Standard operating procedure (SOP) for Offline Maintenance of Lintern AC

Department: Coke plant SOP No. TSK/EM/BF/SOP/SS_AUX/0084

SAFETY:-
A. Hot zone
B. Slipping due to oil spillage or water logging
C. Dusty Enviroment
D. Electrical Hazard
E. Fall of Material from top of the transformer
F. Insufficient place to work around the unit
G. CO Gas & BF Gas
H. Fire

PPE & Tools Remarks / Reference

Step No. Activity [WHAT] Associated Hazards/Impacts/Quality Responsibility [WHO] PPE Tool Process Steps [HOW] /
SAFETY:- 1. Safety Shoes NA 1. Conduct toolbox talk to educate the workers
Indentified Associated Hazards in this 2. Safety Goggle regarding the hazards associated with this functional
functional Location: 3. Helmet location.
A. Hot zone 4. Dust Mask 2. Use the designated walking path to
B. Slipping due to oil spillage or water logging 5. Ear Muff approach the transformer. Beware of slippery surface
C. Dusty Enviroment 6. Safety due to water logging
D. Electrical Hazard Jacket 3. Use dust mask
Get yourself acquainted with
E. Fall of Material from top of the transformer Shift Incharge/Area 7. Hand Gloves 4. Before start up any electrical maintenance be aware
1 the functional location hazard as
F. Insufficient place to work around the unit Incharge 8. CO Detector that the transformer is charged and online inspection to
mention above
G. CO Gas & Dust particle be done from a safe distance.
H. Fire 5. Use Helmet,Safety shoe,Fire retradent
ENVIRONMENT:- NA jacket,Safety goggles
6. Use portable CO detector & keep oxygen pack at
QUALITY : -The SOP and hazards must site. 7.Use fire extingusiher with proper validity.
be understood by all the Electrical 8.Use heat resistive handgloves when maintenance
Staff working in BF. activity is carried out at hot zone.
SAFETY:- NA NA NA The manpower involved to execute the job have to
ENVIRONMENT:-NA be trained
QUALITY:- 1. Hazarous about the job execution
Ensure to deploy the trained Shift Incharge/Area
2 1. Knowledge about the hazard 2.knoweledge of the job
manpower to execute the Incharge
associated with the job. 3.Rescue system during any accident of the job
job
2. Skill of manpower
3. Knowledge about job.
SAFETY:- NA Shift Incharge/ Area NA NA Ensure all required Tools are in good condition &
3 Preparation of necessary tool ENVIRONMENT:-NA Incharge Tested OK.
QUALITY:- NA
SAFETY:- NA Shift Incharge/ Area NA NA Ensure the ESI from the relevant area for Industrial AC.
ENVIRONMENT:-NA Incharge
Ensure availability of
4 QUALITY:-
ESI Document.
ESI document understood and locking points
identified.
SAFETY:- NA Shift Incharge/ Area NA NA 1. Switch OFF the Power/Incomer From Main Switch
ENVIRONMENT:-NA Incharge Board.
5 Positive isolation of the system QUALITY:- NA 2. Ensure No Power is present by using Power tester,
3. Put the Positive isolation lock & RED-tag at feeder no
as mentioned as per ESI Document
4. Barricade the area before starting of the job.

Printed By -M K Nageswararao(197522) Print valid till - 05-Apr-2024 Printed on - 26-Mar-2024 SOP Valid Till - 23-Mar-2025
 PPE & Tools Remarks / Reference
Step No. Activity [WHAT] Associated Hazards/Impacts/Quality Responsibility [WHO] PPE Tool Process Steps [HOW] /
SAFETY: NA NA 1. Take Work Permit from the owner agency
Work permit Procedure violation, Ignorance mentioning specific job & required time duration
to Tata Steel safety guidelines, 2. Work permit is valid for BF Gas concentration
Use of improper tools, Uncoordinated jobs, (CO gas<50 ppm) at work site
absence of site supervisor, work by 3. Working agency personnel trained on the SOP to do
untrained persons may lead to accidents the job
ENVIRONMENT:- NA Shift Incharge/ Area 4. Six directional hazard to be filled at site after
6 Work Permit
Incharge assessment of working area and checking interface
QUALITY : -
1. Work permit form in all three copies to be with process
legible and have details of working 5. Work permit copy to be with respective agencies
personnel with valid Gate pass no
2. The right transformer should be identified
before going for inspection.
Isolation required for following activities:
SAFETY: Shift Incharge/ Area 1. Safety Shoes 1. Double ended 1. Dust cleaning By Air Blower, Brush/Cotton.
1. Do the preventive maintenance when moving car is in
shut down condition . If preventive maintenace required in Incharge 2. Safety Goggle spanner 2. Evaporator & Condenser outside coil cleaning
emergency condition it also maintainance on running 3. Helmet 2. Plier By Airblower.
cars .then follow the below safety guide lines. a. Don't step up
Wet cleaning of condenser to the running cars when it is in operation b. Use handrailing c. 4. Dust Mask 3. Screw Driver 3. AC Filter & Evaporator/Condenser Unit Dust Cleaning
Inform the Operator d. Don't do any activities and movement Isolation
7 and evaporator coils. 5. Ear Muff 4. Nut Driver by Air Blower
during the movement of car e. Don't touch any moving Required at
equipments & electric pannel 6. Safety
2. Use positive isolation lock at AC PANEL UNIT during the Ac panel
time of maintainance. Jacket
ENVIRONMENT: 7. Hand Gloves
1. Dusty 8. CO Detector
2. CO Gas
QUALITY : NA

Replacement of any switches, SAFETY : We need to change the Filter Dryer ,liquid indicator
,compressor, condensor coil , evaporator coil in both Running and Shut Shift Incharge/ Area 1. Safety Shoes 1. Dual Pressure 1. Pump Down the AC system .
down Machines so we have to follow the below safety guide lines. a. Don't
filter dryers, liquid indicators. step up in the running Machines , step up when it is in stop condition. b. Incharge 2. Safety Goggle gauge 2. Required Positive Isolation
Use handrailingc. Inform Operatord. Don't do any activities and
and any type of spares like movement in the moving machinee. Don't touch any moving equipments 3. Helmet 2. Rachet set 3. Open the system as per requirement, ie, any safety
& electric panel
Condenser coil 4. Dust Mask 3. Power Tester devices or switches / filter drier / liquid indicator /
ENVIRONMENT:
and evaporator cooling coil, 5. Ear Muff 4. Clamp meter condenser coil / evaporator coil / compressor /
1. Dusty
compressor replacement. 6. Safety 5. Screw driver thermostatic expansion valve / any fittings / internal or Isolation
8 2. CO Gas
thermostatic expansion valve, Jacket 6. Plier external hook up kit / motor and motor operated blower Required at
QUALITY : NA
internal hook up 7. Hand Gloves 7. Vaccum Pump or fan etc. replacement. Ac panel
kit, external hose hook up kit, 8. CO Detector
motor operated evaporator
blowers and condenser fans,
fitting ' replacements

SAFETY : We need to do the change of Compressor Oil in both Running

and Shut down machines , then we have to follow the below safety guide Shift Incharge/ Area 1. Safety Shoes 1. Dual Pressure 1. Pump down the Ac system.
lines.
a. Don't step up to the running cars , step up when it is in stop condition. Incharge 2. Safety Goggle gauge 2. Requierd Positive Isolation.
b. Use handrailing c. Inform to the Operator d. Don't do any activities
and movement during in the moving car e. Don't touch any moving 3. Helmet 2. Rachet set 3. Open compressor drain out cap.
equipments & electric pannel .
4. Dust Mask 3. Power Tester 4. Drain out old comp. oil .
Compressor oil,drain out and oil ENVIRONMENT: Isolation
9 1. Dusty 5. Ear Muff 4. Clamp meter 5. Pour fresh comp.oil into the comp.upto 3/4 or 75%
charging into the compressor Required at
2. CO Gas 6. Safety 5. Screw driver of comp.(indicator) and tight drain cap.
Ac panel
QUALITY : NA Jacket 6. Plier
7. Hand Gloves 7. Vaccum Pump
8. CO Detector
 PPE & Tools Remarks / Reference
Step No. Activity [WHAT] Associated Hazards/Impacts/Quality Responsibility [WHO] PPE Tool Process Steps [HOW] /
Safety: Shift Incharge/ Area 1. Safety Shoes 1. Spanner set 1. Disconnect the incoming & outgoing cable of the
1.Do the Electrical equipments change or maintenance when Action :1.Use healthy (220v) air blower for
moving car is in shut down condition . If Electrical Incharge 2. Safety Goggle 2. Rachet set existing motor/MPCB from the terminals . cleaning , extension cable and plug top should be
equipments change or maintenance required in emergency
Electrical situation or shut down condition then follow the below safety 3. Helmet 3. Screw Driver 2. Mounting bolts to be removed from the base in good condition.2. Take care not to fold or bend
tubing fins . Use a fin comb to straighten fins.3.
equipment(Compressor,Condens guide lines. a. Don't step up to the running cars when it is in
operation b. Use handrailing c. Inform the Operator d. Don't
4. Dust Mask 4. Plier frame by using proper tools. Use calibrated dual pressure gauge and charging
pipe which should be in good condition. 4.When
10 er fan, Blower motor , do any activities and movement during the movement of car 5. Ear Muff 5. Insulation Tape 3. Replace the equipment with right one and you connect the charging pipe in compressor that
e. Don't touch any moving equipments & electric pannel time ensure that service valve should be in close
MPCB,Contactor, TB) 6. Safety connect the cables and bolts as it is. position. 5. Use LV gloves at the time of current
Replacement Jacket measurement from terminal points and Clamp
meter should be calibrated. 6. At the time of
7. LV Rubber Hand electrical tightness checking be ensure that the
power should be Put positive isolation equipment
ENVIRONMENT: Gloves lock on switched off MCCBs. 7.At the time of
1. Dusty 8. CO Detector mechanical tightness checking be ensure that the
sppaners and other tools should be in healthy and
2. CO Gas good condition.
QUALITY : NA

SAFETY: Shift Incharge/ Area 1. Safety Shoes 1. Clamp Meter 1. Check the insulation resistance of the required
1.chance of lightening and electric suck . use LV Incharge 2. Safety Goggle 2. Power Tester motor by using Megger& Note down the readings .
rubber hand gloves to avoid this hazard . 3. Helmet 3. screw Driver 2. If any abnormality found , then inform to the
Meggering Insulation-resistance
ENVIRONMENT: 4. Dust Mask 4. Plier area incharge & plan for the motor
value of the Isolation required at ac
11 1. Dusty 5. Ear Muff 5. Insulation Tester replacement .
compressor/condenser/Blower 2. CO Gas panel
6. Safety 6.Megger
motor. QUALITY : NA Jacket (all clamp meter ,
7. LV Rubber Hand power tester ,
Gloves megger ,
8. CO Detector insulation tester
should be tested)
Safety:
1. Do the preventive maintenance when moving car is in shut down
Shift Incharge/ Area 1. Safety Shoes 1. Air Blower 1. Required Positive Isolation From main power
condition . If preventive maintenace required in emergency condition it Incharge 2. Safety Goggle (415/3/50) source.
also maintainance on running cars .then follow the below safety guide
lines. 3. Helmet 2. After Positive Isolation , required 220 volts power
a. Don't step up to the running cars when it is in operation
b. Use handrailing 4. Dust Mask supply for Air Blower to cleaning job (Conenser Coil,
Dry cleaning of the whole system c. Inform the Operator 5. Ear Muff Evaporator Coil ,AC mechanical filter and entire AC Isolation Required at Ac
12 d. Don't do any activities and movement during the movement of car
using the air blower. e. Don't touch any moving equipments & electric pannel 6. Safety unit.) panel
2. Use positive isolation lock at AC PANEL UNIT during the time of
maintainance. Jacket
ENVIRONMENT: 7. Hand Gloves
1. Dusty 8. CO Detector
2. CO Gas
QUALITY : NA
SAFETY: Shift Incharge/ Area 1. Safety Shoes NA 1. Return/Closel the working clearance.
NA Incharge 2. Safety Goggle 2. Remove all the materials & tools from the site
ENVIRONMENT:- 3. Helmet
NA 4. Dust Mask
Closing of Work permit &
13 QUALITY : - 5. Ear Muff
Report writing
6. Safety
Ensure all tasklist points are covered Jacket
7. Hand Gloves
8. CO Detector
Prepared By Approved By
Name and Desiganation : Name and Desiganation:
Signature with Date Signature with Date: