SOP Field Engineering Department - oilweb.oilindia.in Field... · Field Engineering Department ... Engine Overhauling 18. Oxy-Fuel Gas Welding ... Tools SOP 35. Welding & Cutting

Field Engineering Department

Directory of S.O.P.Directory of S.O.P.Directory of S.O.P.Directory of S.O.P.

Index

1. Using a Ladder

2. Crude oil Despatch Pump

3. Lathe Machine

4. Crane EOT

5. Pipe Line Laying

6. Crude Oil StorageTank cleaning and steam coil

replacement job at CTF.

7. Lifting Manual. 8. Gen. Set

9. IR Filter

10. Spray Painting

11. Welding

12. Pedestal Grinding Machine

13. Air Compressor Portable

14. Milling Machine

15. Bendsaw Machine

16. Engine Stationary

17. Engine Overhauling

18. Oxy-Fuel Gas Welding

19. Air Compressor Fixed

20. Shaping Machine

21. Roof Repairing

22. Pressure Testing

23. Jack

24. Motor Lifting at Pontoon

25. Battery Use

26. Bore well Drilling

27. Mobile Crane

28. Sulphuric Acid Handling, Battery Room

29. Hand Tools SOP

30. Pipe handling & racking.

31. Sand Blasting

32. Handling of Chlorine

33. Shop (CWS/ICE) SOP

34. Tools SOP

35. Welding & Cutting SOP

36. Engine handling at ICE shop

37. Working with Solvent

38. Drill Machine

39. Handling Liquid Nitrogen

40. Power Tools

Kept Intentionally Blank


S.O.P.

For Using a Ladder

• Make sure the ladder is suited for the type of job you plan to do

• Before using a ladder, especially a ladder that has been stored in

the garage for a while, inspect it for cracks or broken joints.

• Place your ladder on a stable, even, flat surface. Never place a

ladder on top of another object.

• Use the 1:4 ratios to ensure a stable working platform. Place the

base of the ladder 1 foot away of whatever it leans against for

every 4 feet of height to the point where the ladder contacts at the

top.

• When using an A-frame stepladder, make sure the brace is locked

in place.

• If climbing onto another surface, make sure the ladder extends at

least three feet past the platform you're climbing onto.

• Secure tall ladders by lashing or fastening the ladder to prevent

movement.

• Always face the ladder when climbing or descending.

• Keep both feet on the ladder - never put one foot on a rung and the

other foot on a different surface.

• Do not climb higher than the second rung/srep on stepladders or

the third rung on straight or extension ladders.

• Never stand on the top or the paint shelf of a stepladder.

• Keep your belt buckle (if you have one) positioned between the

rungs so it doesn't catch.

• Never leave ladders unattended - kids love them.

• When working with electricity, use a ladder made of wood or

fiberglass.

Maintaining Ladders

� Inspect ladders regularly.

� Stepladders and extension ladders should be inspected for

broken or frozen joints or latches.

� Aluminum ladders should be inspected for cracks and

broken welds.

� Aluminum ladders should also be inspected for rough spots

and burrs before first use.

� Wood ladders should be inspected for cracked wood,

splinters, and rot. Look for broken or loose hardware.

� Protect wood ladders with linseed oil or clear sealant.

� Never paint a wooden ladder - the paint may hide

imperfections such as rot or cracks.

� Fiberglass ladders are protected with a clear sealant.

� If the fiberglass is damaged through the sealant, sand lightly

before applying another coat of lacquer

Field engineering DepartmentField engineering DepartmentField engineering DepartmentField engineering Department

S.O.P.

CRUDE OIL DESPATCH PUMP

1. Check the following safety devices are there in order:

(a) A barrier wall with seal between prime mover and pump

(b) Spark arrestor on the insulated exhaust of the prime mover

(c) Safety Relief Valve (SRV) on the delivery line with its outlet to

pump suction line to avoid spillage

(d) Guard on all rotating parts

(e) High water temperature switch, high/low lube oil alarm etc.

(f) Pressure gauges

(g) Adequate number of fire extinguishers placed near the pump

2. Use personnel protective equipment

3. Check pump/engine and surrounding area for cleanliness

4. Check oil level in the crankcase of prime mover and pump

5. Check water level in the prime mover radiator

6. Disengage the clutch

7. Open the suction and circulating lines of the pump

8. Open the suction valve of the storage tank /line.

9. Check for proper functioning of the pressure recorder / gauge in

suction and delivery lines

10. Open the bypass valve and shut the delivery valve

11. Open the fuel line of the prime mover

12. Start the engine and observe for 5 to 10 minutes

13. Inform receiving section of the tank farm

14. Engage the clutch to run the pump and observe for about 5 minutes

15. Throttle the by pass valve slowly and to open the delivery valve

slowly

with close observation on the pressure gauge for at least 10 minutes

for stabilization of required operating pressure

16. Close the bypass valve completely

17. Check for proper lubrication of the lubricating points of the pump

18. Check oil temperature ( 60° to 70° C )

19. Check lube oil pressure ( 35 psi) at operating temperature.

20. Check suction pressure

21. Check discharge pressure

22. Check functioning of pulsation dampener

23. Check for fluid leaks

24. Check oil level in gear case

25. Check oil temperature ( 60° to 70° C ) in gear case

26. Check oil seals and gland packing for any leakages

27. Record the log sheet properly

Shut Down Procedure:

1. Disengage the clutch to stop the pump

2. Run the engine on no-load condition for 2 to 5 minutes

3. Shut the fuel supply valve to stop the engine

4. Close the delivery valve of the pump

5. Close the suction valve

NOTE:

1. Stop pumping for any abnormal sound or vibration or any

hazards observed to avoid major breakdown and report to

superior / Installation Manager

2. Check and restart as per SOP after rectification of defects in

the presence of maintenance personnel.


SAFETY OPERATING PROCEDURES

Metal Lathe

Safety glasses must be worn

at all times in work areas.

Long and loose hair must

be contained.

Appropriate footwear with

substantial uppers must be

worn.

Close fitting/protective

clothing must be worn.

Rings and jewellery must

not be worn.

Gloves must not be worn

when using this machine.

PRE-OPERATIONAL SAFETY CHECKS

1. Check workspaces and walkways to ensure no slip/trip hazards are present.

2. Locate and ensure you are familiar with the operation of the ON/OFF starter and E-Stop (if fitted).

3. Ensure all guards are in place. 4. Check that the job is clamped tight in the chuck. 5. Remove all tools from the bed and slides of the machine. 6. Ensure correct speed for machining process is selected. 7. Remove the chuck key before starting the lathe. 8. Do not try to lift chucks or face plates that are too heavy for you.

9. Faulty equipment must not be used. Immediately report suspect machinery.

OPERATIONAL SAFETY CHECKS

1. Never leave the lathe running unattended. 2. Before making adjustments or measurements switch off and bring the

machine to a complete standstill. 3. Do not attempt to slow/stop the chuck or revolving work by hand.

4. Avoid letting swarf build up on the tool or job. Stop the machine and remove it.

5. Always remove the chuck key from the chuck. 6. Do not store tools and parts on top of the machine.

HOUSEKEEPING

1. Switch off the machine and reset all guards to a fully closed position. 2. Leave the machine in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Flying objects - chuck key left in chuck �� Cutting tool injury when cleaning, filing or polishing �� Rotating machine parts - entanglement �� Metal splinters/swarf �� Eye injuries

Field Engineering Departmewnt

SOP

OVERHEAD CRANE (EOT)

OVERHEAD AND GANTRY CRANE OPERATION

� Hoist operators must inspect equipment daily before use.

� Do not operate a crane or hoist if limit switches,steel ropes, chains or

other components are wornor in disrepair.

� Replace nylon or web slings immediately if excessively worn.

� Associates in the direction of travelshould be warned to move and

remainclear of a lifted load at all times.

� Loads should not be suspended over personnel below.

� Under no circumstances may anyone ride the hook or load.

� Directional movement should be made smoothlyand deliberately.

Avoid rapid movements in anydirection.

� Do not exceed the rated loadcapacity of the crane, hoist,chain, cable,

slings, or othercomponent.

� Slings, load chains and other lifting devices mustbe fully and securely

seated in the hook beforemoving a load. Remove slack from the

sling,chain, or cable before lifting a load.

Use the following practices to avoid swingingloads:

� Locate the hoist directly above thelifting point of the load before

lifting

� Lower loads directly below the hoist.

� Keep hoisting ropes vertical. Do notpull or push the load.

� Maintain two full wraps of cable on thehoisting drum.

� When lifting loads at or near capacity, test thehoist brakes by

returning the master switch orpush button to the “OFF” position after

raisingthe load a few inches off the floor. If the brakesdo not hold,

lower the load to the floor slowly anddo not operate the crane. Report

the situationimmediately and DO NOT USE until repaired.

� Ensure that all loads are lifted high enough toclear obstructions before

moving the bridge ortrolley. Whenever possible, maintain a

minimumclearance of one foot above loads and to the sides.Raise the

load only to the height necessary toclear lower objects.

� Never pull a hoist by the pendantcable.

� Never leave the controls unattended while a loadis suspended. If it

becomes necessary to leave thecontrols, lower the load to the floor.

� Familiarize yourself with the location of the disconnect switch.

� If loss of electrical power occurs, place controlsin the “OFF” position

to prevent unexpected startup upon restoration of power.

� Disconnect power to a hoist that is unsafe or inneed of repair. Arrange

to have thedisconnect switch locked and the controlpanel tagged with

and “Out of Order”or “Do Not Operate” tag. Never operatea hoist that

has been tagged with an“Out of Order” or “Do Not Operate”tag, or is

your opinion, UNSAFE TO OPERATE…

� Follow laid down Shutdown Procedure

HOISTS / CRANES Inspection Checklist

� Check for any loose or missing parts.

� Check end stops. End stops prevent thetrolley from running off the

beam.

� Know the location of disconnect switch that will cut the power

off only to the hoist or crane. Be sureit is readily accessible and not

blocked.

� Make sure all control buttons are labeled to indicate their

function.Operate each button to make sure it functions properly,

releases immediately, and does not stick.

� Check upper hoist limit switch by slowly raisingthe block to trip the

switch.

� Lower the hoist block to activate the lower limitswitch if the hoist is

so equipped, leaving at leastone turn of rope on the take-up drum.

� Make sure all control buttons arelabeled to indicate their

function.Operate each button to make sureit functions properly,

releasesimmediately, and does not stick.

� Check upper hoist limit switch by slowly raisingthe block to trip the

switch.

� Lower the hoist block to activate the lower limitswitch if the hoist is

so equipped, leaving at leastone turn of rope on the take-up drum.

� Make sure wire rope is properly seated in its drum and sheave grooves

without any slack oroverlapping.

� Operate the crane or hoist several feet in eachdirection that it travels.

Listen for any unusual noises. Look for any jerky movements.

� . Check all hooks. Hooks should not be cracked,stretched, bent, or

twisted. Each hook must havea safety latch that closes the throat of

the hook. If the latch is bent, springis broken, or is otherwise damaged

the latch must be repaired before use. Hooks should rotate freely in

block assembly without any “grinding”felt or heard.

� Check the block assembly for structural damage or cracks in any

components. Sheaves should rotate freely without any grinding felt or

heardcoming from the bearings. The sheave guard must be unbroken

and intact. No part of the sheave guard should be in contact with the

wirerope or sheave.

� Check the wire rope by lowering the block to thelowest level and

looking for the following conditions.If any of these conditions are

observed, they should bereported immediately.

� Reduced diameter of the rope. This may indicatethe rope has been

stretched, has lost its inner coresupport, or has worn outside wires.

� Any number of broken strands of wires.

� Cheack for Kinked, crushed, cut, or“bird caged” wiring, or wiringwith

heat damage.

� Check load chain for damage, wear at contactpoints, cracks, or

distorted (bent, twisted, orstretched) links. Inspect all mechanical

couplinglinks to insure linking pins are secure and in goodcondition.

Report unsafe conditions immediately.


S.O.P. for 16 inch pipe line laying

1. Get introduction to site by company’s representative 2. Discuss access to site with company’s representative. 3. Identify likely hazards to be found on site 4. Receive clearance from company’s representative to mobilise to site. 5. Obtain Clearance to Work Permit if applicable 6. Clear area of trip hazards & debris 7. Induct workers to the site 8. Ensure ALL identified permits and clearances are available and valid 9. Ensure correct PPE is worn and is in good condition 10. Use trench barriers as necessary 11. Use an alert attendant as a spotter 12. Ensure trench walls are stable and safe 13. Ensure a supply of dry welders gloves are on site 14. Put trench barrier if kept exposed 15. Take permission before using earth excavator 16. Take utmost care to protect underground cables 17. All site to be checked by authority for electrical underground cables 18. Gas tester should be available at site while working in front of industrial

area 19. Any unknown object found/observed underground to be informed to

company’s representative immediately. 20. While using trench cutting by earth excavator utmost care to be taken to

avoid touching/hitting/damaging personnel as well as hazardous object like electrical over head/underground lines, gas pipes, etc.( Hot Work Permit Needed)

21. Do not work in absence of company’s representative.

22. Put sufficient No. of warning/safety signboards 23. Clear debris, level surface, clean area before leaving the site


S.O.P. for Crude storage Tank cleaning and steam coil

replacement job

Pre-tank Entry SOP

1. All contractors’ personnel should be explained about the hazards

present in the tank farm area, inside the tank and on the tank roof to

make familiar with the hazards persist.

2. Contractor should submit the list of workers engaged by him for the

job mentioning age, address etc.

3. All workers should be fit for working in confined space.

4. First aid box is to be arranged by the contractor for workers at site.

5. Entire tank bandh area and tank roof should be gas tested, record and

action to be taken accordingly.

6. Area should be cordoned off from all sides and precautionary sign

board should be displayed.

7. Attendance registers in form ‘E’ to be maintained by the contractor

and to be counter signed by the OIL competent person every day

morning.

8. All contractor personnel to be trained for use of fire extinguishers and

sufficient and correct extinguishers as assessed by Fire service of S &

E Dept.

9. All necessary PPE should be in use.

10. A hazard assessment to be carried out by using FE department’s

“Confined Space Pre-Entry Checklist” and necessary precaution to be

taken accordingly.

11. All electrical connection to be disconnected.

12. All workers should work in working days only and working hour

should be 7.00AM to 3.00 PM.

13. Establish who will be responsible for the safety of the workers.

14. All necessary safety precaution to be assessed and addressed while

laying lines, running evacuating pump etc during emptying the tank.

15. Mobiles, matchboxes or any other ignition sources carried by the

contractor’s workers should be deposited to OIL’s supervising officer

at COCP office before going to work.

16. During Lightning & Thundering storm, all work inside and outside

the tank shall cease and workers shall leave the tank and moved to a

designated area.

17. Cold Work permit from IM to be collected.

18. Fire water hose with nozzle should always be connected to the nearest

fire hydrant point.

19. While emptying by pumping, roof manhole should be kept open to

avoid tank under vacuum condition.

20. No worker should be allowed to enter any other area except the

tank area where they are engaged to work.

Tank Entry & Cleaning SOP

1. All the points laid in pre-tank entry SOP to be followed.

2. The tank should be isolated from all lines connected to the tank by

using suitable blanks/blinds

3. Atmospheric testing: The tank atmosphere both inside & above roof

shall be tested for flammable vapors & oxygen content on hourly

basis.

� Entry should not be allowed if oxygen content is less than 19.5%

and more than 23.5%.

� Entry should not be allowed if flammable vapors are above 20%

LFL.

� The results of atmospheric testing, time and date of testing

properly signed by the tester should be recorded.

4. Daily Entry/exit format should be followed.

5. Work shall be carried out in presence of competent person of both

from OIL and contractor.

6. Always at least one attendant should be present out side the tank to

respond during any crisis happen inside the tank.

7. Life line should be used by the workers going inside the tank.

8. If forced ventilation is required, only FLP blower to be used.

9. All tools used should be non sparking tools.

10. Worker should be encouraged to wear light colored clothing as it

helps to identify inside the tank.

11. Sludge should be kept in the designated place and there should not be

any haphazard sludge deposition.

12. The floor of the tank is very slippery and steam coil and other

mechanical part inside the tank may cause tripping hazards and care

should be taken accordingly.

13. A fire man with suitable extinguishers shall remain standby.

14. Workers should be closely monitored for signs of heat stress.

Hot work SOP

1. All the points laid in pre-tank entry SOP and tank entry and cleaning

SOP to be followed

2. Hot work permit should be taken from IM on daily basis.

3. Hoses & torches associated with welding & cutting machine shall be

disconnected or removed during break periods exceeding 1 hour

unless the tank atmosphere has been retested before work resumes.

4. First fire inside the tank shall be done in presence of a fire officer,

senior officer from the department, contractor along with his

competent person and a standby fire tender.

5. Welding fumes may cause health hazard, hence welding should be

carried out intermittently to allow the fume to escape.

Returning the tank to service SOP

1. The tank inside should be thoroughly checked and ensured that no

person or material remains inside.

2. Electrical earthing should be checked.

3. Tank should be hydraulically tested before re –commissioning.

4. No person should go onto the pontoon for a period of at least 18 hours

after re-floating the roof. However with proper gas testing entry may

be permitted.

Note: The above SOP has been prepared in line with the following

standard/audit

� API STD 650: tank Inspection, Repair, Alteration and

Reconstruction.

� API STD 650: Welding Steel Tanks for Oil Storage.

� API STD 2015: Planning and managing Tank Entry from

Decommissioning through Re-commissioning.

� API RP 2026: Safe Access/Egress involving Floating Roofs of

Storage Tanks in petroleum service.

� Inspection/audit report of Sri C.Bose, CE (S&E) vide ref

No.S&E/S/5/765 dated 30.06.2008

Made By: R.Bhowmik,

Dy.CE (Proj & TF)

Date: 27.02.2012

SAFE OPERATING PROCEDURE (SOP)

MANNUAL LIFTING

1. Always plan your lift/job

2. Seek assistance even for small loads.

3. Inspect the route of the load and the place where the load to be unloaded

4. Think of alternative methods of moving the object, eg. Push, Pull,

Roll.

5. Always use chain pulley, crane etc in preference to lifting.

6. Have firm footing and make sure the standing surface is not

slippery.

7. Determine the best way to hold the load using any handles,

gripping areas or special lifting tools.

8. Get a firm on the load.

9. Keep your back straight by tucking your chin in.

10. Tighten your stomach muscles and lift with your legs.

11. Lift the load slowly. DO NOT JERCK!

12. Hold the load as close to the body as possible. Be sure you position

the load close to the body before lifting. DO NOT STRETCH TO

PICK UP THE LOAD!

13. Do not twist during your lift or when moving the load.

14. Set the load down gently. Use your legs and keep your back as straight as possible.

15. Be sure your fingers are out of the way when putting the load down and when moving the load through tight spaces.

16. Use recommended PPE ( hand gloves are must)

S.O.P. for Gen. Set

SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE EQUIPMENT IS CORRECTLY OPERATED AND MAINTAINED.

� Observe all WARNING/CAUTION notices. � All electrical maintenance/repair should be performed by Electrical Department.

� Do not operate the generator with protective covers, access covers or terminal box covers removed.

� Disable engine starting circuits before carrying out maintenance. � Disable closing circuits and/or place warning notices on any circuit breakers normally used for connection to the mains or other generators, to avoid accidental closure.

� Observe all IMPORTANT, CAUTION, WARNING, and DANGER notices leveled on the Gen. Set.,

A. CHECK AND MAINTAIN ENGINE OIL LEVEL IN CRANKCASE.

B. CHECK AND RECORD ENGINE OIL PRESSURE.

C. CHECK AND MAINTAIN COOLANT LEVEL

.

D. RECORD COOLANT TEMPERATURE.

E. CHECK VEE BELTS AND CONDITION OF BATTERIES.

F. CHECK RESERVOIR GAS PRESSURE AND DRAIN OCCASIONALLY

G. FOLLOW SAFE OPERATING PROCEDURES WHILE PUTTING UNITS

ON / OFF LINE.

H. MAINTAIN PROPER HOUSE KIPPING IN AND AROUND EQUIPMENT

RECORD EQUIPMENT PARAMETER IN THE LOG BOOK PROVIDED

I. No Naked light / Mobile inside Gen Set house.

SAFE OPERATING PROCEDURE (SOP) FOR HANDLING CHEMICALS FOR IR FILTER OF WATER TREATMENT PLANT

1. PRIOR TO WORKING WITH A CHEMICAL, READ THE INSTRUCTIONS WRITTEN ON THE CHEMICAL CONTAINER AND FOLLOW.

2. PERSONAL PROTECTIVE EQUIPMENT (PPE) MUST BE WORN WHEN WORKING

WITH CHEMICALS. 3. USE CHEMICAL SPLASH GOGGLES FOR CHEMICAL SPLASH, SPRAY AND MIST

PROTECTION. 4. USE RUBBER OR NITRILE HAND GLOVES. 5. USE RUBBER BOOTS. 6. USE RUBBERISED APRON. 7. AVOID DIRECT CONTACT WITH ANY CHEMICAL. 8. NEVER SMELL, INTENTIONALLY INHALE OR TASTE A CHEMICAL. 9. INSPECT EQUIPMENT OR APPARATUS OR CONTAINER / POT FOR DAMAGE

BEFORE ADDING A HAZARDOUS CHEMICAL. DO NOT USE DAMAGED EQUIPMENT OR APPARATUS OR CONTAINER / POT.

10. NEVER USE MOUTH SUCTION TO FILL A POT. 11. KEEP EYE WASHES AND SHOWER EXITS CLEAR. 12. NEVER EAT, DRINK, CHEW GUM, APPLY COSMETICS OR WEAR OPEN TOED

SHOES. 13. CONFINE HAIR, LOOSE CLOTHING AND JEWELLRY. 14. DO NOT HANDLE CHEMICALS UNLESS YOU HAVE BEEN PROPERLY

INSTRUCTED. 15. DO NOT WORK ALONE DURING CHEMICAL HANDLING.

16. KEEP YOUR HAND AND FACE CLEAN. WASH THOROUGHLY WITH SOAP AND WATER AFTER HANDLING ANY CHEMICAL AND WHENEVER YOU LEAVE THE WORK PLACE.

17. AVOID DIRECT CONTACT WITH ANY CHEMICAL. >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>><<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<



Spray Painting Plant

DO NOT use this machine unless it is instructed

you in its safe use and operation and has given

permission.



Long and loose hair must be

contained.



worn.

Close fitting/protective clothing

must be worn.


not be worn.

A respirator fitted with

approved respiratory cartridges

may be required.


1. Ensure no slip/trip hazards are present in workspaces and walkways. 2. Locate and ensure you are familiar with the operation of the ON/OFF starter. 3. Locate and check air isolation valve. 4. Visually check that the primary spray booth filters are in sound condition.

5. Check hoses and fittings are in good condition and are properly connected. 6. Check air pressure regulator and pressure gauge operates. 7. Ensure fume extraction unit is on before beginning to spray.

8. Faulty equipment must not be used. Immediately report suspect plant.


1. Close water drain tap on both air compressor and regulator liquid traps. 2. Adjust pressure regulator to suit work requirements. 3. Place the workpiece in a position where the spray gun operator always has the

spray between themselves and the exhaust fan.

HOUSEKEEPING

1. Switch off the compressor. 2. Turn off fume extraction. 3. Ensure solvents, paints etc. are stored in an approved storage facility. 4. Leave the work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Compressed air �� Hazardous substances �� Whipping hoses �� Explosions �� Spontaneous combustion

FORBIDDEN

� Directing air stream at yourself or other people � Spraying without a compliant respirator


Manual Metal Arc Welder



permission.


at all times in addition to

welding mask.


contained.

Sturdy footwear with rubber

soles must be worn.


clothing to cover arms and

legs must be worn.

Respiratory protection

devices may be required for

some operations.

Oil free leather gloves and

spats must be worn when

welding.


not be worn.

A welding mask with correct

grade lens for MMAW must

be worn.


9. Ensure no slip/trip hazards are present in workspaces and walkways.

10. Ensure the work area is clean and clear of grease, oil, and any flammable

materials.

11. Keep the welding equipment and work area dry to avoid electric shocks.

12. Ensure the gloves are dry and free from holes to avoid electric shocks.

13. Ensure electrode holder and work leads are in good condition.

14. Ensure fume extraction unit is on before beginning welding operation.

15. Ensure other people are protected from flashes by closing curtain to

welding bay or by erecting screens.

16. Faulty equipment must not be used. Immediately report suspect

equipment.


1. Keep welding leads as short as possible and coil them to minimise

inductance.

2. Ensure the electrode holder has no electrode in it before turning on the

welding machine.

3. Ensure current is correctly set according to electrode selection.

4. Do not use bare hands and never wrap electrode leads around yourself.

5. When welding is finished or interrupted, remove electrode stub from

holder and switch off power source.

HOUSEKEEPING

5. Switch off the machine and fume extraction.

6. Hang up electrode holder and welding cables and leave the work area in a

safe, clean and tidy state.

POTENTIAL HAZARDS

� Electric shock � Fume � Radiation burns to eyes

or body

� Body burns due to hot or molten materials � Flying

sparks

� Fire


Pedestal Grinder



permission.




contained.



worn.




not be worn.

Hearing protection must be

used when using this

machine.

Only one person may operate this machine at any one time.


1. Check workspaces and walkways to ensure no slip/trip hazards are present.

2. Ensure all guards and safety shields are in position before starting the grinder.

3. Ensure that the wheels do not touch the work rest and that the gap between wheel and rest is no greater than 1.5mm.

4. Check that wheels are running true and are not glazed or loaded. 5. Locate and ensure you are familiar with the operation of the ON/OFF

starter. 6. Faulty equipment must not be used. Immediately report any suspect

machinery.


1. Stand to the side of the wheels when starting up. 2. Let the wheels gain maximum speed before starting to grind. 3. Do not grind on the side of the wheel. 4. Small objects must not be held by hand. 5. Never leave the machine running unattended. 6. Do not bend down near the machine whilst it is running. 7. Never force the workpiece against a wheel. 8. Slowly move the workpiece across the face of the wheel in a uniform

manner. 9. Coolant spilt on the floor should be immediately absorbed.

HOUSEKEEPING

1. Switch off the machine. 2. Leave the machine in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Hot Metal �� Sparks �� Noise �� Sharp edges and burrs

�� Entanglement �� Wheels ‘run on’ after switching off �� Eye injuries

FORBIDDEN

� Workpiece must never be held with gloves, cloth, apron or pliers � Grinding non-ferrous metals

SOP

Portable Air Compressor



18. Locate the compressor in a suitable location for safe operation. 19. Lock the wheels on the base of the compressor to prevent

movement. 20. Check that all fittings and connections are in good condition

prior to starting. 21. Check all fittings are securely connected prior to being

pressurised. 22. Faulty equipment must not be used. Immediately report suspect

machinery. 23. Locate and ensure you are familiar with the operation of the

ON/OFF starter.


6. Start the compressor noting pressure increase and cut-out/cut-in pressure.

7. Listen for any air leaks from any flexible airlines and immediately report if any leaks are observed.

8. Adjust pressure regulator to suit work requirements.

9. Check the compressor at regular intervals.

HOUSEKEEPING

7. Switch off machine.

8. Leave the machine, hose and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Unsecured hoses whipping under pressure � Compressed air


Milling Machine



permission.




contained.



worn.




not be worn.

Gloves must not be worn



1. Ensure no slip/trip hazards are present in workspaces and walkways. 2. Locate and ensure you are familiar with the operation of the ON/OFF

starter and E-Stop (if fitted). 3. Do not leave equipment on top of the machine. 4. Check that machine guards are in position. 5. Ensure cutter is in good condition and securely mounted. 6. Check coolant delivery system to allow for sufficient flow of coolant. 7. Faulty equipment must not be used. Immediately report suspect

machinery.


10. Keep clear of moving machine parts. 11. Never leave the machine running unattended. 12. Follow correct clamping procedures- keep overhangs as small as

possible and check work piece is secure. 13. Set the correct speed to suit the cutter diameter, the depth of cut and

the material. 14. Before making adjustments and measurements or before cleaning swarf

accumulations switch off and bring the machine to a complete standstill.

HOUSEKEEPING

9. Switch off the machine. 10. Remove milling cutters and store them safely. 11. Leave the machine and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Sharp cutters �� Moving components - hair/clothing entanglement �� Eye injury �� Skin irritation �� Metal splinters and burrs �� Flying debris


Bandsaw



permission.




contained.

Sturdy footwear must be

worn at all times in work

areas.




not be worn.

Hearing protection may be

required for some operations.



2. Locate and ensure you are familiar with the operation of the ON/OFF

starter and E-Stop (if fitted).

3. Check that all guards are in position.

4. Ensure push stick is available.

5. Lower the blade guide and guard to full effect.

6. Start the dust extraction unit before using the saw.


machinery.


Keep fingers off the line of the cut at all times

1. Never leave the machine running unattended.

2. The workpiece should be fed forward evenly and held firmly on the table

to ensure effective control during cutting whilst keeping hands in a safe

position.

3. Use a push stick when feeding material past the blade.

4. Do not force a wide blade on a cut of small radius. Use relief cuts when

cutting sharp curves.

5. Before making adjustments switch off the saw and bring the machine to a

complete standstill.

6. Stop the machine before attempting to back the work away from the

blade.

7. Stop the saw immediately if the blade develops a ‘click’. Report it to

your teacher.

HOUSEKEEPING

1. Switch off the saw and reset all guards to a fully closed position.

2. Leave the machine in a safe, clean and tidy state.

FORBIDDEN

�� Attempting to cut very small items

� Cutting cylindrical or irregular stock


Stationary Engine



permission.




contained.



areas.




not be worn.

Hearing protection must be

worn when using this engine.


24. Ensure that the engine has operating and maintenance instructions

permanently located and clearly visible.

25. The equipment must be used in accordance with manufacturer’s

instructions.

26. Ensure the area is clean and clear of grease, oil, and objects that may be a

slip/trip hazard.

27. Familiarise yourself with and check all machine operations and controls.

28. Check all safety devices are in good condition.

29. Ensure work area is well ventilated and fume extraction is switched on

before operating.

30. Ensure all flammable materials are correctly stored before operating.


equipment.


15. Engines must not be run unless a qualified staff member is supervising

operation.

16. Only one person shall operate the engine at a time.

17. Ensure area is clear of people and equipment before operating.

18. Never leave the engine running unattended.

19. During operation and when cooling down, parts of the plant are hot

and/or rotating.

20. When finished ensure that the battery (if fitted) and fuel line are turned

off.

HOUSEKEEPING

12. Switch off equipment.

13. Leave the equipment and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

� Hot components

� Entanglement hazards – rotating shafts

� Fume

� Trapping hazards

� Crushing hazards

� Fire

� Fuel

SOP FOR ENGINE OVERHAULING

------------------------------------------------------------------------------------------------------------

i) Wear appropriate eye & skin protection.

ii) Disconnect the battery and discharge any capacitors before

beginning any repair work. Disconnect the air starter

motor, if equipped, to prevent accidental engine starting.

Put a “DO NOT OPERATE” tag the control panel.

iii) Use ONLY the correct crank shaft barring techniques for

manually rotating the crank shaft.

Do not attempt to rotate the crankshaft by pulling

or prying on the fan. This practice can cause serious

personal injury, property damage, or damage of the fan blades.

iv) If an engine has been operating and the coolant is hot, allow

the engine to cool and slowly loose the filler cap and relieve

the pressure from the cooling system.

v) Do not work on anything that is supported ONLY by lift

jack or a hoist. Always use blocks or correct stands to

support the product before performing any service work.

vi) Relive all pressure in the air, gas, coolant & oil from the

engine that have to be worked upon. Do not check for

pressure leaks with hand (use a board or a piece of cardboard) as it may cause personal injury.

vii) Always use tools that are in good condition. Make sure user

understand how to use them before performing any service

work.

viii) Always use same fastener part number (or equivalent) when

replacing fasteners.

ix) As far as possible, make all repairs on a level, hard surface.

x) Be careful when cover plates are removed. Gradually back

off the last two bolts or nuts that are located at opposite

ends of the cover or device. Then pry the cover loose in

order to relive any spring pressure or other pressure before

the last two bolts or nuts are completely removed.

xi) Do not damage wiring during removal operations.

xii) Tighten connections to the correct torque. Ensure that all

clamps, guards and shields are instated carefully. This will

help to prevent damage from: vibration, rubbing against

other parts, and excessive heat during operations.

Particular attentions for correct installation should be given

to shields that protect against oil and fuel spray onto hot

exhaust components.

xiii) Any high speed rotating component that has been damaged

or altered should be checked for balance before reusing.

xiv) Avoid touching heater and radiator hoses and other hot

engine parts.

xv) Avoid breathing exhaust fumes. Always vent the fumes

outsides of the shop.

xvi) Keep hands away from fans and other moving parts.

xvii) Remove the ignition key to prevent accidental starting of

the engine.

xviii) Ensure that all of the “safety” signs on the product are read and under stood

xix) For initial start-up of a new engine or for an engine that has

been serviced, make provisions to stop the engine if an over

speed occurs. This can be accomplished shutting off the fuel

supply and/or air supply to the engine.

------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------


Oxy-Fuel Gas Welding

DO NOT use this equipment unless it is instructed


permission.

PERSONAL PROTECTIVE EQUIPMENT

Welding goggles must be


areas.


contained.



areas.




not be worn.

Oil free leather gloves must

be worn when welding.



33. Keep area clean and free of grease, oil and other flammable material.

34. Gas hoses must be in good condition and not create a tripping hazard.

35. Before lighting up make a visual inspection of all equipment for damage.

36. Check that the area is well ventilated and fume extraction unit is on.


equipment.

PRESSURE SETTING

1. Check that the oxygen and acetylene regulator adjusting knobs are loose.

2. Check that both blowpipe valves are closed.

3. Slowly open the cylinder valves on each cylinder for half a turn only.

4. Screw in the regulator adjusting knobs slowly until the delivery pressure

gauges register 70kPa. 5. Purge and check for constant oxygen gas flow.

�� Open the oxygen blowpipe for 2 seconds valve and check the delivery

gauge.

�� If necessary re-adjust the oxygen regulator to achieve a 70kPa

pressure.

� Close the oxygen blowpipe valve.

6. Purge and check for constant acetylene gas flow.

�� Open the acetylene blowpipe valve for 2 seconds and check the

delivery gauge.

�� If necessary re-adjust the acetylene regulator to achieve a 70kPa

pressure.

� Close the acetylene blowpipe valve.

LIGHTING UP

1. Open the acetylene blowpipe valve slightly and light the blowpipe with a

flint lighter.

2. Continue to slowly open the acetylene valve until the flame no longer

produces soot.

3. Slowly open the oxygen blowpipe valve until a neutral flame is produced.

SHUTTING OFF BLOWPIPE

1. Close the acetylene blowpipe valve first.

2. Then close the oxygen blowpipe valve.

CLOSING DOWN

1. Close down both cylinder valves.

1. Open oxygen blowpipe valve to allow the gas to drain out.

2. When oxygen gauges read zero, unscrew regulator-adjusting knob.

3. Close oxygen blowpipe valve.

4. Turn off acetylene cylinder valve.

5. Open acetylene blowpipe valve and release gas.

6. When acetylene gauges read zero, release regulator adjusting knob.

7. Close acetylene blowpipe valve.

HOUSEKEEPING

14. Hang up welding blowpipe and hoses.

15. Turn off fume extraction.

16. Leave the work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

� Burns � Flying sparks

� Fumes

� Oil and grease � Combustible materials

� Flashbacks

� Radiation damage to eyes � Explosion by gas leakage

FORBIDDEN

� Lighting blowpipe with matches or lighters

� Using oil, grease or other hydrocarbons

� Using oxygen as a substitute for compressed air


Fixed Air Compressor



permission.




contained.



areas.




not be worn.

Ensure all flammable

materials are safely stored.



39. Locate the compressor in a suitable location for safe operation.

40. Lock the wheels on the base of the compressor to prevent movement.

41. Check that all fittings and connections are in good condition prior to

starting.

42. Check all fittings are securely connected prior to being pressurised.


machinery.

44. Locate and ensure you are familiar with the operation of the ON/OFF

starter.


21. Start the compressor noting pressure increase and cut-out/cut-in pressure.

22. Listen for any air leaks from any flexible airlines and immediately report

if any leaks are observed.

23. Adjust pressure regulator to suit work requirements.

24. Check the compressor at regular intervals.

HOUSEKEEPING

17. Switch off machine.

18. Leave the machine, hose and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

� Unsecured hoses whipping under pressure

� Compressed air

Safe Working Practices

For repairing of roof

1. Only workmen who are mentally and physically suitable should

work on sloping roofs.

2. Suitable bamboo structure should be used for all work on sloping

roofs. .

3. A suitable barrier should be erected at the edge & side of the

roof.

4. All bamboo structure or ladders must be properly supported and

securely fixed or anchored.

5. The fall of materials or articles from sloping roofs must be

prevented.

6. Particular attention should be given to all roofs and other areas

made of fragile materials.

7. When working near fragile materials erect guard rails or cover the

surface with suitable material.

8. Always use safety belt and tie it to the bamboo structure securely.

9. Never work on slippery roof that may occur due to fog or rain

water.

10. Safety belt to be used when climbing up to the roof. Position of

belt to be changed as required.

11. The bamboo structure/scaffolding to be approved by installation

manager.

12. List of workers to be submitted to the installation manager before

start of the job and any change should be approved by the

installation manager.

13. Smoking will not be permitted while working.

!4, No horseplay will be allowed.

15. The work personnel should not loiter inside the shop.

16. Cold work permits to be collected before star of the job and to be

renewed every day.

17. Working will be allowed only at day time when visibility is

adequate.

18. All necessary PPE to be used.

19. A safety briefing to be given to the work personnel before start of

the job.

20. Any distress faced by the work personnel to be brought to the

notice of the installation manager.

21. The job should be carried out in presence of a competent person

from the contractor, Civil Engg. Dept. & GWS.

22. All dangerous openings must be railed off or suitably covered.

45


Shaping Machine


you in its safe use and operation and has given permission.

Safety glasses must be worn at all

times in work areas.


contained.


substantial uppers must be worn.

Close fitting/protective clothing

must be worn.

Rings and jewellery must not be

worn.

Hearing protection must be worn



45. Ensure no slip/trip hazards are present in workspaces and walkways. 46. Check that machine guards are in position. 47. Do not leave equipment on top of the machine. 48. Ensure cutter is in good condition and securely mounted. 49. Locate and ensure you are familiar with the operation of the ON/OFF starter and E-

Stop (if fitted). 50. Faulty equipment must not be used. Immediately report suspect machinery.


25. Keep clear of moving machine parts. 26. Never leave the machine running unattended. 27. Do not leave equipment on top of the machine. 28. Follow correct clamping procedures- keep overhangs as small as possible and

check work piece is secure. 29. Ensure you have selected correct speed and rate. 30. Ensure you have set the correct depth of cut. 31. Before making adjustments and measurements or before cleaning swarf

accumulations switch off and bring the machine to a complete standstill.

46

HOUSEKEEPING

19. Switch off the machine. 20. Leave the machine and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

�� Sharp cutters �� Skin irritation �� Moving machine parts �� Eye injuries �� Metal splinters and burrs �� Loose clothing entanglement

47

S.O.P

Hydrostatic Pressure Testing of water pipe line. Field Engineering Department

OIL INDIA LIMITED

----------------------------------------------------------------

In order to prevent accident from hydrostatic test operation, it is required to make good

preparation:

� Prior to do the test

� During the pressurization process

� Depressurizing operation.

Hydrostatic test preparation:

1. Specification sheet of the equipments and or pipe line, which mentions pressure and

temperature designs are available and complete.

2. Hydrostatic test pressure and temperature standard are already clearly defined in the related

document.

3. Supported documents such as Layout and isometric drawing are available.

4. Pressure test planning has to be distributed to all relevant sections in the plant site at least two

days before the execution date.

5. Make good coordination among related sections that involve in the test.

6. All test equipments and tools shall be inspected for wear and damage.

7. Pressure measurement tools are calibrated and their statuses of calibration are still valid.

8. Pressure gauges used in the test have enough capacity. The gauges are recommended to have

150% of the maximum allowable working pressure.

9. The pressure gauge is safety type, with blowout back.

10. Pressure gauges must be installed at a proper location so that it can be easily read and do not

create additional hazards to the hydrostatic test or expose personnel to the vessel being tested.

11. All the temporary tools (such as valve, fitting, hoses, flanges, blind plate, etc) have to be rated

more than the maximum hydrostatic pressure.

12. Isolate other equipments and pipe lines that do not include in the hydrostatic test.

13. Vents are available and installed the high points to vent air. Check the vent line before testing

and make sure it is not blocked.

14. Choose drain valve at the lowest point in order to completely empty the vessel and pipe.

15. Safety relief valve is already installed. Safety relief valve setting is 1.1 times maximum

allowable working pressure.

48

16. Safety relief valve is calibrated.

17. Isolate the test area and surround it with safety line. Put appropriate safety sign at that area.

18. Do not allow person who does not have any relation with the hydrostatic test, to enter the test

area.

19. If possible perform the test from a remote area.

20. Make sure that all pipe and vessel supports are in good condition and have been inspected.

21. All hoses must be tied down.

22. Water temperature must be more than 16oC (60 F).

23. The hydrostatic-pressurizing pump is completed with safety relief valve.

24. Wear proper personal protective equipments.

25. Do not start the test if a problem is identified.

26. Issue a work safety permit by authorized personnel.

Pressurization process:

1. Remove all air from the vessel and pipe line by water through vent line.

2. Pressurization is conducted gradually/slowly.

3. Mark all leak points and repair them before preceding the test.

4. Do not monitor during pressurization step directly from the front of sight glass or level glass.

De-pressurization process:

1. Start de-pressurization by opening gradually the vent valve. Do it slowly.

2. Do not open the drain valve if the vent valve if still closed. This is to avoid vacuum condition

inside the vessel.

3. Open the lowest drain point to completely remove water from the vessel and pipeline.

4. Ensure that no remaining pressure trapped inside the pipe line or vessel.

Note: Any hazard may vary with time of operation, location or any other factor, concern engineer

should evaluate and include accordingly in the S.O.P.

49

S.O.P for the use of Jacks

1. Employees will be properly and thoroughly trained before attempting to do any

work with or on any jack.

2. All jacks must be inspected for any faulty or missing parts, hydraulic oil leaks,

etc., before being put into use. Any jack that does not pass an inspection will not be

used until repaired or will be discarded from use.

3. When jacks are used on ground surfaces, wood blocking no less than two times

the size of the jack base will be used.

4. Wood blocking or metal plating will not be used to extend the height of the jack.

5. Jacks will be operated vertically with the jack under the center of the load.

Never exceed the load capacity of the jack.

6. Wood blocking with a minimum of 2 inches larger than the head of the jack

must be used when there is metal to metal contact between the jack head and the

load.

7. Jack handles will be operated only when the wing is unobstructed and with the

employee standing to one side.

8. “Cheater” extensions are not permitted.

9. After loads are raised to the desired height, wood blocking will support the load.

10. Do not drop or throw jacks. Damage may occur.

11. When operating jacks on floors, do not exceed the load capacity of the floor

when performing the lift.

50

SAFE WORKING PROCEDURE

LIFTING OF ELECTRICAL MOTOR FROM PONTOON

• Recommended PPE

i.) Hand Gloves

ii.) Safety shoes

iii.) Helmet

iv.) Life saving jacket/device

1) Check that work area is clear. 2) Electrical motor to be disconnected by electrical personnel.

3) Check all tools 4) Use recommended PPE

5) Keep life saving floating device

6) To be carried out under supervision of competent person.

7) To be carried out under supervision of competent person.

8) Chain pulley block to be used should be inspected before use. 9) Check walk way 10) Remain alert and careful.

11) Minimum 4 persons are required to carry out the job.

12) Use winch for safe pulling. 13) Follow procedure for working in confined space 14) Clean up work area. 15) Follow SOP for manual material handling

51

Battery User safety precautions

SOP

Disassembly

Never disassemble a battery, as the materials inside may be toxic and may damage skin and clothes.

Short-circuiting

Never attempt to short-circuit a battery. Doing so can damage the product and generate heat that can

cause burns.

Throwing batteries into a fire or water

Disposing of a battery in fire can cause the battery to rupture. Also avoid placing batteries in water, as

this may cause the battery to fail.

Soldering

Never solder anything directly to a battery. This can destroy the safety features of the battery by

damaging the safety vent inside the cap. Permanent connections to an energy cell may be made by spot

welding solder tags to the terminals. A soldered connection can subsequently be made to the tag.

Inserting the batteries with their polarities reversed

Never insert a battery with the positive and negative poles reversed as this can cause permanent

damage to the battery which may swell or rupture.

Charging

Never charge with an unspecified charger or specified charger that has been modified. This can cause

breakdown of the battery or swelling and rupturing.

Never attempt to charge a battery which has been physically damaged.

Overcharging at high currents and reverse charging

Never reverse charge or overcharge with high currents (i.e. higher than rated). Doing so causes rapid

gas generation and increased gas pressure, thus causing batteries to swell or rupture.

Don't leave the battery in the charger once it is fully charged.

52

Installation in equipment (with an airtight battery compartment)

Always avoid designing airtight battery compartments. In some cases, gases (oxygen, hydrogen) may

be given off, and there is a danger of the batteries bursting or rupturing in the presence of a source of

ignition (sparks generated by a motor switch, etc.).

Use of batteries for other purposes

Do not use a battery in an appliance or purpose for which it was not intended. Differences in

specifications can damage the battery or appliance.

Short-circuiting of battery packs

Special caution is required to prevent short circuiting any battery since the consequences can be very

dangerous. Care must be taken during the design of the battery pack shape to ensure batteries cannot

be inserted in reverse. Also, caution must be given to prevent accidental short-circuiting of the battery.

Using old and new batteries together

Avoid using old and new batteries together. Also avoid mixing batteries using differing cell

chemistries such as ordinary dry-cell batteries, Ni-Cd, NiMH batteries or with another manufacturer's

batteries. Differences in various characteristic values, etc., can cause damage to the batteries or the

product.

Storage

Store the batteries in a cool place and when in use don't allow them to remain in environments which

may be subject to overheating. (e.g. direct sunlight in a locked car)

ESD (Electrostatic Discharge) Bags

Do not put batteries into plastic bags designed to protect components from electrostatic discharge.

These bags are made from conductive material which could cause the battery to be short circuited.

Other Precautions

Batteries should always be charged prior to use. Be sure to charge correctly.

Warning Notice

Be sure to indicate this safety warning clearly in all operating instructions as a handling

restriction for ensuring safety

53

SAFETY GUIDELINES FOR BOREWELL DRILLING

SOP

� Safety Guidelines for Movement of Drill Rigs :Before moving a rig, the

operator must do the following:

1. As practical, inspect the planned route of travel for depressions, mud,

ditches, road curbs, and other long and horizontal obstacles and other

obstacles.

2. Check the brakes of the truck/carrier, especially if the terrain along the

route of travel is rough or sloped.

3. Discharge all passengers before moving on rough or steep terrain.

� Drill rig safety and maintenance is the responsibility of the drill rig operator.

� Before a drill rig is positioned to drill, the area should be cleared by removing

obstacles and the rig should be leveled if sloped. The cleared/leveled area should

be large enough to accommodate the rig and supplies.

� The location of overhead and buried utility lines must be determined before

drilling begins, and their locations should be noted on boring plans.

� When overhead power lines are close, the drill rig mast should not be raised

unless the distance between the rig and the nearest power line is at least 6 m, or

other distance as required by local ordinances, whichever is greater. The drill rig

operator or assistant should walk completely around the rig to make sure that

proper distance exists.

� When the drill rig is positioned near an overhead line, the rig operator should be

aware that hoist lines and power lines can be moved towards each other by wind.

Presence of power lines requires special safety provisions as they present serious

danger

� Safe Use of Hand Tool

54

� Each tool should be used only to perform tasks for which it was originally

designed.

� Damaged tools should be repaired before use or they should be discarded.

� Safety goggles or glasses should be worn when using a hammer or chisel. Nearby

coworkers and by standers should be required to wear safety goggles or glasses

also, or to move away.

� Tools should be kept cleaned and stored in an orderly manner when not in use.

� Minimum Protective Gear : Hard hat, Safety shoes & Gloves

� Safety goggles or glasses should be worn when:

(1) Driving pins in and out of drive chains,

(2) Replacing keys in tongs,

(3) Handling hazardous chemicals,

(4) Renewing or tightening gauge glasses

(5) Breaking concrete, brick, or cast iron,

(6) Cleaning material with chemical solutions,

(7) Hammering or sledging on chisels, cold cuts, or bars,

(8) Cutting wire lines,

(9) Grinding on abrasive wheels,

(10) Handling materials in powered or semi powered form,

(11) Scraping metal surfaces,

(12) Sledging rock bits or core heads to tighten or loosen them

55

(13) Hammering fittings and connections

(14) Driving and holding the rivets.

� Safety belts and lifelines should be worn by all persons working on top of an

elevated derrick beam..

� Life vests must be used for work over water.

� Traffic Safety: Drilling in streets, parking lots, or other areas of vehicular traffic

requires definition of the work zones with cones, warning tape, etc., and

compliance with local police requirements.

� Fire Safety

1. Fire extinguishers should be kept on or near drill rigs for extinguishing small

fires.

2. If any gas or anything other than soil/rock is found in the borehole then the

stop boring and inform head F.E. immediately.

3. Work shall stop during lightning storms.

56

Mobile Crane Operation

S.O.P.

� Get proper training on crane operation and load preparation and securing.

� Prior to operating a mobile crane, the operator must make a complete walk around the

equipment to ensure that people are clear of the equipment, all equipment is in a safe

condition, and to identify any overhead electrical hazards.

� Confirm safe site conditions - checking for hazardous weather, excessive wind and mud.

� Barricades, warning signs or other methods must be used to prevent entry into a lift area or

turn radius of the crane. Traffic patterns and pedestrian safety must be considered.

� All controls must be tested by the operator prior to operating the equipment. Any malfunctions

must be corrected or repaired before operating the crane.

� Whenever there is any doubt as to safety, the operator has the authority and obligation to stop

all hoisting activities and refuse to handle loads until safety has been assured.

� Before each use - cranes must be visually inspected by the operator to make sure it is in safe

operating condition,

� Wear hard hats, safety boots, and high visibility clothing when operating or working around

cranes.

� Falling loads from mobile cranes pose a severe hazard to operators and nearby workers to be

watchful.

� Never exceed the load capacity of the mobile crane.

� If unsure about the load size and weight, calculate the weight to ensure that it meets crane’s

capacity.

� Load indicating devices, called load moment devices to be fitted in the crane

� Properly secure the loads that will be lifting.

� Inspect all slings, chains, and hooks that will be used to lift and secure the load.

� Rotate, raise, and lower the crane boom slowly. Avoid sudden stops or accelerations that could

jar the load. When rotating the load, you can use taglines or guidelines to control the arc and

swing.

� Try to avoid lifting loads over workers or over the cab of the crane. If this type of lifting is

necessary, use safety hooks or other approved devices.

� Suspended loads shall not be left unattended without proper safeguards.

� If two cranes are required to lift a load, a qualified person should be in charge of planning and

directing the lift.

� Cranes can accidentally come in contact with electrical lines. Before starting any work,

survey the site for potential electric hazards. Consider all lines energized unless they are

certified by the owner/operator and visibly grounded at the site. Always maintain the required

clearances from electrical lines. ..

� Tip-overs and instability are another mobile crane hazard. Soft or unlevel ground can cause a

crane to tip. Use outriggers to stabilize the crane when the ground surface or the load requires

it.

� Never operate a crane if the load or slope lifts the wheels off the ground.

� For stability when traveling, keep the boom steady in the direction of the movement.

57

� Boomstops should be used if there is a danger of the boom falling backward.

� Get the area clear as workers near mobile cranes can get run over if they do not pay attention

or if the operator loses sight of them.

� Operators should use an audible warning and operating signal device to notify workers of

movement.

� Workers should stay out of the way of the load, the crane wheels, and outrigger wheels.

� If the operator has a limited view, a qualified signals person should direct and communicate

the operations.

� Never ride a load on a crane.

� Always lash or secure empty hooks when moving the crane so they do not swing.

� Lack of training is the leading cause of accidents: Get trained.

� Crane operator should be certified by authority according to boom length capacity.

58

SAFE OPERATING PROCEDURE

FOR

SULPHURIC ACID HANDLING AND STORING

Handling:

� Wash thoroughly after handling.

� Remove contaminated clothing and wash before reuse.

� Use only in a well ventilated area.

� Do not get in eyes, on skin, or on clothing.

� Keep container tightly closed.

� Do not ingest or inhale.

� Do not allow contact with water.

� Discard contaminated shoes.

Storage:

� Keep container closed when not in use.

� Store in a cool, dry, well-ventilated area away from incompatible substances. Corrosives

area.

Personal Protective Equipment

� Eyes: Wear appropriate protective eyeglasses or chemical safety goggles

� Skin: Wear appropriate protective gloves to prevent skin exposure

� Clothing: Wear appropriate protective clothing to prevent skin exposure.

� Respirators: approved respirator when necessary.

59

HAND TOOLS

S.O.P

Introduction:

Hand tools include a wide variety of non-powered devices such as

wrenches, pliers, hammers, and screwdrivers. These tools may seem

harmless, but they are the cause of many injuries. The following is a

summary of safety practices related to hand tools.

General Hazards:

• The two most common hazards associated with the use of hand tools

are misuse and improper maintenance.

• Misuse occurs when a hand tool is used for something other than its

intended purpose. (An example would be using a screwdriver as a chisel.

This may cause the tip to break and strike someone).

• Improper maintenance allows hand tools to deteriorate into an unsafe

condition. (Examples would include cracked wooden handles that allow

the tool head to fly off or mushroomed heads that can shatter upon

impact).

• Specially designed tools may be needed in hazardous environments.

(Always use non-sparking tools in the presence of flammable vapors or

dusts. Insulated tools with appropriate ratings must be used for electrical

work).

Personal Protective Equipment:

• The type of personal protective equipment (PPE) needed when using

hand tools depends on the nature of the task. At a minimum, eye

protection should always be worn.

60

• The use of hand protection may also be appropriate to provide

protection against cuts, abrasion, and repeated impact.

Wrenches:

• Choose a wrench that properly fits the fastener that is to be turned.

Using the correct size reduces the chances of wrench slippage.

• Avoid using a length of pipe or other extension to improve the leverage

of a wrench. Manufacturers design wrenches so that the amount of

leverage obtained with the handle is the maximum safe application.

• Use socket wrenches for hard-to-reach areas.

• Always try to pull on a wrench (instead of pushing) in case the fastener

suddenly loosens.

• Inspect wrenches periodically for damage such as cracking, severe

wear, or distortion

Pliers:

• Do not increase the handle length of pliers to gain more leverage. Use

a larger pair of pliers or bolt cutters.

• Do not substitute pliers for a wrench when turning nuts and bolts.

Pliers cannot grip these items properly and will slip.

• Never use pliers as a hammer or hammer on the handles. Such abuse is

likely to result in cracks or breaks.

• Cut hardened wire only with pliers designed for that purpose.

• Always cut at right angles. Never rock from side to side or bend the

wire back and forth against the cutting edges.

Hammers:

• Do not use a hammer if the handle is damaged or loose.

• Never weld, heat, or regrind a hammer head.

• Remove from service any hammer exhibiting signs of excessive wear

such as cracks, chips, or a mushroomed head.

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• Match the proper type of hammer to the job it is designed to perform.

• Do not strike the surface at an angle. The hammer face should contact

the striking surface squarely. Glancing blows made with a hammer often

lead to injury.

Screwdrivers:

• Never use a screwdriver as a pry bar, chisel, punch, stirrer, or scraper.

• Always use a screwdriver tip that properly fits the slot of the screw.

• Throw away screwdrivers with broken or worn handles.

• Use magnetic or screw-holding screwdrivers to start fasteners in tight

areas.

• Never use pliers on a screwdriver for extra leverage. Only use a wrench

on screwdrivers specifically designed to accept them.

Utility Knives/Blades:

• Always use a sharp blade. Dull blades require more force and thus are

more likely to slip. Replace the blade when it starts to “tear” instead of

cut.

• Never leave a knife unattended with the blade exposed. Consider using

a self-retracting knife with a spring-loaded blade. (The blade will retract

when pressure on the knife is released).

• Keep your free hand away from the line of the cut.

• Don’t bend or apply side loads to blades by using them to open cans or

pry loose objects. Blades are brittle and can snap easily.

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PIPE HANDLING AND STORAGE S.O.P.

1. When handling pipe, use a clear communication system.

2. When handling threaded pipe three or more inches in diameter,

use a hardwood hand stick.

3. When two or more people are carrying pipe, carry pipe on

shoulders and walk out of step of each other and carry the pipe on

the same shoulder.

NOTE: For large diameter pipe, use a pipe caliper.

4. Pick up and lay down the pipe in harmony.

5. When handling pipe by mechanical means; personnel will stay

clear of the load.

6. When handling pipe by mechanical means do not put fingers or

hands into the ends of the pipe.

7. Keep feet away from pipe when pipe is lowered or picked up.

8. Keep the pipe racks in an orderly and safe condition.

9. The space around pipe racks shall be kept clear of obstruction.

10. Rack the pipes evenly and joint above a joint and in a vertical

direction.

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11. Rack the pipe so the joint ends overlap the pipe racks evenly on

both sides.

12. Pipe racked on ground racks shall not be racked higher than 10

(ten) feet above rack sills.

13. Use supports or strips between the layers of stacked pipe.

14. Pipe racks will be pined or blocked. Pins should not be under

load.

15. Do not park vehicles near the loading or unloading areas.

16. Do not walk on pipe racks that have not been secured.

17. Use PPE like hand gloves, safety boots etc

18. Avoid, if possible wet pipe racking.

19. While pipes are rolled, always tie up with rope to secure over

rolling.

64

SOP

Sand blasting

Pre Start Checks and Safety

� Ensure you have the correct equipment for the job you are doing � Drain any condensation out of the moisture traps � Check that no foreign objects have entered the hopper � Check oil levels in the compressor unit and engine � Ensure blast vessel and hoses are drained of air before disconnecting any hoses etc

� Ensure blasting area is clear of other people and animals � Compressed air is dangerous, handle with extreme care � Incorrect body protection can cause serious injury � Ensure correct sand is used for blasting and it is dry and sieved � Extra ceramic filter may need to be added if humidity is high � Filters aren’t uni directional and must be positioned in direction of arrows for air flow

Starting procedure

� Check that the air release valves and air intake valves are closed � Connect compressed air hoses and blast hose � Fill the hopper with the correct type of sandblasting sand that should also be dry and sieved

� Start the compressor unit � Open air outlet tap from compressor

When Operating

� Hold the blast hose and blast nozzle firmly and open the air intake valve � Commence blasting � Regulate the amount of sand required by using regulator tap on the bottom of the hopper

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� If ceramic filter is being used drain cock must be open slightly during operation

� Check filters regularly when used continuously

Stopping and After Use

� Hold the blast hose and blast nozzle firmly � Open the air intake valve � Commence blasting � Regulate the amount of sand required by using regulator tap on the bottom of the hopper

Stopping and After Use

� Hold the blast hose and blast nozzle firmly � Open the air intake valve � Commence blasting � Regulate the amount of sand required by using regulator tap on the bottom of the hopper

Recommended PPE

• Ear Muffs

• Hard hat

• Gloves

• Safety Boots

• Apron

• Face shield

• Breather filter

• Eye Glass

==============================================================

66

SOP

Handling of Chlorine

It is very important that the consumer is well informed regarding the properties of chlorine, the recommended procedures and recognized precaution in its safe handling. Chlorine accidents have been due to lack of knowledge and carelessly handled, it could result in serious personal injuries and property damage. The information contained in this handout is gathered from sources believed to be reliable, and is furnished as a guide for all users of chlorine.

General characteristic

• Chlorine sold as liquid chlorine in steel containers is liquefied compressed dry gas which will have both liquid and gas phase.

• Chlorine is a greenish yellow gas with an irritating and penetrating odor. Liquid chlorine is clean and amber colored.

• Chlorine by itself is non - inflammable and non - explosive. It is a hazardous and toxic chemical.

• At atmospheric pressure liquid chlorine boils at -34°C. • The gas is about two and one - half times as heavy as air. If it escapes from a container or system, it will seek the lowest level in the area and will only slowly diffuse into the atmosphere.

• The vapour pressure inside a chlorine container at ordinary temperature (30°C) is about 8. 6 Kg /cm².

• The vapour pressure goes up steeply with temperature. Therefore care should be taken to see that all chlorine containers are KEPT AWAY FROM HEAT SOURCES.

• Chlorine is only slightly soluble in water and any escaping chlorine cannot be absorbed satisfactorily in water.

• Dry chlorine dose not react with or corrode many metals such as iron, copper, steel.

• Moist chlorine is very reactive and strongly corrosive to most common metals. Therefore, every precaution should be taken to keep chlorine container valves and other equipments free from moisture.

• It reacts with ammonia readily even in traces to from white fumes. This is made use of in detecting chlorine leakages.

• Chlorine reacts readily with caustic soda, soda ash and lime. These solutions are used to absorb chlorine in case of a leak from a container

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Precautions and Procedures in handling of Chlorine Container

• Chlorine is supplied to consumers in steel containers of two standard sizes

o Cylinder - 68 kg net chlorine capacity (approx.) o Ton container - 900 kg net chlorine capacity (approx)

• The cylinder is fitted with a value at its top covered with a value protective hood. cylinder valve is equipped with a fusible plug as a safety device.

• The toner is equipper with two values located in the dished end on one side. The valves are protected by a single hemispherical hood or two hood.

• The valves are connected inside the toner to educator pipes which extend in opposite directions towards the side of the toner.

• Some toners have fusible plugs located in the dished ends as a safety device.

• Fusible plugs are designed to melt at around 75°C in order to release the inside pressure in the event of exposure to heat, as otherwise container could rupture.

• A valve consists of a valve body, spindle (or stem) , packing gland , ring packing, packing nut, outlet cap and gasket.

• Both in the interest of safety and for longer service life it is important that containers are handled with care.

• DO NOT DROP OR ALLOW TO STRIKE against other object with force. Dropping of containers from the truck either to the ground directly or any cushioning media SHOULD NOT BE ALLOWED. Sudden impact could damage the valve.

• Use crane , hoist equipment or forklift for lifting and movement. It is recommended that a channel iron lifting hood be used for handling toners. Toners are generally moved by rolling on any roll - on - platform.

• Using valve hood as a support for loading/unloading of small cylinders should be avoided.

• Secure containers against toppling and rolling off while transporting in trucks. Use strong ropes and wooden blocks as wedges. Ensure that the containers do not project outside the truck frame.

• Transport containers in trucks having side covers. Never stack toners in more one layer.

• Ensure that valve outlet caps and protective hoods are fitted while the containers are moved. Returned empty containers should have the outlet

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caps and valve protective hoods fitted properly.

Storages

• Store containers in cool, well ventilated covered place free from dampness and away from acids and other inflammable articles.

• Protect against any sources of heat (40°C max.). Containers should not be wet or muddy.

• Toners should be kept in a single row in horizontal position. Cylinders should be kept in a upright position.

• Filled containers should be used in the order in which they are received in order to avoid any container remaining unused for a longer period.

• In the case of cylinders gaseous chlorine is withdrawn through the valve with the cylinder in the upright position. To withdraw liquid, secure cylinder in inverted position with the valve end lower.

• Toners should be kept in a horizontal position with two valves in a vertical line. in this position gaseous chlorine can be drawn from the upper valve and liquid chlorine can be drawn from the lower one. (In the case of ton - containers of different design seek help from the supplier regarding positioning)

• When container valve is opened to discharge the gas and release the pressure, liquid will boil and vaporize causing the remaining liquid and the container to chill.

• Do not heat the container to withdraw chlorine at fast rate. • The amount of chlorine remaining in a container can be ascertained only by checking the weight.

Connecting to Process

• Connecting to the valve of container should be made of copper flexible tubing to withstand a working pressure up to about 18 kg/cm².

• Clamp (Yoke) and adapters are recommended for connection to the container valve outlet. As the valve outlet threads are not strong enough for direct connection, nut union type connection should be avoided. Flexible copper tubes, brass yoke clamp and adapters and lead washers are recommended to be used.

69

• The valve outlet threads should not be damaged while connection/ disconnection. Never force connections that do not fit.

• Frequent operation of valve will cause damage to the valve. The container valve is not meant for controlling the flow of chlorine. A separate regulating valve on the process side should therefore be used for this purpose.

• It is advisable to have a pressure gauge ( 0 - 25 kg/cm² ) on the line between container valve and regulating valve to monitor the cylinder pressure and to know whether a container is empty or not.

• An inverted U - type barometric leg should be always used in the chlorine discharge system, particularly where any process liquid is used, to avoid suck - back of process liquid into the container due to drop in pressure.

• When chlorinating water use a standard chlorinator equipment.

Valve Operations

• Use correct size wrench or spanner ( 3/4 " square wrench not more than 4 " long) to operate the valve.

• To open, turn stem slowly in counter clockwise direction. valve will completely open with only 1¼ turn. One complete turn of the spindle is sufficient to permit maximum chlorine discharge.

• Do not attempt to turn the valve stem further as it will damage the valve. • Never use a pipe wrench or a hammer in operating a valve stem. If the stem is stuck so that it will not open when the wrench is struck with the palm of the hand, the packing nut may be loosened about ¼ turn and the operation repeated. After the stem is freed retighten the packing nut immediately.

• When the container is empty, close the valve by turning clockwise until seated without using excessive force.

• While stopping withdrawal of gas, first close the container valve the then the process valve.

• As soon as a container is disconnected the valve outlet cap and the protective hood should be fitted.

• If withdrawal of chlorine from a container to process has to be suspended for long interval, it should be disconnected from the system and valve outlet cap and valve protective hood replaced.

70

Dealing with Emergencies

• As soon as there is an indication of the presence of chlorine in air due to leak immediate steps should be taken to correct. Even a slightest leak should not be neglected. A chlorine leak never gets corrected by itself, it always gets worse if not promptly attended to.

• All persons should be kept away from the affected area in case of a leak and only authorized trained personal equipped with suitable gas masks should investigate and taken action.

• It is advisable to move all persons on to windward side and to higher areas. If leak is extensive an effort should be made to warn all persons in the pass of gas.

• Gas masks and emergency devices should always be available at easily accessible place.

• The industrial canister type mask with a full face piece and a chlorine filter (canister) is suitable for minor leakages where chlorine concentration in the air is moderate. A bad gas mask is worse than no gas masks.

• The self containing breathing apparatus with a full face piece and a cylinder of air should be used in case of major leakages where the concentration of chlorine in the atmosphere is high.

• To locate the leak, wrap a rag on a stick, soak it in ammonia water and hold closed to the suspected point. A white fume will show the location of the leak.

• In the event of a leak in the valve the container should be positioned so that only the gas escapes and not the liquid. For example, if valve stem is leaking in a small cylinder it should be kept in an upright position to minimize the quantity of leak.

• Do not apply water to a chlorine leak. the application of a stream of water to chlorine leak is hazardous and makes the leak worse due to corrosive action of chlorine and water.

• Never throw a cylinder or toner into a pond of water. It will float when still partly full of liquid chlorine and gas will evolve never the surface. Water is not an effective absorbent for chlorine gas.

• If the leaking container is moveable, it is desirable to move it out door or to a location where the escaping chlorine will do the least harm.

• If a chlorine leak develops in transit in a populated area it is advisable to keep the transporting vehicle moving until an open country is reached in order to minimize the hazards.

71

• Leaks around the valve stem can often be stopped by tightening the packing nut, or by closing the valve and valve outlet could be closed with a clamp and blank adapter.

First Aid

• Clothing if wet with chlorine should be removed. Treat any external burns by liberal rinsing in water.

• If oxygen inhalation equipment is available oxygen be administered until the victim is able to breathe easily by himself. If patient stops breathing, start artificial respiration at once. Oxygen administration or artificial breathing should be carried out only by authorized competent persons. Anyone seriously affected by chlorine should be treated by a physician.

• Milk or butter milk could be given in mild cases of chlorine attack. • If even minute quantities of liquid chlorine enter the eyes or if eyes have been exposed to strong concentration of chlorine gas they should be flushed eighth large quantities of good running water.

72

SOP For SHOP (CWS/ICE)

i) Tie back or tuck in long hair

ii) Do not wear jewelry such as chain etc.

iii) Keep stairs, walkways, etc clean and clear

iv) Return tools and products to their proper storage location

v) Clean up spills immediately

vi) Make sure the work area has recommended illumination &

ventilation.

vii) Wear clothing and use personal safety equipment appropriate to work

being performed.

viii) Do not use electrical equipment in wet areas.

ix) Get help before lifting heavy objects.

x) Use care when climbing to avoid falls.

xi) Maintain support under objects being raised.

xii) Follow product and equipment maker’s safety recommendation.

xiii) Clean waste generated like jute, scrap spares etc. and discharge in

waste bin only.

xiv) Do not smoke inside the shop.

xv) Use safety belt as & when required.

xvi) Follow all SOP for Tools,Lifting,etc

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SOP FOR TOOLS

i) Use proper tools for the job.

ii) Do not use any tool you have not been trained to use.

iii) Do not use any tool that is not working properly.

iv) Do not keep sharp tools in your pockets.

v) Make sure safety guards are in place before using

power tools.

vi) Do not exceed any tool maker’s speed, pressure, or

power restrictions.

vii) Disconnect power tools before clearing, cleaning, adjusting or oiling.

viii) Turn off equipment when it is not in use.

ix) Follow equipment maker’s safety recommendations.

x) Before servicing any electrical equipment, lock the

power circuit in the

xi) OFF position and tag the switch to show the

equipment or circuit is being worked on.

74

Welding and cutting SOP

Welding and cutting are two forms of hot work that require special

safety considerations. Unless they are done in a designated shop area,

welding and cutting are strictly prohibited without proper

authorization. Before conducting welding or cutting operations, inspect

your equipment for the following:

• Welding cables must be completely insulated and in good condition.

• Cutting tools must be leak-free and equipped with proper fittings, gauges,

regulators, and flashback devices.

• Oxygen and acetylene tanks must be secured in a safe place.

In addition, follow these guidelines for most welding and cutting

procedures:

• Conduct welding and cutting operations in a designated area free from

flammable materials. When welding or cutting is necessary in an

undesignated or hazardous area, have someone nearby act as a fire

attendant.

• Periodically check welding and cutting areas for combustible atmospheres.

• Take care to prevent sparks from starting a fire.

• Remove unused gas cylinders from the welding and cutting area.

• Keep hoses out of doorways and away from other people. A flattened hose

can cause a flashback.

• Mark hot metal with a sign or other warning when welding or cutting

operations are complete

75

SOP for Safe Fuel handling at ICE Shop

Fuel Safety: To avoid injury when working around or with fuel, shop

personnel should follow these safety precautions.

i) Keep fuel, fuel tanks, and fuel containers away from any

sparks or flame.

ii) Do not turn ignition switch ON or crank the engine with a

fuel line disconnected.

iii) Have the proper fire extinguishers available.

iv) Always relive fuel pressure before performing any engine

repairs.

v) Store fuel only in a approved container.

vi) Do not fill containers completely with liquid fuel. Leave about

25mm (one inch) for expansion.

vii) If filled containers must be transported, make sure they are

secured to prevent tipping.

viii) Do not store a partially filled container for a long time.

ix) Never leave containers open after filling or pouring from the

container.

x) Before welding, grinding or cutting on a gas engine, turn off

the gas supply and run the engine until it stops and

disconnect the battery.

76

SOP

Handling of Engine at ICE Shop

NOTE: To avoid injury when working on an engine, shop personnel

should follow these safety precautions.

xx) Wear appropriate eye & skin protection.

xxi) Disconnect the battery and discharge any capacitors before beginning

any repair work. Disconnect the air starter motor, if equipped, to

prevent accidental engine starting. Put a “DO NOT OPERATE” tag

the control panel.

xxii) Use ONLY the correct crank shaft barring techniques for manually

rotating the crank shaft.

Do not attempt to rotate the crankshaft by pulling

or prying on the fan. This practice can cause serious personal injury,

property damage, or damage of the fan blades.

xxiii) If an engine has been operating and the coolant is hot, allow the engine to cool and slowly loose the filler cap and relieve the pressure from the

cooling system.

xxiv) Do not work on anything that is supported ONLY by lift jack or a

hoist. Always use blocks or correct stands to support the product before performing any service work.

xxv) Relive all pressure in the air, gas, coolant & oil from the engine that

have to be worked upon. Do not check for pressure leaks with hand (use a board or a piece of cardboard) as it may cause personal injury.

xxvi) Always use tools that are in good condition. Make sure user

understand how to use them before performing any service work.

xxvii) Always use same fastener part number (or equivalent) when replacing

fasteners.

xxviii) As far as possible, make all repairs on a level, hard surface.

xxix) Be careful when cover plates are removed. Gradually back off the last

two bolts or nuts that are located at opposite ends of the cover or

device. Then pry the cover loose in order to relive any spring pressure

or other pressure before the last two bolts or nuts are completely

removed.

xxx) Do not damage wiring during removal operations.

77

xxxi) Tighten connections to the correct torque. Ensure that all clamps,

guards and shields are instated carefully. This will help to prevent

damage from: vibration, rubbing against other parts, and excessive

heat during operations. Particular attentions for correct installation

should be given to shields that protect against oil and fuel spray onto

hot exhaust components.

xxxii) Any high speed rotating component that has been damaged or altered

should be checked for balance before reusing.

xxxiii) Avoid touching heater and radiator hoses and other hot engine

parts.

xxxiv) Avoid breathing exhaust fumes. Always vent the fumes outsides

of the shop.

xxxv) Keep hands away from fans and other moving parts.

xxxvi) Remove the ignition key to prevent accidental starting of the

engine.

xxxvii) Ensure that all of the “safety” signs on the product are read and

under stood

xxxviii) For initial start-up of a new engine or for an engine that has

been serviced, make provisions to stop the engine if an over speed

occurs. This can be accomplished shutting off the fuel supply and/or

air supply to the engine.

78

SOP Working with Solvents, Resins and other Chemicals

1. Learn about the chemicals that you are planning to use before opening

them. Read the instructions and MSDS sheet.

2. Use water-based cleaners instead of solvents where possible.

3. Avoid skin contact. Wear latex gloves.

4. Do not use solvents around hot metal surfaces and flames.

5. Do not smoke or light flames in areas where solvents are used and stored.

6. Report and clean up any spills immediately.

7. Do not pour any chemicals down the drain.

9. Only use solvents in well ventilated areas - do not work with them in

confined, unventilated areas.

10. Do not drink alcoholic beverages or take medications containing

alcohol before or during working with solvents. Alcohol in the

bloodstream sometimes causes synergistic reactions with various

solvents that can lead to loss of consciousness, and even possibly, death.

11. Report any ill effects and skin disorders to the area supervisor.

12. Develop and maintain good personal hygiene habits. Remove protective

equipment and wash thoroughly after contact with solvents.

13. Fumes from paints, solvents, adhesives, and the abrasive cut-off saw

used can drift into the shop. Work with staff to minimize these problems.

14. Mix resins in small batches.

79

SOP For Drill Press

1. Run drill at correct RPM for diameter of drill bit and material..

2. Always hold work in a vise or clamp to the drill table.

3. Use a correctly ground drill bit for the material being drilled.

4. Use the proper cutting fluid for the material being drilled.

5. Remove chips with a brush, never by hand.

6. Ease up on drilling pressure as the drill starts to break through the bottom

of the material.

7. Don't use a dull or cracked drill. Inspect the drill before using.

8. Don't drill with too much pressure.

9. Always try to support part on parallels or a backing board when drilling

thru material.

10. Never place taper shank tools such as large diameter drills or tapered

shank reamers in a drill chuck. Only straight shank tools such as standard

drills can be clamped in chucks.

11. Always clean drill shank and/or drill sleeve, and, spindle hole before

mounting.

12. Remove taper shank tools from spindle or sleeve with a drill drift and

hammer.

13. Never try to loosen the drill chuck while the power is on.

14. Lower the drill spindle close to the table when releasing the drill chuck

or taper shank drill to reduce the chance of damage should they fall onto the

table.

15. Never clean a machine while it is in motion!!

16. If the drill binds in a hole, stop the machine and turn the spindle

backwards by hand to release the bit.

17. When drilling a deep hole withdraw the drill bit frequently to clear

chips and lubricate the bit.

18. Always remove the drill chuck key, or, the drill drift from the spindle

immediately after using it.

19. Wear safety eye protection while drilling.

20. Let the spindle stop of its own accord after turning the power off. Never

try to stop the spindle with your hand.

80

SOP

Handling of Liquid Nitrogen

• Read MSDS for Nitrogen liquied.

• Protect hands at all times when working with liquid nitrogen with Cryo Gloves.

Contact of liquid nitrogen or any very cold gas with the skin or eyes may cause

serious freezing (frostbite) injury.

• Never allow any unprotected part of your body to touch objects cooled by liquid

nitrogen.

• Wear protective clothing : use face shield or safety goggles, cryo gloves(The

gloves should fit loosely, so that they can be thrown off quickly if liquid should

splash into them.)

• Wear high-top shoes.

• Trousers (which should be cuffless if possible) should be worn outside the shoes.

• Use only containers designed for low-temperature liquids .

• Use only the cap provided along with the Nitrogen Can.

• Use proper transfer equipment to prevent splashing and spilling when

transferring liquid nitrogen into or from a can.

• To be filled slowly to minimize the internal stresses that occur when any material

is cooled. Excessive internal stresses can damage the container.

• Check the unit periodically to be sure that venting is not restricted by

accumulated ice or frost.

• Do not overfill containers

• Never use hollow rods or tubes as dipsticks.

• Nitrogen gas can cause suffocation without warning. Store and use liquid

nitrogen only in a well ventilated place.

• Keep unit upright at all times except when pouring liquid from dewars

specifically designed for that purpose.

• If a person seems to become dizzy or loses consciousness while working with

liquid nitrogen, move to a well-ventilated area immediately. And call ambulance.

• Never dispose of liquid nitrogen in confined areas or places where others may

enter.

• Disposal of liquid nitrogen should be done outdoors in a safe place. Pour the

liquid slowly on gravel or bare earth where it can evaporate without causing

damage. Do not pour the liquid on the pavement.

81

• Do not place these units in closed vehicles where the nitrogen gas that is

continuously vented from unit can accumulate. Prevent spillage of liquids and

damage to unit by securing it in the upright position so that it cannot be tipped

over. Protect the unit from sever jolting and impact that could cause damage,

especially to the vacuum seal.

• Keep the unit clean and dry

• When transporting liquid nitrogen dewar, maintain adequate ventilation and

protect the unit from damage.

82

SOP

Power Tools

Note: Portable electric power tools are just what their name implies, power tools. Because they are

powerful workers need to be aware of their limitations and potential hazards.

� Use and maintain tools with care. Keep them sharp and clean for their best and safest

performance.

� Follow the manufacturer’s instructions for lubricating and changing tool accessories. Use the

right tool for the job.

� Don’t force a small tool or attachment to do the job of a heavy-duty tool. It overstrains the tool

and overloads the motor.

� Keep guards in place and follow lockout/tag out procedures.

� Unless its designed for it, never use a portable electric tool where there are flammable vapors

or gases present.

� If the tool is equipped with a three-pin plug, it should be plugged into a three-pin electrical

socket.

� Keep the cord in good condition. Keep it away from heat, oil, and sharp edges.

� Never carry a tool by its cord.

� Report any defective or broken plugs and insulation on cords.

� The greatest hazard of power tools is electric shock, so make sure the tool is properly grounded

before its turned on.

� It’s dangerous to use power tools in damp or wet locations or if the worker is moist.

� Moisture helps electricity flows more easily through the body. Rubber gloves and footwear are

recommended when working outdoors where it’s damp.

� Wear proper clothing and personal protective equipment when working with power tools.

Loose clothing or jewelry that can get caught in moving parts.

� Safety glasses or goggles can protect against flying particles or chips from entering the eye.

Keep others out of the plane of rotation so they won’t be hit by flying particles.

� Keep your balance and proper footing when working with power tools.

� When you’ve finished with the tool, put it down or store it so that it cant cause an injury to

another worker.

� Keep the work area well lit and clean.

Note: The above evaluations and/or recommendations are for general guidance only and should

not be relied upon for legal compliance purposes.

.

Documents

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