase Requisition/ Purchase Orders are raised
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3. Rates are approved as per budget and PO raised

4. Purchase are duly authorized as per company purchase procedure
5. Original Billing documentation received from vendor
6. Material Received in good working condition
7. Material Received Note / MIR / MRN signed and attached with original invoice
8. Material Inward / Outward entered in Fixed Assets Register

4. Capitalization Policy
1. A capitalized fixed asset is property of the company, such as equipment / tools / others with
a cost or value equal to or greater than Rs. 5,000 at the date of acquisition, and an expected
useful life of more than one year.

2. Capitalized fixed assets are acquired for the use in normal operations and are not for resale /
for use in execution of project / transfer to client. All capitalized fixed assets are entered the
Fixed Assets Register for inventory and financial reporting purposes.

3. Assets costing below Rs. 5,000 are expensed in the financial year of purchase and are not
capitalized nor maintained through the Fixed Assets Register.

The exception to this rule is are:

1. Any tangible items having useful life more than 12 months to be capitalized and charged
with 100% depreciation.
2. Items purchased in bulk, total valued more than Rs. 5,000,

Costs incurred to keep a fixed asset in its normal operating condition that do not extend
the original useful life of the asset or increase the asset’s future service potential are not
to be capitalized, therefore, to be charged to profit & loss account. These costs are
expensed as repairs or maintenance.

5. Valuation of Capitalized Assets

The valuation of capital, whether purchased or fabricated, is based on unit cost. The total
unit cost is determined by the sum of:
1. Purchase value shall be net of any discount, CENVAT, Input Credit of VAT if applicable
2. Total Cost of Freight & Cartage, loading / unloading,
3. Cost of Labour, Material & installation etc to be added in the unit cost of assets

6. Classifications of Capital Fixed Assets

Capital fixed assets are items that are:

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1. Permanent in nature, tangible, durable (useful life greater than one year);
2. Held for purposes other than investment or resale; and
3. Have a cost which equals or exceeds limit set established by the Company.

The types of Capital Fixed Assets:

1. Computers & Printers
2. Furniture & Fixtures
3. Office Equipment & Appliances
4. Plant & Equipment
5. Tools & Service Equipment
6. Vehicles
7. Software
8. Temporary Structures / Porta Cabins

7. Custodian of Fixed Assets

(A) Operations Department – Scope of Coverage: All Project Sites
1. Material at Stores / Godowns
2. Computers & Printers
3. Furniture & Fixtures
4. Equipment & Appliances
5. Plant & Equipment
6. Tools & Service Equipment
7. Software
8. Temporary Structures / Porta Cabins
9. Fire Fighting Equipment
10. Vehicles

(B) IT Department- Scope of Coverage: Head Office & Project Sites

1. Laptop / Desktop
2. Printer / Scanners
3. Software
4. Photocopiers
5. VC Devices
6. Networking Devices / Server
7. Firewall / other related Equipment

(C) Administration Department – Scope of Coverage: Head Office

1. Furniture & Fixtures

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2. Electrical Fittings
3. Office Appliances
4. Fire Fighting Equipment
5. Vehicles
6. Material at HO Stores / Godowns

8. Buying / Acquisition of Capital Assets

1. Purchase procedure to be followed by all departments.
2. User department shall raise indent to Controller of Assets who shall check the availability of
assets in stock at any site.
3. Based on the availability of assets at site / or cost of transfer, he / she will decide for fresh
buying / transfer.
4. In case of transfer process as per clause no.09 shall be followed,
5. In case of buying decision, he will sign of the purchase indent and submit to the procurement
department.
6. Procurement department shall initiate the process as per SOP on procurement.
7. Controller of Assets shall ensure entry in Fixed Assets register based on MIR and Original
Documents.
9. Disposal of Capital Assets
1. An item of fixed assets classified as unused / scraped shall be reported to Controller of Assets
by the custodian of assets with his / her recommendation for sale / disposal.
2. The final decision to sale / disposal of the assets shall be taken by Controller of Assets in
consultation with Head F&A and COO.
3. An item of fixed assets should be eliminated from the balance sheet and the fixed asset
register on disposal or when the asset is permanently withdrawn from use and no future
economic benefits or potential service delivery is expected from its disposal.
4. When a tangible capital asset is disposed of, the cost and accumulated depreciation are
removed from the books of accounts, such disposals represent a reduction in the tangible
value of capital assets.
5. Any difference between net proceeds and the carrying amount of the asset is accounted for
as a revenue or expense in the profit & loss statement.

10. Transfer of Capital Assets

1. Assets Coordinator shall have details of all the assets available in the company at any given
time.
2. All the requirement of assets at any site / location shall be submitted to assets coordinator
by the user department.
3. Assets coordinator shall check the availability of the assets required from its records and
coordinates with existing user and coordinate with transfer.
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4. While transfer proper documentation shall be made with copy to accounts department for
booking in the accounting system.
5. Assets coordinator shall make necessary recording in fixed assets records for recording of
transfer.

11. Physical Verification

1. Physical Verification shall be done on half yearly basis at all locations
2. Any variation must be reported to concerned Head of Department and explanation to be
called. Unexplained variation to be enquired.
3. Written off can only be done against approval of Management.
4. Physical Verification Report shall be submitted in hard copy.

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Standard Operating Procedure for

Expenses and Controls

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1. PURPOSE:

The purpose of this SOP is to explain the procedure to be followed by employee for claiming
expenses within the budget, ensuring due diligence and exercising internal control before
incurring of any expenses for official purpose.

2. SCOPE:

To cover all Expenses incurred for official work at Project sites and Head Office / Branch Office
by any employee of the company.

GENERAL PROCEDURE:
• Expenses incurred by employee shall have valid supporting in the form of Invoice, Bills, and
Challans etc.
• All expenses must be duly signed and approved by Head of respective department before
submission to Finance Department and in case projects / operations by respective Project
Head.
• Any deviation from the budget / any extraordinary expenses need pre approval from COO
through respective Departmental Head.
• If bill is in a language other than English / Hindi, employee is required to specify the detail
of items purchase and name / details of vendor in English or Hindi.
• Expenses shall be submitted to head office as defined under separate SOPs like, Purchase,
Advance, and Travel etc.
• In case of payments made through Imprest, payment voucher must be duly signed by the
recipient of payment with his contact number.
• Bills and claims shall be duly supported by approval, justification, details, mails,
comparisons, quotations etc.

GUIDELINES:
Vehicle Hiring:
• Hiring of vehicles on daily basis is discouraged.
• If it is required in case of emergency, it can be arranged in the best interest of project.
• However, hiring of vehicle for more than three days shall be preapproved through mail from
Head Operations & Head Admin at HO.
• Bill shall be submitted along with duly signed duty slips and mentioning purpose /
justification of journey performed.
• Operations department to verify the requirement of hiring in relation to contract.
• Any vehicle hiring for more than 10 days shall be allowed only through proper work order
and rate approval from Head office Admin and payment shall be made through banking
process.

Machinery Hiring:

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• Rates of machinery / equipment hiring shall be negotiated with more than one agency and
lower rate to be finalized.
• If machinery is required for more than one day, preapproval shall be taken through mail
from Head Operations at HO.
• If machine is required for more than 10 days, it shall be allowed only through proper work
order and rate approval from Head office and payment shall be made through banking
process.
• Operations to ensure verification & justification of its usage through time sheet which is to
be attached with the bill.

Contractor/ Labour / Helper/ Sweeper / Cook Expenses

• Wage Rates to be approved from Head Office.
• Number of persons to be deployed shall be approved by Head Operations / HR before
deployment.
• In case of labour payment, name wise attendance & wage sheet should be signed by each
person.
• Operations to verify the justification / and output of labour deployed.
• Subcontract can only be finalized through head office after comparing the terms and
conditions, rates and other aspects.
• Payment to sub contractors to be made through banking process and only after bills
certification.

Material Procurement
• Material procurement in excess of Rs.5000/- shall be procured as per SOP on purchases.
• Cash Payment in excess of Rs.10000/- is not allowed.
• Proper bills / supporting shall be attached with MIR.
• No capital item shall be procured at site without the approval of HO Operations &
Procurement.
• Project Incharge to ensure the receipt of material at site and verify each bills / Challan for
any material purchased by site / Head Office in terms of quantity and quality.
• Project Incharge shall ensure to prepare MIR and send the certified copy along with bill to
HO.

Other Expenses
• Food expenses not to be claimed if covered under CTC as part of salary. Food expenses
incurred with client shall be approved by Head operations at HO along with bills.
• No guest house rent to be paid from Imprest without having valid rent agreement routed
through Admin Department at HO.
• In case of person is on tour for more than 15 days, he / she to take local number for
communication to save on roaming expenses.
• Telephone and internet expenses are to be claimed actual for official usage or entitlement
as per policy whichever is lower.
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Advance to Staff / Vendor

Any advance to staff can only be given with prior approval of HR / Operations Head and must be
intimated immediately to accounts for its booking in the books.

Advance to vendor if required in case of emergency can only be given with approval and shall be
intimated immediately to accounts for its booking in the books.

3. RESPONSIBILTY:

• All employees at site to ensure compliance as per guidelines.

• Operations, Admin, Procurement & accounts to ensure to get the compliance done at site
and head office.

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Standard Operating Procedure for

Operations Budgeting

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1. PURPOSE:
The purpose of this SOP is to provide written directives for preparation of operations budget
of each project awarded to the company by setting a budgeted target for operations & other
functional department for smooth and timely execution of the project within the defined
cost to achieve the desired profitability.

2. SCOPE:
To cover all the projects awarded after 1st Jan-2014.

STANDARD REQUIREMENTS:
• Detailed Cost Estimation Sheet with Breakup of Costing
• LOA / LOI issued by Client
• Contract Documents
• Minutes of first kick-off Meeting

3. REFERENCES:
Refer LOA, SOR & Contract documents of the respective Projects for the purpose of rated
items.

4. PROCEDURE:
• Finance department shall collect the detailed cost estimation sheet from Estimation
Departments, LOI / LOA, Contract Documents and other relevant data.
• Based on the estimations sheet and other contract data, finance department shall prepare an
initial yearly estimate after discussion with Estimation department.
• Approved budget for of the project shall be given to the Operations & HR / Admin
Department for execution of the project as per the budgeted cost.
• HR / Admin / Procurement and Operation Department shall ensure that project shall be
mobilise within due time and deploy the resources within the budgeted cost and ensure to
maintain the profitability of the project as envisage.
• Finance & Accounts Department shall ensure that payments shall be released based on the
SOP and budgeted cost, any deviations shall be preapproved as per approval matrix.
• Finance Department shall prepare and make a comparison with the budget with actual
profitability of the project and deviations shall be reported and discussed for corrective
measures.

5. RESPONSIBILTY:
• Finance Department for Initial Budget
• Operations / HR / Admin for Project Execution within Budget
• Finance Department for making comparisons, reporting and corrective actions

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Standard Operating Procedure for

Giving Advances to Employees & Reconciliation

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1. PURPOSE:

The purpose of this SOP is to explain the procedure to be followed by Employee for taking
Advance from the company for meeting Imprest need of project / office and Submission of
Expenses and approval thereof. It is desirable that cash payment should be avoided to the
extent possible and payment through cheque / NEFT/ RTGS should be encouraged.

2. SCOPE:

• To cover Advances admissible to employees for official work at Project sites and Head
Office.
• To exclude the following Expenses/ payments which are required to be processed / paid
through separate payment processes / procedure.
1. Purchase of any Capital Assets / Equipment in excess of Rs.5000/-
2. Monthly Vehicle Payments
3. Monthly Guest / Office House Rents
4. Monthly Sub Contractor Payments
5. Any payment in Excess of Rs.10000/-
6. Any payment which is possible to be paid by cheque / NEFT.

3. PROCEDURE:

• The advance can be given to designated employee at site against the Fund Forecast for the
next month (As per format attached). The site Incharge is required to submit the Fund
Forecast as per the attached format to their respective Project Incharge. Project Incharge
with his recommendation shall forward the requisition to the Operations / Project Head
with copy to Finance at the Head office.

• Project Head / Operations at Head Office shall vet the requirement of the funds keeping in
view the budget, need and execution planning of the project and shall submit the
requisition to Finance Department with copy to project incharge.

• The payments in advance to meet expenditure requirements at site will be given in 3

installments with an interval of not less than ten days for the month on the basis of
approved Funds Forecast (FF) from the Project Head / Operations.

• Project Incharge to ensure to submit the details of expenses incurred as per attached format
with comparison with approved fund forecast. Any deviation shall be approved from Head
Operation through Project Head at HO.

• Hard copy of bills, vouchers and other related documents duly signed and approved by
Project Incharge shall reach to Head Office on Monthly basis before 4th of next month.

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• To fill-up and submit the Expenses sheet (as per format) signed /approved by Project Head
to Accounts HO immediately after use of 70% approximately of funds received in advance
for site expenses so that cycle of funds issued to respective site shall continue smoothly.

• The next installment of advance against Funds Forecast (FF) will issued after receiving /
confirming Expenses sheet approved by project head and checked & cleared by accounts.

• The details of expenses done as per client requirement i.e. reimbursable expenses should be
shown separately in expenses sheet.

• Further it is relevant to point out that if any employee has taken any advance on account of
Reimbursable bill the same should be cleared from the client within two Months positively
to avoid reconciliation problem.

• The Advances can be given to any employee at per entitlement of TA policy at Head office of
his request on the basis Of Travel Form. The Employee will fill the Travel Form and submit it
to his / her Head of Department. After recommendation of HOD & approval of COO form
shall be submitted to Finance for payment with copy to Admin Department for necessary
arrangements.

• The Details of Expenses as per Travel Voucher should be submitted to Admin with in 10 days
after returning to Head office; else the Advance taken shall be adjusted in his salary by the
Company. Next advance shall only be given after submission of bills of against previous
advance taken.

• The Expenses should be approved by the concerned Department Head and submitted to
Finance by Admin. Any expenses incurred which are considered out of norm from travel
policy shall be processed and approved through approval matrix before submission to
finance department.

4. RESPONSIBILTY:

• All employees must ensure to submit the approved fund requisition in advance for doing funds
planning.
• Details of Expenses incurred shall be submitted for each installment before next installment
due.
• Original Bills, Vouchers and supporting shall be submitted by 4th of Next Month.
• Operations and Finance shall ensure controlling of expenses within budget.
• Operation and Finance shall ensure that expenses incurred against reimbursable shall be duly
reconciled with client bill on monthly basis.
• Any person taking advance shall ensure to reconcile his / her account on monthly basis with
accounts department.

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5. ENCLOSURE:

• Format of Fund Forecast

• Format of Expenses Detail
• Travel Form
• Travel Voucher

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STORES

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1. INTRODUCTION
The scientific management of Storehouse is an essential part of the Organization s
operations. The stores management function assumes special significance in
Construction Industry where identity of the materials, then handling, proper storage and
accuracy in accounting during issue are of paramount importance in the efficient
operation of the Store House.

• The task of stores management relates to safe custody and preservation of the materials
stocked and their receipt, issue and accounting. The objective is to efficiently and
economically provide the right material at the time when it is required and in the
serviceable condition in which it is required.

• Efficiency in the store starts with precise forecasting and planning of the necessity for
materials, and this presupposes that the need itself has been forecast with a
considerable degree of accuracy. The forecast also must be subjected to periodic review.
The art of stores management is largely that of optimizing the use of resources to meet
actual needs in an efficient manner.

• The relative function of the stores management function depends upon the nature and
size of the organization or activity concerned, and in all cases it has to be designed to
suit the particular need of the organization it serves. There is, therefore, no standard
system which can be universally recommended or applied, but in the course of time,
certain principles and practices of general application have been evolved. The
understanding of these principles is essential for efficiently practicing the art of Stores
Management.

2. DEFINITION:

Storehouse refers to a building or room or place where materials are kept. It can also be
defined as the Management of the following operations: -

2.0 Receipt of materials.

2.1 Efficient Storage.

2.2 Safe custody.

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2.3 Timely issue.

2.4 Stock Accounting.

2.5 Scrap Management.

Storage is an essential part of the economic cycle and Stores Management is today a
specialized function which can contribute significantly to the overall efficiency and cost
effectiveness of the materials management.

3. OBJECTIVES AND RESPONSIBILITIES

• The objective of this SOP is to ensure scientific and efficient management of receipts,
storage and issues of materials keeping in view the economics, security of stock as well
as safety requirements.

• To define the Organization s policy and scope for managing a Storehouse.

• To establish a procedure to facilitate speedy handling and accounting of receipts,

storage and issue of materials.

3.1 The major responsibilities of Storehouse are listed below: -

Identification of all materials stored. Receipt of incoming materials.
Inspection of all receipts from suppliers. Storage and Preservation.
Materials Handling. Issue of materials to users within the organization. Maintenance of
Stock Records. Stores Accounting. Submission of Management Information Reports.

4. SCOPE:

This SOP covers all aspects of receipts, storage, issues, handling, status reports as well
as safety and security requirements for: -

▪ Tracking tools and stores.

▪ Construction Materials.

▪ Workshop Machinery.
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▪ Operating / Miscellaneous supplies for Building Maintenance and

Administrative Services.

▪ Uniforms & Safety Equipment.

▪ Office Equipment & Stationery.

▪ House Keeping Stores

▪ Rejected materials.

▪ Scrap of all types.

5. Policy:
• Only authorized persons shall have access to the Store House.

• Store house shall not be kept open unattended during working hours.

• All materials will be issued against mis (Material issue slip).

• All materials will be received at the store house and person

/department concerned will be notified promptly on receipt.

• All materials should be stacked properly.

• All materials approved after inspection shall be stored in the designated locations.

• Hazardous materials are to be stored separately.

• All materials rejected shall be kept at a designated place and

arrangements for their disposal made on the advice of concern
purchasing official.

• Expensive and attractive articles should be stored in steel cupboards

and always locked up.
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• A Gate pass should be made for taking out materials. These should be signed only
by authorized person

6. RECEIVING, INSPECTING AND INWARDING

• Stores Personnel shall inward materials after ensuring the following.

• Supplier s Delivery Challan (DC) / Invoice bears the inward stamp.

• Supplier s Delivery Challan / Invoice bears the reference of

purchase order.

• In Case of consignment received without any documents or any discrepancy

noticed in the documents received, Purchase official will be notified
immediately for obtaining necessary information for awarding. Till such time
material will not be in warded.

• All apparent damages/leakages/broken seal in the consignment received are

immediately recorded in the DC/LR/Invoice and bring the same to the attention of Dy.
Dir (S&M) or concerned authority.

• Verify the identity of the material received. Ensure description of the material given in
the consignment and number of containers / packages received as per the DC / LR /
Invoice.

• Materials shall be received on all working days only during working hours. For allother
materials, in warding is based on 100% physical verification by way of counting,
measuring & weighing. The Stores Personnel shall inward the materials within 24 hours
of receipt by way of preparing the Receipt Voucher and sign at the relevant places.

7. STORAGE:

The term storage refers to the physical act of storing the materials in a Storehouse on
pallets, shelves, racks, boxes, almirah, etc. with the objective of retrieving them later for
issue to the user. The purpose of any storehouse is to provide to users the right materials,
in the right quantity, at the right time.

The following main objectives for storage shall be considered carefully while storing the
materials: -

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• Maximum utilization of space consistent with adequate care and protection of materials.
• The storage system must be such as to enable accurate identification of the materials
stored.
• Ease of storing and picking, thus enabling speedy operations
• All materials must be protected from temperature, moisture, pilferage, insects, rodents
etc.
• A very important principle in store keeping is FIFO or First-in-First-out. Most materials
have a shelf life, and this is specially so in the case of paints, cement, food, etc. The
oldest stock must be issued first
• Environmental Conditions within the storehouse should be conducive in terms of lighting,
temperature, ventilation, access to the racks, trade wise stacking.

8. PRESERVATION OF MATERIALS

8.1 Materials often deteriorate in storage making them useless for the intended
purpose. As such, they require adequate preservation. Preservation involves the
keeping of the materials in a fresh and serviceable condition.

8.2 India is a tropical country with a large amount of rainfall and consequently, we
have a high degree of moisture and humidity. Moisture plays a big role in the
damage of materials and the greater the moisture content in the air, the greater
the risk of damage to materials. Except in few cases dry condition for storage
are essential. Preservation therefore assumes special importance during the
monsoon season.

8.3 Similarly, insects and micro-organisms pose a major threat primarily because
they reproduce at an astronomical rate and can spread havoc in the Store in no
time at all.

9. ISSUES OF MATERIALS FROM THE STORE

The usual method of issue is by a Material Indent Form, or Materials Requisition,

which must be signed by the inventor. If a material has been issued on a verbal
instruction because of an emergency, then it must be followed by a written
document without delay. This should, however, be allowed only in exceptional cases.
The responsibility to indent for material should be specifically delegated to officers.
9.0 Only items taken on ledger charge shall be issued.
9.1 Tools, and Non consumable materials will be issued by entering in the
Daily issue Register.
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9.2 Consumable materials will be issued on Indent form.

9.3 For issue of stores to out stations proper gate pass voucher will be
prepared and approval of authorized person.

10. RETURN OF REJECTED MATERIALS

Rejections should be handled promptly and with good judgment. The responsibility
for return of rejected materials lies with the Storekeeper and the Inspecting persons.
When material rejection occurs, immediate action must be taken to return, replace
and / or dispose of the rejections. Decision to return, replace and / or dispose of the
rejected materials is the sole Responsibility of Purchasing & Store official.

11. STORES ACCOUNTING:

11.1 Need for stores accounting: Stores accounting has two aspects, the value of the
materials stored, and the physical quantity of the materials stored. Stores
accounting is necessary for many reasons, of which the following are most
important: -

11.2 The stocks represent assets of the organization and as such it is necessary to
include their value in the accounts of the organization.

11.3 It provides a means of costing of an item used.

11.4 It provides a basis for inventory control by value.

11.5 As for the second aspect, it is necessary all the time to ensure that all the materials
that have been received have been accounted for. All receipts and all issues
must be entered in stock ledgers or registers and must be accounted for.

12. SCRAP MANAGEMENT:

Scrap is inevitable in a training institute. Scrap has a value and must be treated as
any other stores item. It should be accounted for properly and stores personnel
are responsible for it. Collect, sort and prepare the scrap metal and waste. Each
has a different value and if all are mixed up, their value may fall very low. Different
items will have their own buyers. Sorting, categorizing and preparing the scrap are
therefore, important.

Items like empty cement bags, paper, cardboard boxes, wood shave, GI, MS, Steel,
Aluminium, copper, plastic and wood be salvaged, converted into scrap and shall be
taken on ledger charge as scrap through a casual receipt voucher and accounting unit

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will be in Kgs. When considerable quantity is accumulated these can be disposed of in

the local market.

13. STOCK VERIFICATION:

13.1 Physical Stock Taking is the process of counting, weighing, measuring,

etc. of all the items in the stock and recording the results of such an
exercise. The objective of stock taking is as follows: -

13.2 It is a statutory necessity.

13.3 To verify the accuracy of the stock records.

13.4 To disclose the possibility of fraud, theft, loss etc.

13.5 To reveal any weakness in the overall storage system, to make improvements.

13.6 To enable better control of inventories.

13.7 Various methods of stock verification can be adopted. Annual stock taking
shall be carried out before closure of every financial year. As per statutory
requirement each item must be physically checked as per its unit of
measurement at least once in a year and entry to the effect that the physical
stock verification is carried out by way of counting, weighing, or measuring and
found correct to be made in the relevant ledger pages and initialled by the
verifying officer. Discrepancies if any found are recorded and immediately
investigated.

13.8 The stock check should be planned in such a way that all the items are checked at
least once in a year and the important items and costly or attractive items checked
two, three or four times a year.

13.9 A board of Officers will be ordered by the concerned Director of the Institute.

14. SAFETY OF STORES

The term Safety encompasses the safety of the materials, facilities used, and the
safety of the personnel working in a Storehouse.

14.1 ACCIDENTS

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One of the important responsibilities of the Stores personnel is to prevent accidents

from taking place in a Store. Accidents can cause damage to materials, machines or
facilities, and injury to workers or even their death. It is necessary, therefore, that all
precautions are taken to avoid accidents. The worst case one can visualize is a fire
where the entire premises can be destroyed.
Some of the main causes of accidents in a Store are given below: -

Materials falling from racks, Wires, unwanted ropes, steel rods or empty cartons kept
carelessly on walkways. Injury arising from lifting very heavy loads, or normal loads
unscientifically. Collisions with bins. Falling while climbing to reach the upper shelves.
Injury to hands resulting from lifting or handling of materials. Slipping on oil, grease or
even water spillages. Injury caused by nails left on empty cases and battens of boxes.
Injury from corrosive acids. Dropping goods on one’s feet without protective boots.
Most of the accidents occur due to non-observance of precautions, carelessness and
indiscipline. Accidents also arise from poor facilities like poor lighting, wobbly ladders or
racks, badly laid out bins etc. Good supervision in the matter of observance of safety
rules cannot be overstressed. Stores personnel should educate, encourage and advise
workers to change their attitudes and give the highest priority for good housekeeping.

15. FIRE PREVENTION:

One of the major hazards in a Store relates to fire. It is necessary to take every precaution
against fire and ensure that all fire regulations are strictly observed by all the staff. It is
needless to add that adequate measures are also to be provided to fight a fire in case one
occurs. This might range from having a foam extinguisher in a small store to installing a
water reservoir, generator and firefighting pumps in a very big store. A place where in
flammable articles are stored, is especially vulnerable. It would also be a very desirable
practice to have periodic fire drills so that people know what is to be done in case of a fire.
Stores personnel should also be trained in firefighting and specific responsibilities given to
specific people so that there is no confusion when a fire occurs.

Fire is caused usually by an accident. While safety measures are necessary, prevention of
accidents is also extremely important.

16. SECURITY OF STORES:

Security in all Stores should be properly planned and organized. Doors should be strong
and provided with good locks and windows should be provided with iron grills or wire
mesh.

16.0 The internal layout is arranged in such a way that there is a spacious issue
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counter where people can obtain materials without entering the storehouse.

16.1 Stockyards should be enclosed with fencing which is adequately high. For extra
Protection there could be a barbed wire fence along the top of a brick wall. Gates
similarly should be strong and locked.

16.2 Custody of keys: All keys of storehouse and stockyards should be numbered, and
specific persons must be made responsible for them. duplicate keys should be
restricted. In case where a key lost, a full enquiry should be held and the lock
changed, and not a duplicate key made. In this regard a master list of keys with
numbers (Permanent/Temporary) should be maintained.

16.3 Entry into Store Premises: No one except the authorized staff should be allowed
access into the stores. Staff coming to receive materials issued from the Stores
should not have access to the storage area.

16.4 Housekeeping: Good housekeeping is one of the major responsibilities of every

Stores Supervisor. Neat and orderly premises are not only a morale booster but also
an important element in accident prevention.

16.5 Theft/Pilferage/Malpractice: It is usually said that there is a latent urge in

everybody to steal, which is activated when the environment is congenial to its
manifestation. Precaution against theft involves the creation of an
environment which is not congenial for these instincts to be manifested.

16.6 Loss of Stores: Any loss of stores shall immediately be reported to the
institutional head. When the person responsible for such loss is unable to
explain a discrepancy, Loss statement will be prepared as per the format attached
at Appendix I and will be submitted to DG NAC for his approval through Director Finance.
After the approval of the Loss Statement, write-off should be done, and stock records
adjusted accordingly.

16.7 Precaution against Fire: One of the major hazards in a Store relates to fire. It is
necessary to take every precaution against fire and ensure that all fire regulations
are strictly observed by all the staff. Adequate firefighting equipment should be
provided. Stores personnel should be trained in firefighting. Instructions contained
in Para 15.2 above shall be followed.

16.8 Tally Cards / Bin Cards: These should be kept up dated and hung/placed suitably on
the racks/almirah /stacks.

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Sanmarg Projects Private Limited

OUTSOURCING OF WELDERS

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OUT SOURCING OF WELDERS
W.E.F.: 15.05.2019

1. PURPOSE:

The purpose of this SOP is to define a procedure for Outsourcing the welders in the
pilferage/leakage on Cross Country Pipeline.

2. SCOPE:

The scope of this SOP explains how to select the welder for any emergency
preparedness.

3. SAFETY REQUIREMENTS:

a) Ensure that all the safety requirements while doing the job are met as per OISD
guidelines
b) PPE Required:
➢ Helmet
➢ Goggles
➢ Safety Shoes
➢ Hand Gloves (Normal, Electrical & Welding)
➢ Cover All
➢ Ear Muffs/Ear Plugs

4. REFERENCES:

• API 1104 - Welding of pipeline and Related Facilities

• API 1107 - Pipeline Maintenance Welding Practices.

5. PROCEDURE:

• Welder should hold WQT in last six months for a reputed concern.
• The welders may have to qualify the Welders Qualification Test (WQT) or Procedure
Qualification Test (PQT) or any test for assessing the suitable.
• The Minimum experience of the welders should have to be at least 2 years

6. RESPONSIBILTY:

• Project Incharge

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REFERENCES

Sanmarg Projects Private Limited

REFERENCES

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REFERENCES

REFERENCES: This Standard Operating Procedure (SOP) shall be read in conjunction with the
following standards, codes and publications.

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
ASME B31.8 Gas Transmission and Distribution Piping System

ASME B31.8 S Managing System Integrity of Gas Pipeline

ASME B 31.3 Process Piping

ASME PCC-2 Repair of Process Equipment and Piping

ASME B 31 G Manual for Determining the Remaining Strength of Corroded Pipelines

API 5L Specification for Line Pipe

API 1102 Recommended Practice for Steel Pipelines Crossing Railroads and
Highways.

API 1104 Standard for Welding Pipelines and Related Facilities

API 1107 Recommended Pipeline Maintenance Welding Practices

API 1109 Recommended Practice for Marking Liquid Petroleum Pipeline Facilities

API 1110 Recommended Practice for Pressure Testing of Liquid Petroleum

Pipelines.

API 1117 Movement of In-Service Pipelines

Managing System Integrity of Hazardous Liquid Pipelines

API 1160

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REFERENCES

API 1161 Guidance Document for The Qualification of Liquid Pipeline Personnel

API 1163 In-Line Inspection Systems Qualification Standard

API 1166 Excavation Monitoring and Observation

API 2009 Safe Welding, Cutting, And Other Hot Work Practices in The
Petroleum and Petrochemical Industries

Repairing Crude Oil, Liquified Petroleum Gas, And Product Pipelines

API 2200

Procedure for Welding or Hot Tapping on Equipment in Service

API 2201

NACE-SP-01-69 Recommended Practice Control of External Corrosion on Underground

or Submerged Metallic Piping Systems

NACE-SP-01-75 Recommended Practice - Control of InternalCorrosion in Steel

Pipelines Systems.

OISD-STD-141 Design, Construction and Inspection Requirements for Cross Country

Liquid Hydrocarbon Pipelines

OISD-STD-226 Natural Gas Transmission Pipelines and City Gas Distribution

Networks

OISD-STD-124 Predictive Maintenance Practices

OISD-STD-105 Work Permit System

OISD-STD-130 Inspection of Pipes, Valves and Fittings

OISD-STD-125 Inspection and Maintenance of Mechanical Seal

OISD-STD-137 Inspection on Electrical Equipment

OISD-STD-142 Inspection on Fire Fighting Equipment

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REFERENCES

OISD-STD-178 Guidelines on Management of Change

OISD-STD-233 Guidelines on Inspection of on land Non-Pig gable Pipelines

PRCIPR-218-9307 Pipeline Repair Manual

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PIPELINES MAINTENANCE PHILOSOPHY

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PIPELINES - MECHANICAL MAINTENANCE PHILOSOPHY

SR. DESCRIPTION OISD NORM SANMARG SOP Ref. & Pg.

NO. PRACTICE No.
1. STRAINER CLEANING HALF YEARLY HALF YEARLY SPPL/SOP/40

2. FILTER CLEANING HALF YEARLY HALF YEARLY SPPL/SOP/33

3.0 MAINTENANCE OF PUMPS SPPL/SOP/43

3.1 VIBRATION ANALYSIS - MONTHLY SPPL/SOP/43

3.2 OIL ANALYSIS - HALF YEARLY SPPL/SOP/43

3.3 ALIGNMENT ONCE IN TWO YEARLY SPPL/SOP/43

YEAR
3.4 PREV. MAINT CHECKS YEARLY HALF YEARLY BY SPPL/SOP/39, 43
MAINT

4. TSV CALIBRATION YEARLY YEARLY SPPL/SOP/38

5. UT GAUGING OF PIPING ONCE IN 3 ONCE IN 3 YEARS SPPL/SOP/30

YEARS
6. VISUAL INSPECTION OF YEARLY YEARLY SPPL/SOP/03
STATION FACILITIES

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PIPELINES CORROSION MONITORING AND MAINTENANCE PHILOSOPHY

SR. DESCRIPTION PNGRB NORM SANMARG PRACTICE

NO.
1. TRU/ CPPSM UNIT POWER AND FORTNIGHTLY FORTNIGHTLY
PSP READING AT FEEDING POINT
2. INSPECTION OF RECTIFIERS QUARTERLY
QUARTERLY

3. ROAD/RAILWAY/RIVER CASED
QUARTERLY QUARTERLY
CROSSINGS
4. PSP ON READING AT TLP
QUARTERLY QUARTERLY
LOCATIONS
5. INSTANT OFF POTENTIAL AT TLP
ONCE IN YEAR ONCE IN YEAR
LOCATIONS
6.
CURRENT CONSUMPTION DATA ONCE IN A YEAR ONCE IN YEAR

7.
INSULATING JOINTS ONCE IN A YEAR ONCE IN YEAR

8.
SURGE DIVERTER ONCE IN A YEAR ONCE IN YEAR

9. ONCE IN 5 YEARS ONCE IN 5 YEARS

CIPL SURVEY

10. CAT AND DCVG TO ELABORATE TO ELABORATE COATING

COATING DEFECTS DEFECTS
11. SAFETY APPLIANCES AGAINST SIX MONTHS
INTERFERENCE FROM FOREIGN QUARTERLY
OBJECTS
12.
INSPECTION OF CORROSION
NOT SPECIFIED ONCE IN A SIX MONTHS
COUPON

13. CORROSION INHIBITOR DOSING BASED ON CORROSION BASED ON CORROSION

RATE RATE

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14.
MUCK ANALYSIS BASED ON MUCK BASED ON MUCK

15. INTELLIGENT PIGGING OF NOT TO EXCEED IN 10 ONCE IN 10 YEARS

PIPELINES YEARS

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