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Tuesday, 14 November 2017

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Calicut University Btech S5 Results Published

Calicut University Btech S5 Results are published, Click on the below link to Know Results


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Wednesday, 8 November 2017

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Safety operation Procedures required at an LPG plant

STANDARD OPERATING PROCEDURES : CYLINDER UNLOADING
SOUND EMPTY CYLINDER RECIEPT

1.       BEFORE UNLOADING THE STACK TRUCK,
2.        PHYSICALLY CHECK AND VERIFY THAT THE TOTAL NUMBER OF CYLINDERS IN THE TRUCK BY COUNTING NUMBER OF ROWS AND STACKS SO AS TO CHECK IT WITH THE NUMBER OF CYLINDERS MENTIONED IN THE ERV AND RECORD SAME AS IN ERV. MAKE ALL THE ENTRIES IN THE UNLOADING REGISTER.
3.       GET THE TRUCK UNLOADED ON UNLOADING FINGERS OR ALWAYS AT 15MTRS DISTANCE FROM THE SHED.
4.       ENSURE THAT ALL THE CYLINDERS HAVE SAFETY CAPS FITTED ON THE VALVES. RECORD THE DISCREPANCIES IF ANY, SO THAT APPROPRIATE DEBITS CAN BE RAISED ON THE TRANSPORTER OR DISTRIBUTOR.
5.       ALLOW THE SOUND EMPTY CYLINDERS FOR SEGREGATION AND FILLING/ STACKING, AS PER REQUIREMENT.
6.       ANY MARKET RETURN CYLINDERS RECEIVED SHALL BE CHECKED AGAINST REMARKS ON THE BACK OF THE CHALLAN AND RECORD THE DETAILS IN THE MARKET RETURN CYLINDER REPORT FOR GIVING THE IMMEDIATE CREDIT TO THE DISTRIBUTOR.
7.       ACKNOWLEDGE THE RECIEPT OF CYLINDERS, SHORTAGE OF SAFETY CAPS, MARKET RETURN CYLINDERS AND ANY OTHER DISCREPANCY IN THE ERV.
8.       ENSURE NO CYLINDERS FALL ON THE GROUND AT UNLOADING POINT.
9.       ENSURE CAPS ARE FIXED ON ALL THE DEFECTIVE CYLINDERS.
10.   ENSURE RUBBER MATS ARE PROVIDED AT UNLOADING POINT TO AVOID ANY IMPACT OF  THE CYLINDERS ON THE FLOOR.
11.   IN CASE OF ANY EMERGENCY AND ABNORMAL SITUATION, INFORM THE OIC IMMEDIATELY FOR CORRECTIVE ACTION.
12.   ENSURE GOOD HOUSE KEEPING IN THE AREA.


STANDARD OPERATING PROCEDURES : CYLINDER HANDLING, MOVEMENT AND STORAGE

1.       ENSURE THAT CYLINDERS ARE MOVED EITHER BY ROLLING THEM ON THEIR FOOT RING, ON TROLLEYS OR ON CONVEYORS ONLY.
2.       ENSURE THAT THE CYLINDERS ARE NOT DROPPED, ROLLED ON SIDES OR SUBJECTED TO ANY VIOLENT CONTACT WITH ANY OTHER CYLINDER WHILE THEY ARE BEING HANDLED.
3.       CYLINDER REJECTED AS UNFIT AS PER THE GUIDELINES PROVIDED IN WORK INSTRUCTION FOR SEGREGATION, SHOULD BE STACKED SEPERATELY AND SHALL BE SENT TO COLD REPAIR SHED ON DAY TO DAY BASIS FOR VALVE REMOVAL AND DEGASSING.
4.       ENSURE THAT THE CONVEYORS FROM THE CAROUSAL TO THE WASHING UNIT ARE ALWAYS FULL WITH EMPTY CYLINDERS SO THAT THE BOTTLING OPERATION DOES NOT STOP AT ANY POINT OF TIME FOR WANT OF EMPTY CYLINDERS.
5.       AT THE END OF THE DAY, GET ALL THE CYLINDERS REMOVED FROM THE CONVEYORS AND STACKED IN THE APPROPRIATE SHEDS, EXCEPT AS REQUIRED IN STEP (03) ABOVE AND THOSE IN AND AFTER THE INLINE TEST BATH.
6.       NOTE ALL THE DETAILS OF BODY LEAK CYLINDERS DETECTED AT THE BUNG LEAK DETECTOR IN THE REGISTER FOR THE PLANT DEFECTIVE CYLINDERS. MARK THESE THROUGH CHALK AND SEND ALL THE BODY LEAK, BUNG LEAK CYLINDERS FOR IMMEDIATE EVACUATION AND FURTHER RECTIFICATION FOR BUNG LEAK CYLINDERS AND BODY LEAK CYLINDERS FOR SCRAPPING AFTER VALVE REMOVAL.
7.       CAP ALL THE VALVE LEAK AND OTHER DEFECTIVE CYLINDERS IMMEDIATELY TO PREVENT ESCAPE OF LPG TO AIR.
8.       ENSURE THAT THE CYLINDERS ARE STACKED PROPERLY IN THE SHED, IN THE SHEDS CYLINDERS SHOULD BE STACKED VERTICALLY, IN LOTS OF 200 CYLINDERS EACH (25 CYLINDER LONG, 4 CYLINDRE WIDE AND 2 CYLINDER HEIGHT) OR LESS AND ONLY INSIDE THE YELLOW BANDS PAINTED FOR THIS PURPOSE. ENSURE THAT ALL THE CYLINDERS STACKED ARE FIXED WITH SAFETY CAPS.
9.       IF THE SPACE PERMITS , THE NEW CYLINDERS SHALL BE UNLOADED IN EMPTY CYLINDER CUM FILLING SHED AND SHALL BE STORED IN VERTICAL POSITION IN LOTS OF 25*4*2 AS MENTIONED  IN 6. IN CASE OF SPACE CONSTRAINT , THESE CYLINDERS SHALL BE STACKED ON GROUND IN HORIZONTAL POSITION WITH THE BELLY OF CYLINDERS TOUCHING EACH OTHER ( SLEEPING POSITION). THESE CYLINDERS SHALL BE TAKEN IN TO THE BOTTLING SHEDS AS AND WHEN REQUIRED.
10.   NEVER KEEP THE CYLINDERS AT THE EDGE OF THE SHEDS. NEVER KEEP CYLINDERS WITH LPG VAPOUR IN OPEN.

STANDARD OPERATING PROCEDURES : DE CAPPING OF CYLINDERS

SWITCH ON THE WASHING UNIT AND THE CONVEYOR PASSING THROUGH  IT. DECAP EACH CYLINDER AS IT COMES OUT OF THE WASHING UNIT, AS PER THE FOLLOWING PROCEDURE.

  1. EXPAND THE CAP SPRING BY EITHER INSERTING THE DECAPPING TOOL BETWEEN THE  CAP BODY AND SPRING OR PULLING THE CAP SPRING.
  2. PULL UP THE CAP KEEPING THE SPRING EXPANDED AND HANG IT OUT THROUGH CYLINDER STEP RING.
  3. VISUALLY INSPECT THE INNER SIDE OF THE SC VALVE TO ENSURE THAT THERE IS NO FOREIGN MATERIAL PRESENT INSIDE AND ENSURE THAT ‘O’ RING IS PRESENT.
  4. IN CASE THE CAP OF ANY CYLINDER IS NOT COMING OUT EASILY, REMOVE THE CYLINDER FROM THE CONVEYOR AND KEEP IT ASIDE. LATER DECAP AND PUT THE CYLINDER BACK IN THE LINE. ENSURE THAT THE SAFETY CAPS REMOVED FROM THE CYLINDERS ARE NOT LITTERED AROUND AND ARE PUT PROPERLY IN THE BIN KEPT FOR THE SAME.
  5. ALWAYS ENSURE THAT THERE ARE SUFFICIENT EMPTY CYLINDERS ON THE CONVEYOR SO THAT THE CAROUSALS DO NOT STOP FOR WANT OF CYLINDERS.
  6. STORE THE CAPS WITHOUT STRING , OLD DAMAGED CAPS IN THE BIN MARKED FOR THE SAME. SEND THESE CAPS FOR REPAIRS ON REGULAR BASIS.
  7. SEGREGATE THE DAMAGED CAPS FROM THE GOOD CAPS AND STORE THEM PROPERLY IN THE DRUMS MARKED FOR THE SAME IN SCRAP YARD.
  8. ENSURE THAT THE REMOVED, UNUSABLE NYLON CHORD IS STORED PROPERLY IN THE BIN MARKED FOR THE SAME. SEND THIS TO SCRAP YARD ON DAILY BASIS FOR PROPER DISPOSAL.
  9. ENSURE GOOD HOUSE KEEPING IN THE AREA.


STANDARD OPERATING PROCEDURES : LEAK DETECTOR (VL/BL DETECTION)

  1. DRAIN OUT THE WATER FROM THE AIRLINE . BLOW OUT DIRT AND WATER FROM THE FILTER REGULATOR UNIT OF LD-01. CLEAN ALL THE PHOTO DIFFUSIVE SENSORS OF LD-01
  2. RESET LD-01 BY PRESSING THE (.) DOT BUTTON ON THE TOP RIGHT CORNER OF HMI AND WAIT TILL ‘CUC IN PROCESS MODE’ DISPLAYS. PRESS START BUTTON
  3. PUT VL TEST CYLINDER ON THE CONVEYOR.
  4. CHECK WHETHER THE UNIT IS REJECTING IT OR NOT. IF THE CYLINDER IS NOT GETTING REJECTED ADJUST THE SENSITIVITY SO THAT VL CYLINDERS OF LEAKAGE ABOVE 0.5GM/HR ARE REJECTED.
  5. CARRY OUT THE CHECK EVERY TWO HOURS AND RECORD IT.


STANDARD OPERATING PROCEDURES : LEAK DETECTOR (O RING LEAK DETECTION)

  1. DRAIN OUT THE WATER FROM THE AIRLINE . BLOW OUT DIRT AND WATER FROM THE FILTER REGULATOR UNIT OF LD-02. CLEAN ALL THE PHOTO DIFFUSIVE SENSORS OF LD-02
  2. RESET LD-02 BY PRESSING THE (.) DOT BUTTON ON THE TOP RIGHT CORNER OF HMI AND WAIT TILL ‘CUC IN PROCESS MODE’ DISPLAYS. PRESS START BUTTON
  3. PUT ORL TEST CYLINDER ON THE CONVEYOR.
  4. CHECK WHETHER THE UNIT IS REJECTING IT OR NOT. IF THE CYLINDER IS NOT GETTING REJECTED ADJUST THE SENSITIVITY.
  5. CARRY OUT THE CHECK EVERY TWO HOURS AND RECORD IT.


STANDARD OPERATING PROCEDURES : VALVE CHANGE WITHOUT EVACUATION

STEP1:SWITCH ON THE HYDRAULIC POWER PACK
STEP2:LOADING
  1. INTRODUCE THE LPG CYLINDER ON THE BASE PAD (RUBBER PAD) OF THE MACHINE AND CENTER IT APPROXIMATELY UNDER THE SEALING BELL.
  2. IN THE START OF OPERATION, SEALING BELL & TOLL REMAIN IN ITS UPWARD POSITION.
  3. OPERAT THE (WRENCH SHAFT LEVER) HAND VALVE DOWN POSITION FOR LOWER WRENCH SHAFT.
  4. THE WRENCH SHAFT LOWER DOWN & ENTER IN SEALING BELL, WRENCH SHAFT HOLD NEAR THE BALL VALVE, UNTIL BALL VALVE FULL OPEN (A PNEUMATIC ROLLER VALVE MOUNT AT SEALING BELL STRUCTURE, THIS ROLLER VALVE PRESSED BY ALUMINIUM SLID FIX ON THE WRENCH SHAFT STRUCTURE PORTION & MOVE UP & DOWN WITH WRENCH SHAFT & GIVE THE SIGNAL TO THE BALL VALVE ACTUATER FOR BALL VALVE OPEN/CLOSE)
  5. AFTER OPENING  THE BALL VALVE, WRENCH SHAFT ENTER IN THE BALL VALVE & CLOSE IT OR SEALING BELL LEVER.
  6. OPERATE THE (SEALING BALL LEVER) HAND LEVER VALVE DOWN POSITION FOR DOWN THE SEALING BELL.
  7. LOWER THE SEALING BELL UNTIL THE WRENCH IS SLIGHTLY ABOVE THE TOP OF THE CYLINDER VALVE ( WRENCH SHAFT ARRANGEMENT DOWN WITH SEALING BELL BECAUSE WRENCH SHAFT ARRANGEMENT ATTACHED WITH BELL PORTION).

              STEP 3: ALIGNMENT
  1. THIS STEP IS CRITICAL TO THE SUCCESS OF ALL FURTHER OPERATIONS
  2. SHIFT THE CYLINDER UNTIL THE CYLINDER VALVE IS ALLIGNED WITH THE WRENCH SOCKET.
  3. DO NOT TILT CYLINDER TO GET THIS ALLIGNMENT.
  4. THE FOOT RING OF THE CYLINDER MUST BE FULLY ON THE BASE PAD BEFORE ENGAGEMNT IS ATTEMPTED.
  5. USE THE VP RING OR BODY OF THE CYLINDER TO MOVE IT.
  6. DO NOT INTRODUCE YOUR HAND UNDER THE SEALING BELL.
  7. LOOK FROM TWO ORTHOGONAL POSITIONS TO ENSURE PROPER AXIAL ALLIGNMENT.
  8. LOWER THE SEALING BELL FURTHER SO THAT THE SOCKET ENGAGES THE VALVE.
  9. LOWER THE SEALING BELL FURTHER STILL UNTIL THE FACE CONTACTS, THE LPG CYLINDER & PRESSES DOWN FIRMLY ON IT.
  10. LEAVE THE SEALING BELL CONTROL LEVER.
  11. YOU ARE NOW READY TO UNSCREW THE CYLINDER VALVE.


STEP4:UNSCREWING
  1. SHIFT THE UNSCREW CONTROL LEVER AND HOLD IT UP TO ROTATE THE WRENCH ANTICLOCKWISE.
  2. AS THE VALVE UNSCREWS THE WRENCH SHAFT WILL CREEP UP AUTOMATICALY.
  3. WHEN THE VALVE IS FULLY UNSCREWED .THE WRENCH SHAFT WILL STOP CREEPING UP.
  4. KEEP THE UNSCREWING MOTION ON AND SIMULTANEOUSLY SHIFT THE WRENCH SLIDE LEVEL TO THE UP POSITION.
  5. AS SOON AS THE WRENCH LIFTS 40 TO 50 MM RELESE THE UNSCREW CONTROL LEVELBUT KEEP WRENCH TOOL VALVE IN THE UP POSITION TO CONTINUE LIFTING THE SHAFT.
  6. LPG PRESSRE RISE IN THE PRESSURE GAUGE. PRESSURE GAUGE MOUNTS ON THE SEAL BELL
  7. WHEN THE WRENCH SHAFT WITH SC VALVE CROSSED THE BALL VALVE 20MM (AFTER LIFTING 320 MM FROM SEALING BELL LOWER PORTION), A PNEUMATIC ROLLER LEVER VALVE GIVES THE SIGNAL TO BALL VALVE FOR CLOSING.WRENCH SHAFT WILL LIFT OUT OF THE SEALING BELL WITH THE VALVE ALLOW IT TO TRAVEL FULLY UP.

STEP5: SCREWING
  1. AFTER REPLACING THE NEW SC VALVE ON THE WRENCH SOCKET, PRESS WRENCH LEVER DOWN POSITION TO MOVE THE WRENCH SHAFT IT’S DOWN POSITION.
  2. THE WRENCH SHAFT ENTER IN THE SEALING AREA & STOP NEAR THE BALL VALVE (A PNEUMATIC ROLER GIVE THE SIGNAL FOR OPEN THE BALL VALVE).
  3. AFTER FULLY OPEN THE BALL VALVE WRENCH SHAFT MOVE DOWN POSITION.
  4. NOW SHIFT THE SCREW LEVER FOR SCREWINING TO ROTATE THE WRENCH SHAFTCLOCKWISE.
  5. THE WRENCH SHAFT DOWN MOVE SLIGHTLY. AFTER VALVE SCREWING THE WRENCH SHAFT WILL STOP AUTOMATICALY.
  6. YOU HAVE NOW SCREWED THE NEW VALVE ON CYLINDER.
  7. NOW RELEASE THE SCREW LEVER STOP POSITION & SHIFT THE SEALING BELL LEVER IT’S UP POSITION.
  8. NOW PRIMARY VENT IS ON FOR LPG PRESSURE VENTILATION IN COLD FLAIR.
  9. AFTER COMPLETE THE LPG FLAIR.SEALING BELL LIFT UPPER SIDE.
  10. BELL WILL NOT LIFT UP IF THE PRESSURE INSIDE THE BELL IS NOT 0 TO 0.5GM FOR THIS SAFETY INTERLOCK, TWO PNEUMATIC PRESSURE SWITCHES CONNECTED WITH SEALING BELL. WHEN IT GIVES THE SIGNAL FOR COMPLETE FLARING SEALING BELL WILL LIFT OTHERWISE IT WILL NOT LIFT UP.

STEP6: SHUT DOWN PROCEDURE END OF THE DAY SHIFT.
  1. THE END OF THE DAY THE MACHIN SHOULD BE SHUT DOWN IN THE IN THE CORRECT CONDITION.
  2. THERE SHOULD BE NO CYLINDERS IN THE MACHINE.
  3. MOVE THE SEALING BELL DOWN TO ITS LOWEST POSITION AND LEAVE THE CONTROL LEVEL IN NATURAL.
  4. MOVE THE WRENCH SLIDE DOWN TO ITS LOWEST POSITION AND LEAVE THE CONTROL LEVER IN THE SHUTDOWN POSITION.
  5. SWITCH OFF THE HYDRAULIC POWER PACK.
  6. TURN OFF THE AIR SUPPLY

              NOTE: PROBLEMS DURING SCREWING/UNSCREWING
  1. IN THE CASE VALVE NOT COMPLETE THE SCREW/UNSCREW, VALVE DROP OUT THE WRENCH IN THE SEALING BELL AREA.
  2. IN SUCH CASE THE LPG IN THE CYLINDER MUST BE VENTED VIA SECONDARY VENT BEFORE THE SEALING BELL CAN BE LIFTED.
  3. A LPG VENTILATION PIPELINE ATTACHED WITH PRIMARY & AND SECONDARY VENT LINE FOR REMOVING THE LPG PRESSURE FOR COLD FLAIR

              INTERLOCKS:
  1. AN INTERLOCK PROVIDED FOR CHECKING THE BALL VALVE CLOSED POSITION, THE TOLL SHAFT UPWARD POSITION STOP IN SEALING AREA TILL THE BALL VALVE FULLY CLOSED SIGNAL.
  2. AN INTERLOCK PROVIDED FOR CHECKING THE BALL VALVE OPEN POSITION THE WRENCH SHAFT DOWNWARD POSITION STOP IN SEALING AREA TILL THE BALL VALVE FULLY OPEN SIGNAL.
  3. THE PRESSURE SWITCH USED IN BELL. THE SEALING BELL LIFT UP,WHEN SEALING BELL INSIDE PRESSURE IS NILL.
  4. A PRESSURE RELEASE VALVE PROVIDED IN POWER PACK FOR AVOIDING THE OVER PRESSURE.THIS VALVE RELESE THE EXTRA OIL PRESSURE IN RETURN LINE.


STANDARD OPERATING PROCEDURES : AUTOMATIC VALVE TESTING SYSTEM (ELECTRONIC TYPE)

  1. NORMALLY WHEN THE MACHINE IS ON AND THERE IS NO TESTING GOING ON, THEN ‘ INSPECTION OFF’ WILL  APPEAR ON THE GLASS WINDOW SCREEN.
  2. WHEN A CYLINDER COMES FOR TESTING AND DURING TESTING ‘INSPECTION ON’ WILL APPEAR ON THE GLASS WINDOW SCREEN.
  3. ONCE THE TESTING IS COMPLETED AND THE CYLINDER IS OK THEN ‘OK’ WILL APPEAR ON THE GLASS WINDOW SCREEN.
  4. DURING TESTING IF THE CYLINDER IS REJECTED FOR PIN LEAK OR ‘O’ RING DEFECT THEN ‘REJECT’ WILL APPEAR ON THE GLASS WINDOW SCREEN.

DO’S AND DON’T’S

  1. DO NOT CHANGE THE POSITION OF SENSORS.
  2. DO NOT CHANGE THE AIR PRESSURE FROM THE MAIN FRL UNIT WHICH IS SET NORMALLY AT 5KG/CM^2.
  3. DO NOT CHANGE THE PRESSURE SETTING OF THE PRESSURE REGULATOR PROVIDED INSIDE THE CONTROL PANEL.
  4. DO NOT START THE MACHINE WITHOUT AS MUCH AIR AS IT MAY DAMAGE THE COMPONENTS.
  5. DO NOT ALLOW CYLINDERS TO MOVE ON BELLY FOR TESTING.
  6. DO NOT OPERATE FUNCTION KEYS DURING TESTING. (F1,F2,F3…)
  7. ALWAYS KEEP THE INLET AIR PRESSURE TO THE SYSTEM TO THE CORRECT VALUE.
  8. ALWAYS SUPPLY 230V AC TO THE MACHINE THROUGH UPS.
  9. CHECK FOR ANY AIR LEAKAGE IN THE SYSTEM , IF FOUND INFORM OFFICER IN CHARGE.
  10. WITH THE POWER ON DO NOT OPEN THE FLAME PROOF JUNCTION BOX OR TERMINAL JUNCTION BOXES PROVIDED AT THE BACK OF THE CONTROL PANEL.
  11. WITH THE POWER ON DO NOT TAMPER ANY ELECTRICAL CONNECTION.

FUNCTION PUSH BUTTONS IN THE CONTROL PANEL
THESE PUSH BUTTONS ARE TO BE OPERATED ONLY WHEN THE MACHINE IS NOT IN RUNNING CONDITION
F1 WHEN PRESSED WILL SHOW THE NUMBER OF CYLINDERS TESTED IN THE MACHINE
F2 WHEN PRESSED WILL SHOW THE TEST TIME
F3 WHEN PRESSED WILL SHOW SELECT PR ( TO SELECT THE TEST ACCURACY OF THE MACHINE VIZ 0.5,0.75,1.0)
F4 WHEN  PRESSED WILL SHOW PREVIOUS CYLINDER TESTED LEAKAGE VALUE IN TERMS OF CURRENT
UP TO BE OPERATED ONLY TO INCREASE THE F2 BUTTON VALUE OR F3 BUTTON VALUE
DOWN TO BE OPERATED ONLY TO DECREASE THE F2 BUTTON VALUE OR F3 BUTTON VALUE
RESET WHEN PRESSED WILL ERASE THE F1 VALUE
M-RESET TO BE OPERATED ONLY WHEN THE  SUPPLY AIR PRESSURE FALLS BELOW THE SET VALUE AND ‘PNEUMATIC LOW’ APPEARS ON HMI



STANDARD OPERATING PROCEDURES : WEIGHT CORRECTION UNIT



  1. SWITCH ON THE CONVEYOR CHAIN MOTOR AND THEN START THE MACHINE.

  2. AFTER THE INTRODUCTION OF CYLINDER TO THE MACHINE, PUNCH THE TARE WEIGHT OF THE CYLINDER THROUGH PANEL BUTTONS.

  3. WAIT TILL THE EJECTION OF THE CYLINDER FROM THE MACHINE

  4. IN CASE OF ABNORMAL CONDITON , SWITCH OFF THE MACHINE USING EMERGENCY SWITCH AND INFORM THE FLOOR IN CHARGE


CALIBRATION


  1. IN FUNCTION MODE PRESS ‘5’ AND THE DISPLAY SHOWS ‘CONTROL MODE ON’

  2. PRESS ‘ALT’ KEY SO THAT THE SYSTEM WILL DO THE ZEROING OF THE MACHINE AND DISPLAY AS ‘GW = 000.00 CHECKING..’

  3. AFTER FEW SECONDS THE SYSTEM WILL  GIVE THE MESSAGE TO PUT THE STANDARD 30KG WEIGHT ON THE PLATFORM OF THE MACHINES ‘GW = 000.00 PUT 30KG: ALT’

NOW PLACE THE 30KG CALIBRATED WEIGHT ON THE PLATFROM AND PRESS ‘ALT’ KEY AGAIN AND WAIT TILL THE OPERATION OVER MESSAGE IS DISPLAYED ‘ OPERATION OVER’ THEN, ‘GW=030.00 CONTROL MODE ON’ NOW THE CALIBRATION PROCESS COMPLETED AND REMOVE THE STANDARD WEIGHTS.
NOTE: CALIBRATION TO BE DONE ONLY IF THE SYSTEM SHOWS SOME ERROR VALUE FOR THE STANDARD WEIGHTS. WHILE CHECKING WITH STANDARD WEIGHTS ENSURE THAT THE SYSTEM SHOWS ZERO WITHOUT ANY WEIGHT. ALSO ENSURE THAT NO MOVING PART OR CONVEYOR TOUCHING THE STRUCTURE OR PLATFORM.



STANDARD OPERATING PROCEDURES : PORTABLE HOT AIR SEALING SYSTEM



  1. ENSURE THE AIR LINE IS CONNECTED TO THE PHASM.

  2. CONNECT THE EX PLUG PROVIDED WITH MACHINE TO THE EX D SOCKET AND TURN IN CLOCKWISE DIRECTION TO SWITCH ON THE INTERNAL SWITCH ( POWER ON- RED INDICATION LAMB SHOULD GLOW)

  3. DEPRESS THE TRIGGER IN HOT AIR GUN, AND FEEL AIR BLOWING OUT THROUGH THE NOZZLE. ONLY IF CONNECTIONS ARE CORRECT, THE HEATER ON- GREEN INDICATION LAMB WILL GLOW

  4. LOCK THE WHEEL BRAKES TO PRVENT THE TROLLEY MOVING DURING OPERATIONS

  5. TO PURGE OUT ALL COLD AIR OUT OF THE SYSTEM. KEEP THE GUN TRIGGER DEPRESSED FOR APPROX. 5-8 MINUTES. THIS WILL HEAT UP THE FULL SYSTEM,.

  6. KEEP PVC SEAL ON CYLINDER VALVE AND DEPRESS THE TRIGGER FOR APPROX 5 SECONDS

  7. RELEASE THE TRIGGER AND REMOVE THE GUN

  8. SEALING WILL BE COMPLETE

  9. GO TO NEXT CYLINDER AND REPEAT STEPS 6 & 7

  10. DISCONNECT THE POWER AND PNEUMATIC SUPPLY ONCE THE OPERATIONS ARE COMPLETED

NOTES:  

  1. INITIAL WARM UP MAY TAKE LONGER IN COLDER CLIMATIC CONDITIONS. THE WARMUP TIME WILL HAVE TO BE EXTENDED TO SUIT LOCAL CONDITIONS FROM TIME TO TIME.

  2. DO NOT PULL THE TROLLEY BY PULLING THE GUN OR HOSE

  3. THE INDIVIDUAL SEALING TIME DEPENDS ON THE THICKNESS OF THE PVC SEALS AND THE MATERIAL GRADE. GENERALLY IT SHOULD SEAL WITHIN 5 SECONDS




STANDARD OPERATING PROCEDURES : CYLINDER LOADING



  1. LOAD THE SPECIFIED NO. OF SEALED OR ST DUE/ REPAIRER CYLINDERS AS I NSTRUCTED IN LOADING ADVICE

  2. ENSURE THAT THE FILLED CYLINDERS ARE STACKED VERTICALLY.STANDARD OPERATING PROCEDURES : FIRE PUMP HOUSE OPERATIONS


    1. NOTE WHETHER THE JOCKEY PUMP AND THE FIRE ENGINES ARE IN AUTO OR MANUAL MODE

    2. CHECK THE DIESEL TANK LEVEL AND THE ENGINE LUBE OIL LEVEL OF EACH FIRE ENGINE. TOP UP IF NECESSARY

    3. RUN EACH FIRE ENGINE FOR MINIMUM 30 MINUTES TWICE A WEEK. NOTE THE PRESSURE AND TEMPERATURE OF LUBE OIL AND COOLING WATER AND DURATION FOR WHICH THE PUMP IS RUN IN ORDER TO DETERMINE THE CUMULATIVE RUNNING HOURS AND LOG THEM IN THE FIRE ENGINE LOG BOOK

    4. ENSURE THAT ALL THE READINGS ARE WITHIN LIMITS. INFORM THE SAFETY OFFICER, IN CASE ANY CORRECTIVE ACTION IS REQUIRED

    5. ENSURE THAT THE GLAND LEAKAGES ARE MINIMIZED FROM THE PUMPS TO AVOID WASTAGE OF WATER

    6. REPOERT ANY ABNORMAL, EMERGENCY SITUATION TO THE SAFETY OFFICER FOR TAKING THE IMMEDIATE CORRECTIVE ACTION

    7. RECORD ALL THE PARAMETERS OF THE FIRE ENGINES, JOCKEY PUMP AND SECURITY AIR COMPRESSOR IN THE LOG BOOK

    8. MAINTAIN GOOD HOUSE KEEPING IN THE FIRE PUMP HOUSE.

  3. ENSURE THAT ALL VALVES OF HYDRANT/ SPRINKLER SYSTEM ARE OPEN

  4. ENSURE JOCKEY PUMP STARTING AND NOTE THE STARTING PRESSURE AND FREQUENCY OF STARTING

  5. ENSURE THAT THE SIREN HAS ELECTRICAL SUPPLY

  6. ENSURE THAT THE WATER LEVEL IN FIRE WATER TANK ARE MAINTAINED MINIMUM 11MTRS

  7. ENSURE ALL CYLINDERS ARE PROVIDED WITH SAFETY CAPS AND PVC OR ALUMINIUM SEALS DULY CRIMPED BEFORE LOADING IN THE STACK TRUCK OR STACKING IN THE FILLED CYLINDER SHED.

  8. ENSURE THAT TRUCK CREW HAS PROPERLY SECURED THE CYLINDERS TO PREVENT THEM FROM STRIKING AGAINST EACH OTHER FALLING DOWN. ASK THE TRUCK DRIVER TO REMOVE THE TRUCK FROM LOADING POINT.



STANDARD OPERATING PROCEDURES : GAS MONITORING SYSTEM


  1. WHEM GAS LEAK OCCURS, AUDIO VISUAL LARM APPEARS IN GMS PANEL NEAR S&D ( WARNING AT 20% OF LEL AND ALARM AT 60% OF LEL)

  2. S&D TO COMMUNICATE TO CPM/DPM/FLOOR IN CHARGE ABOUT THE ACTIVATED SENSOR NUMBER AND LOCATION

  3. GET CONFIRMATION FROM THE FLOOR IN CHARGE THAT THE LEAK IS ARRESTED

  4. PRESS ‘ ACCEPT’ BUTTON ON THE PANEL

  5. PRESS ‘RESET’ BUTTON ON THE PANEL




STANDARD OPERATING PROCEDURES :ELECTRONIC CAROUSEL

START -UP PROCEDURE

  1. POWER ON THE SYSTEM

  2. DRAIN ALL THE AIR LINES TO REMOVE THE MOISTURE

  3. START THE VAPOUR EXTRCTOR/BLOWER AND CHAIN CONVEYOR

  4. CHEACK ALL THE MACHINE AND CHEAK SCALE FORZERO SETTING

  5. IF WEIGHT VARIATION IS THERE IN THE FILLING MACHINE,CALIBERATE THE MACHINE

  6. CALIBERATE THE CHEACK SCALE AT THE START OF THE SHIFT.

  7. BEFORE PUNCHING THE FIRST TARE WEIGHT AT THE START OF THESHIFT RESET INTRODUCTION UNIT AND CHEAK SCALE.

  8. BEFORE STARTING THE FILLING OPERATION INTRODUCTION BUFFER SHOULD BE FULL.

  9. PRESS CYLINDER BUTTON FOR CHOOSING THE CYLINDER TYPE FOR FILLING:CYLINDER TYPE: 1 (PRESS CYLINDER BUTTON +1) FOR 14.2 KG LPG CYLINDER AND  CYLINDER TYPE: 2 (PRESS CYLINDER BUTTON +2)FOR 19.0 KG LPG CYLIDER



STOP PROCEDURE

  1. THE CONVAYOR FROM INTRODUCTION PUNCHING STATION TO CHECK SCALE & CAROUSEL SHOULD NOT HAVE ANY CYLINDERS.

  2. STOP THE INTRODUCTION UNIT & CHEAK SCALE.

  3. POWER OFF THE SYSTEM

DO’S AND DON’T’S

  1. DURING POWER FAILURE, STOP THE INTRODUCTION UNIT AND EJUCTION UNIT.AFTER THAT REMOVE THE CYLINDERS IN THE OUTLET CONVAYOR AND RESET THE SCALE & START THE NORMAL OPERATION.

  2. BEFORE A BREAK AND AT THE END OF THE WORKING DAY,THE SYSTEM MUST BE EMPTIED OF CYLINDERS.THERE MUST NOT BE ANY CYLINDER PRESENT IN THESYSTEM OUTSIDE NORMAL OPERATION HOURS.

  3. CYLINDER MUST UNDER NO CIRCUMSTANCES BE REMOVED OR ADDED BETWEEN THE ENCODING POSITION AND CAROUSEL INLET AS THIS MAY CAUSE GRAVE SERIAL ERRORS IN THE SYSTEM.

  4. DO NOT INTRODUSE HANDS OR OBJECTS INTOTHE CHAIN CONVAYOR OR THE MACHINE AS THIS MAY ACTIVATE PHOTOCELLS AND MACHINE COMPONENTS AND SO CAUSE PHYSICAL OR MECHANICAL DAMAGES.





STANDARD OPERATING PROCEDURES :ELECTRONIC CAROUSEL

START -UP PROCEDURE

  1. POWER ON THE SYSTEM

  2. DRAIN ALL THE AIR LINES TO REMOVE THE MOISTURE

  3. START THE VAPOUR EXTRCTOR/BLOWER AND CHAIN CONVEYOR

  4. TURN ON MAIN POWER BY FLP ROTARY SWITCH INSTALLED AT THE PLC PANEL

  5. ENSURE THAT THRE IS NO CYLINDER PRESENT FROM THE ENCODING STATION TILL THE CHECK SCALE. (INCLUDING THE FILLING MACHINES ON THE CAROUSEL)

  6. PRESS GREEN PUSH BUTTONS ON THE PLC PANEL;


  1. CR .ON (START ROTTATION),

  2. C/S ON (CHECK SCALE ONLINE)

  3. S/R ON (POWER ON OF FILLING M/C)

                                     

  1. PRESS “0”KEY ON ALL THE MACHINE’S DISPLAY TO MAKE SURE THAT ALL M/C DISPLAYS SHOWS ZERO.

  2. PRESS” F” KEY ON ENCODING STATION

  3. CHOOSE “F-1”(AUTO TARE MODE) OR “F-2” (MANUAL TARE MODE) IN BOTTOM DISPLAY BY UP & DOWN ARROWS

  4. PRESS ENTER KEY

  5. DISPLAY SHOWS “ALL” PRESS ENTER

  6. PRESS CYLINDER BOTTON FOR CHOOSING THE CATEGORY FOR FILLING –C1 (14.2 KG),C2(19.0 KG)

  7. AFTER PRESSING CYLINDER BOTTON CHOOSE 1 OR 2 BY NUMERIC KEYS.

  8. CHECK ALL THE MACHINE AND CHECK SCALE FOR ZERO SETTING.

  9. IF WEIGHT VARIATION IS THERE IN THE FILLING MACHINE, CALIBERATE THE MACHINE.

  10. CALIBERATE THE CHECK SCALE AT START OF THE SHIFT

  11. BEFORE PUNCHING THE FIRST TARE WEIGHT AT THE START OF THE SHIFT RESET INTRODUCTION UNIT AND CHECK SCALE.

  12. START PUNCHING ON ENCODING STATION (IOF MACHINE IS IN AUTO MODE) WHEN THE CYLINDERS ARE PRESENT AT ENCODING STATION OR PUNCHING TARE WT. ON INDIVIDUAL FILLING STATION (IF MACHINE IS IN MANUAL MODE)

  13. IN MANUAL MODE CASE BY PASS THE ENCODING STATION BY SHUT-OFF IT’S AIR.

  14. BEFORE STARTING FILLING OPERATION INTRODUCTION BUFFER SHOULD BE FULL   




STOP PROCEDURE

  1. THE CONVAYOR FROM INTRODUCTION PUNCHING STATION TO CHECK SCALE & CAROUSEL SHOULD NOT HAVE ANY CYLINDERS.

  2. STOP THE INTRODUCTION UNIT & CHEAK SCALE.

  3. POWER OFF THE SYSTEM





STANDARD OPERATING PROCEDURES : 47.5 KG CAPACITY LPG CYLINDER FILLING AMD CHECKING UNIT

STEP1 : TO START FILLING SELECT THE NET WEIGHT

  1. PRESS NET KEY TO  VIEW THE NET WEIGHT

  2. TO CHANGE THE NET WEIGHT, PRESS INC KEY TO SELECT THE NET WEIGHT


STEP 2 REGISTER THE TARE WEIGHT OF THE CYLINDER

  1. PLACE THE EMPTY CYLINDER ON THE WEIGHTAGE PLATFORM

  2. PRESS THE TARE KEY

  3. CORRECTLY PLACE THE GUN ON THE CYLINDER

  4. AFTER THEN ENTER THE TARE WEIGHT OF THE CYLINDER. THEN PRESS ENTER KEY TO REGISTER THE TARE WEIGHT

  5. AFTER REGISTERING THE TARE WEIGHT THE SYSTEM STARTS FILLING BY ENABLING THE COARSE OUTPUT

STEP 3

  1. COARSE OUTPUT WILL BE IN ON POSITION TILL THE ACTUAL WEIGHT REACHES THE COARSE WEIGHT VALUE

  2. AFTER IT REACHES THE COARSE WEIGHT, COARSE OUTPUT WILL BE CUT OFF AND FINE OUTPUT WILL BE ENABLED

  3. FINE OUTPUT WILL BE IN ON POSITION TILL THE ACTUAL WEIGHT REACHES THE VALUE. AFTER IT REACHES THE VALUE, FINE OUTPUT WILL BE CUTOFF AND FILL OVER MESSAGE “FILOVR” WILL BE DISPLAYED IN THE LED DISPLAY

  4. AFTER THE FILL OVER MESSAGE


  1. GUN WILL BE RELEASED FROM THE CYLINDER

  2. THE TARE WEIGHT AND NET WEIGHT OF THE CYLINDER WILL BE SENT TO FILL CHECKING SYSTEM THROUGH SERIAL COMMUNICATION

NOTE: TO ABORT THE PROCESS PRESS THE FUNC KEY ONCE

STEP4 : WEIGH THE NET WEIGHT OF THE FILLED CYLINDER IN CHECK SCALE AND VL & O RING LEAK DETECTION TO BE DONE AT CVT.
STANDARD OPERATING PROCEDURES : PURGING UNIT

FOLLOWING TYPE OF CYLINDERS TO BE PURGED

  1. NEW CYLINDERS RECEIVED FROM THE MANUFACTURERS

  2. CYLINDERSB RECEIVED FROM STATUTORY TESTING PLANT AFTER TESTING

  3. CYLINDERS RECEIVED FROM THE REPAIRERS AFTER HOT REPAIR

  4. ANY OTHER CYLINDERS THAT MAY BE SUSPECTED TO CONTAIN AIR

OPERATION
THE AIR IS SUCKED FROM THE CYLINDER  BY MEANS OF A VACCUM PUMP AND THE PRESSURE INSIDE THE CYLINDER COMES DOWN BELOW THE ATMOSPHERIC PRESSURE THE CYLINDER THEN IMMEDIATELY FILLED WITH LPG VAPOUR ABOVE THE ATMOSPHERIC PRESSURE. IN THIS PROCESS, THE ENTIRE CYLINDER SPACE OCCUPIED BY THE LPG VAPOUR

PROCEDURE

  1. CHECK THE OIL LEVEL IN THE VACCUM PUMP BEFORE START

  2. CHECK AND ADJUST VALVES IN THE PURGING UNIT AS REQUIRED

  3. SWITCH ON THE PNEUMATIC SWITCH AND OPEN THE LPG VAPOUR LINE

  4. START THE VACCUM PUMP AND OBSERVE THE OPERATION FOR 4 OR 5 CYLINDERS

  5. IF THE OPERATION IS OKAY, LET IT GO AUTOMATICALLY

  6. IF NOT, RECTIFY THE PROBLEM AND FOLLOW THE ABOVE STEPS

  7. ONCE THE JOB IS OVER, STOP THE VACCUM PUMP AND SWITCH OFF PNEUMATIC SWITCH CLOSE THE LPG VAPOUR LINE




STANDARD OPERATING PROCEDURES : DELUGE VALVES

OPERATION OF DV IN AUTO MODE:
IN CASE OF FIRE, WHEN THE TEMPERATURE RAISES TO 79 DEGREE CENTIGRADE, THE QUARTZOID BULBS IN THE AIR LINE BREAKS AUTOMATICALLY AND THE DV GETS OPERATED.

THE ACTUATION OF QB WILL INITIATE THE FOLLOWING

  1. OPENING OF DELUGE VALVE OF THE AFFECTED ZONE AS WELL AS ADJACENT ZONES

  2. AUDIO VISUAL ALARM INDICATING THE AFFECTED ZONE AT THE FIRE PUMP HOUSE

  3. FIRE SIREN OF 1KM RANGE

  4. CLOSURE OF ALL REMOTE OPERATED VALVES

  5. TRIPPING OF CONTROL SUPPLY BARRING THE EMERGENCY POWER

  6. THE WATER SPRAY FROM ALL NOZZLES WITHIN 30 SECONDS

  7. THE FIRE WATER PUMPS WILL START BASED ON THEIR SET PRESSURE TO SUPPLEMENT / MAINTAIN THE FIRE WATER PRESSURE IN THE RING MAIN

OPERATION OF DV IN MANUAL MODE

  1. TO OPERATE DV IN MANUAL MODE, OPERATE THE CORRESPONDING EMERGENCY DRAIN VALVE AS INDICATED NEAR THE DV ROOM

  2. DV COULD BE OPERATED MANUALLY  BY OPENING THE CORRESPONDING BYPASS VALVE’

  3. DV COULD VBE OPERATED MANUALLY BY PRESSING THE REMOTE OPERATION BUTTON OF THE DV IN THE DV CONTROL PANEL LOCATED AT THE FIRE PUMP HOUSES.






STANDARD OPERATING PROCEDURES : FIRE ENGINES


  1. THE OPERATION IN MANUAL MODE REQUIRES HUMAN INTERVENTION

  2. IN CASE IT IS REQUIRED TO RUN THE FIRE ENGINE IN MANUAL MODE, THE PMCC OPERATOR AVAILABLE IN THE PLANT ALL THE 24 HOURS MAY BE CALLED ON WALKIE TALKIE TO START THE FIRE ENGINE GIVING THE SPECIFIC REASON FOR THE OPERATION OF THE SAME

  3. THE MANUAL OPERATION OF FIRE ENGINE REQUIRES


  1. FOR THE SPECIFIC FIRE ENGINE TO BE OPERATED, SWITCH OVER THE KNOB FROM AUTO TO MANUAL MODE IN THE RESPECTIVE ENGINE PANEL

  2. PRESS START BUTTON ON THIS PANEL. THIS WILL START THE FIRE ENGINE


  1. THE RPM SHOULD ALWAYS BE SET AT MAXIMUM RATED (2100RPM)

  2. THE HYDRANT LINE PRESSSURE CAN BE INCREASED OR DECREASED BY INCREASING OR DECREASING THE RPM BY ADJUSTING THE THROTTLING KNOB

  3. TO  STOP THE ENGINE, PRESS STOP BUTTON ON THE FIRE ENGINE PANEL

  4. THE ENGINE CAN BE PUT BACK TO AUTO MODE FROM THE FIRE ENGINE PANEL





STANDARD OPERATING PROCEDURES : EVACUATION UNIT

THE UNIT IS USED FOR EMPTYING OF CONTENTS FROM THE LPG CYLINDERS. THE CONTENTS ARE EMPTIED OUT WHEN THE CYLINDER IS FOUND LEAKY, DEFECTIVE OR OVER FILLED

  1. ENSURE THAT THE AIR PRESSURE IS ABOVE 5KG/CM^2 AND START THE CONVEYOR

  2. CHECK THE OIL LEVEL IN THE EVACUATION COMPRESSOR IS OK

  3. OPEN THE INELT STOPPER AND ALLOW THE CYLINDERS TO ENTER EVACUATION CYLINDER BANK AND THEN CLOSE THE STOPPER

  4. PRESS THE GUN DOWN AND FIX THE EVACUATION GUNS TO CYLINDERS BY PRESSING THE GUN DOWN KNOB

  5. OPEN LIQUID AND VAPOUR VALVES CONNECTED TO THE MAIN LINE  EVACUATION VESSEL PROPERLY FOR RECIEPT OF THE PRODUCT AND START THE EVACUATION COMPRESSOR

  6. SELECT THE PROPER VESSEL BY OPERATING THE PNEUMATIC VALVE

  7. ENSURE THAT THE CYLINDER RELEASE STOPPER IS IN CLOSED POSITION


    1. INSERT THE UNIT TO BEGIN EVACUATION

    2. MONITOR THE LIQUID FLOW THROUGH THE SIGHT FLOW INDICATOR AND WHEN THE FLOW STOPS, UPRIGHT THE UNIT

    3. DEPRESSURIZE THE CYLINDERS

    4. RELEASE THE GUNS

    5. RELEASE THE CYLINDERS FROM THE GUNS AND MARK CR WITH CHALK AND FLAG WITH GREEN CONE/CLIP. IF THE EVACUATED CYLINDER IS OF/UF, IT IS TO BE TREATED AS SOUND EMPTY AND NO MARKING TO BE GIVEN.

    6. ENSURE THAT THE LIQUID LEVEL IN THE VESSELS DOES NOT EXCEED 85% AT ANY POINT OF TIME PERIODICALLY INTER CHANGING THE VESSELS

    7. CLOSE ALL THE VALVES AFTER ENSURING THAT THE COMPRESSOR IS STOPPED


    PROCEDURE TO BE FOLLOWED FOR HANDLING OF WATER FILLED CYLINDERS

    1. WATER FILLED MARKET RETURN CYLINDERS RECEIVED AT PLANT SHOULD SEGREGATED

    2. EVACUATION OF THESE CYLINDERS SHOULD BE DONE AT EVACUATION UNIT ONLY

    3. AS A SAFTEY MEASURE NO ATTEMPT TO BE MADE TO DRAIN THE WATER FROM CYLINDERS WITHIN THE PLANT

    4. CONTENT OF THESE CYLINDERS TO BE TRANSFERRED TO STORAGE VESSELS THROUGH EVACUATION UNIT ALONG WITH LIQUID LPG

    5. SUCH EVACUATED CYLINDERS SHOULD BE PURGED BEFORE TAKING THEM  INTO CIRCULATION

    6. AFTER RECIEPT OF THE PRODUCT FROM WATER FILLED CYLINDERS IN THE STORAGE VESSEL DRAINING OF THE CONCERNED VESSEL TO BE ENSURED AS PER WATER DRAINING  PROCEDURE FOR VESSELS.



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