GURU GOBIND SINGH REFINERY

HPCL-MITTAL ENERGY LIMITED, TURNAROUND-2017

SECTION-A
Turnaround Job No N/A
SAP Work Order N/A
Equipment Type Exchanger
Equipment / Line No 509-E-001G
Equipment / Line Name

Work pack Description

Unit Name VGO

System

Package Allocation

Workpack Developed by Turnaround Team

Revision Rev-00
Revision date Nil

IMAGE NOT PROVIDED

WORKPACK APPROVAL

Name
PLANNER / JOB PACKAGE DEVELOPER

LEAD TA PLANNER

ASSET INTEGRITY

TECHNICAL SERVICE

MECHANICAL
ELECTRICAL/ INSTRUMENTATION

CIVIL

OPERATION MANAGER (ACEEPTED)

TA MANAGER

SCHEDULER / CONTROLLER (JOB PACKAGE ADDED INTO SCHEDULE)

Comments:

SAP Wo # : N/A Equipment Tag No#: 509-E-001G

FINERY
AROUND-2017

VIDED

Signed Date
 GURU GOBIND SINGH REFINERY
Workpack Revison Page (Section-B)
Work pack Information

Revision No Date Description Initiator

SAP Wo # : N/A Equipment Tag No#: 509-E-001G

*Initiator Person who propose for the changes

* Planner Person who is making the work pack
* Approver TA Manager
FINERY
tion-B)

Planner Approver
 GURU GOBIND SINGH REFINERY
Workpack Content (Section-C)
Work pack Information

Section Description
Section - A

Section - B

Section - C

Section - D

Section - E

Section - F

Section - G

Section - H

Section - I

Attachments

Attachment 1 Drawings & Technical Information

Attachment - 1.1

Attachment - 1.2

Attachment - 1.3

Attachment - 1.4

Attachment - 1.5

Attachment - 1.6

Attachment 2 Cetificates
Attachment - 2.1

Attachment - 2.2

Attachment - 2.3

Attachment - 2.4

Attachment - 2.5

Attachment - 2.6

Attachment - 2.7

Attachment - 2.8

Attachment 3 Plan & Procedures

Attachment - 3.1

Attachment - 3.2

Attachment - 3.3

Attachment - 3.4

Attachment - 3.5
 Attachment - 3.6

Attachment - 3.7

Attachment - 3.8

Attachment - 3.9

Attachment - 3.9

SAP Wo # : N/A Equipment Tag No#: 509-E-001G

 GURU GOBIND SINGH REFINERY
Workpack Content (Section-C)
Work pack Information

Description Status
Work pack Cover Page Included
Work pack revision

Work pack Content Included

Job Scope and Responsibility Matrix Included
Equipments Tools & Tackles Provision List Included
Consumables / Materials List Not Available
Spade / Blind / Isolation Checklist (LOTO) Included
Equipment inspection requirement

Electircal Requirement

Attachments

nical Information Status

Blind List and Marked Up P&ID Not Available
Marked Up Plot Plan Included
General Arrangement Drawings Included
Detail Drawings Included
Piping Isometric Drawings Not Applicable
Equipment Data Sheet Included

Cetificates Status
Cleaning Acceptance Certificate Included
Pressure Test Certificate Not Applicable
Calibration / Test Certificate (Control Valves, PRV & PSV) Not Applicable

Catalyst Loading Certificate Included

Boxup Certificate Included
Flange Joint Checklist

Torquing / Bolt Tensioning Checklist Included

Job Completion Certificate Included

Plan & Procedures Status

Planning Schedule & Duration (Level-IV) Not Available
Job Safety Analysis Included
Standard Maintenance procedure (SMP), checklist Not Available
Lifting Plan Included
De-contamination/ passivation procedure, MSDS Not Available
 Inspection Advise note Not Available
Inspection procedure Not Available
Waste disposal plan

Rescue Plan

Method statement

: 509-E-001G
 Equip Tag

Activit
y Responsibility Phase
ID

1 Pre TA
2 Pre TA

3 Pre TA
4 Pre TA

1 Operation Shutdown

2 Operation Shutdown

3 Operation Shutdown

1 Engineering Window
2 Engineering Window
3 Engineering Window
4 Engineering Window
5 Engineering Window
6 Engineering Window
8 Engineering Window
9 Engineering Window
10 Engineering Window
11 Engineering Window
13 Engineering Window
14 Engineering Window
15 Engineering Window
16 Engineering Window
17 Engineering Window
18 Engineering Window
19 Engineering Window

1 Commissioning & Start up

2 Commissioning & Start up

3 Commissioning & Start up

1 Post TA
2 Post TA
3 Post TA
4 Post TA
5 Post TA
 Activity description

Pre TA
External Scaffolding, wherever required
Tagging of the Blinds, valves .

Shifting of temporary blinds (For isolation) / Shell / New Tube bundles on site
Fabrication of temporary supports / spools and shifting at site
Operation Shutdown
Removal of Insulation, wherever required

Engineering Window
Piping dismantling & Blinding (____ IND)
Positioning of Crane As per required Capacity at designated area if reqd.
Dome cover bolts opening & dropping
Tube bundle pulling
Floating head cover bolts opening & dropping
Shift the tube bundle at Hydro jetting yard for cleaning
Clean the Shell & dome cover
Offer for inspection to check the clean Shell & Segments
Carryout minor repair and NDT test of Shell & Segments
Blasting & painting and cold compound application of Segments, if required
Replacement of new tube bundle
Box up Channel Cover, Channel Head with Shell Flange Ring and Floating Head Cover
Perform Tube test ( ____ Kg/cm2)
Removal of Channel Head with Shell Flange Ring
Box up Channel Head & Channel Cover
Preform Shell side Hydrotest ( ____ Kg/cm2)
Piping box-up and Deblinding
Commissioning

Post TA
Clean tube bundle by Hydro jetting
Offer for inspection to check the clean tube bundle, Shell & Segments
Shift the old tube bundle to designated area
Removal of Scaffolding
House keeping of the Area
 Duration in Hrs.

Predecessors

Relationship

Supervisor

Gen Fitter

Maint Rigger

Maint Helper

Scaffolder

Fabrication
Supervisor

Fabricator

Welder

Grinder

Gas Cutter

Fab. Rigger
Manpower
Job Scope
GUR
 Fab. Helper

Manpower
Hydrojetter

Torqueing
Technician
Bundle puller
operator

Crane operator

Hydra/Forklift
operator

P & M Helper

Insulation
Technician/Sup
GURU GOBIND SINGH REFINERY

Ele. Technician

Inst. Technician
Job Scope and Responsibility Matrix (Section - D)

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Maint. Supervisor

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Gen Fitter

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Maint Rigger

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Maint Helper
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0
0 0 0 0
 Man-hours

Crane operator

Hydra/Forklift
Bundle puller

P & M Helper
Fab. Helper
Fab. Rigger
Fabrication

Hydrojetter
Supervisor

Technician
Gas Cutter
Scaffolder

Fabricator

Torqueing

operator

operator
Grinder
Welder

0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
 Equipment Resources
Inst. Technician
Technician/Sup

Ele. Technician

Total Total Man-

Insulation

Manpower hours Per

Per Activity Activity Crane Hydra

0 0 0 0 0
0 0 0 0 0

0 0 0 0 0
0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0

0 0 0 0 0
0 0 0 0 0
Equipment Resources

Rigging Plan
Reqd. -Yes
Hydro jetting Welding or No
Bundle puller
Machine Machine
 GURU GOBIND SINGH REFINERY
Equipment,Tools & Tackles Provision List (Sect
Requirements
S.No. Qty's

1 Limited
2 Un-Limited
3 Un-Limited
4 Limited
5 Limited
6 Limited
7 Un-Limited

8 Un-Limited

9 Un-Limited

10 Limited

11 Limited
12 Limited
13 Un-Limited
14 Limited

15 Limited
16 Limited
17 Limited
18 Limited
19 Limited
20 Limited
21 Limited

22 Limited
23 Limited
24 Un-Limited
25 Limited
26 Limited
27 Limited
28 Limited
29 Limited
30 Un-Limited
31 Un-Limited
32 Un-Limited

33 Un-Limited
34 Un-Limited
35 Un-Limited
36 Un-Limited
37 Un-Limited
38 Un-Limited
39 Un-Limited
40 Un-Limited
41 Un-Limited
42 Un-Limited
43 Limited
44 Limited
 45 Limited
46 Limited
47 Limited
48 Un-Limited

49 Un-Limited
50 Un-Limited
51 Limited
52 Un-Limited
53 Un-Limited
53 Limited
Note-1 Coverall, Helmet, safety shoes, Goggles, Ear protection, Hand Gloves, Chin Strap
Note-2 Personal Fall Arrestor System, Disposable Coverall,Hotwork PPE,Gloves(PVC,NITRILE,LATEX) Refer: JSA &
Note-3 Respirators,Self Containing Breathing Apparatus (SCBA)
Note-4 To Be Mentioned by Job Co-Ordinator (Company & Contractor)
Note-5 Line Insert Spades Contractor To Fabricate, As per Required Size & Company will be Provide Enough Steel
SAP Wo # : N/A
 GURU GOBIND SINGH REFINERY
Equipment,Tools & Tackles Provision List (Section - E)
Requirements Responsibility
Description Company Main
Contractor

Multi Gas Detector

Minimum PPE (Refer Note-1)
Special PPE (Refer Note-2)
Breathing Apparatus (Refer Note-3)
Fire Extinguisher (For Class A,B & C)
Fire Hoses & Nozzle
Safety Supervisor/ Hole watch / Confined Space Entry Personnel

Safety Sign Board

Warning Tapes & Barricading Materials

Communication Device: Radio / Walkie Talkie ( for Confined Space Jobs)

Special Tools (Refer Note-4)

Test Rings for Exchanger Hydro test
Spade & Blind for LOTO (Refer Note-5)
HP Water Jetting Equipment and its accessories, manifolds

Crane (Capacity As per Lifting Plan) , Hydra

Fork Lift
Small Truck (Up to 5 Ton Capacity)
Trailer
Vacuum Truck / Gully Sucker
Diesel generator (With Spill Collection Tray + Fire Extinguisher)
Welding machine (With Spill Collection Tray + Fire Extinguisher), mother oven and
carrying oven
Torque tools & equipment
Air compressors (With Spill Collection Tray + Fire Extinguisher)
PWHT Equipment + Heating Coils + Heating Element & Recorders
Vacuum Cleaner (Industrial Use)
Flange Face Machining Machine
Pipe Cold Cutting Machine (Pneumatic Type)
Beam Trolley (For Manual Rigging)
Power cables and Extension cord for contractor equipment
Rigging/ lifting Tools and tackles
General Tool /tackles /spanners/ non sparking tools/ power tools
Oxygen / Acetylene bottles and associated equipment + Gauges

General Consumables
Area lighting - General
Hand lamps ( 24V EX rated)
Electrical testing equipment for contractor equipments
Half Drums (For Re-Usable Stud Bolt Storage & Cleaning)
Wooden Pallet
Manual / Hydraulic Pallet Lifter
Tarpaulins
fire blankets for hot works
Hoses, manifolds and fittings for operation requirement
Air-conditioning Equipment (For Confined Space)
Scaffold material
 Refractory / Insulation & Cladding materials
Blasting / Painting Equipment
Valve, PSV etc. Testing equipment & Work Bench
Air movers / ventilation fans/ Eductor with required accessories and hoses

Service water, Plant Air, Nitrogen & Low Pressure Steam (LPS)
Waste handling + Empty Drums
Hydro test / pneumatic test Tools & Equipment's
Heat Exchanger Chemical Cleaning
Personal H2S & O2 detector with distress alarm
Rescue Equipment like tripod
safety shoes, Goggles, Ear protection, Hand Gloves, Chin Strap
estor System, Disposable Coverall,Hotwork PPE,Gloves(PVC,NITRILE,LATEX) Refer: JSA & MSDS
Containing Breathing Apparatus (SCBA)
by Job Co-Ordinator (Company & Contractor)
s Contractor To Fabricate, As per Required Size & Company will be Provide Enough Steel Plates
Equipment Tag No#: 509-E-001G
 Other Not applicable
Contractor

electrical to confirm


 GURU GOBIND SINGH REFINERY
Consumables / Materials List (Section - F)

S No. SAP Item Code Item / Material Description

1 2000065143 STUD W-NUT 660 CL-A 8UN 3 535MM 2-1/2IN

2 2000065143 STUD W-NUT 660 CL-A 8UN 3 535MM 2-1/2IN
3 2000065116 STUD W-NUT 660 CL-A 8UN 3 640MM 3IN
4 2000065116 STUD W-NUT 660 CL-A 8UN 3 640MM 3IN
5 2000007762 GSKT RJ SS347 OCT R77
6 2000007762 GSKT RJ SS347 OCT R77
7 2000047511 GSKT RJ SS347 OCT R75
8 2000047511 GSKT RJ SS347 OCT R75
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
 51
52
53
54
55
SAP Wo # : N/A Equipment Tag No#: 509-E-001G
 REFINERY
st (Section - F)

Installed Qty Installed Qty X no. of Required UOM

times Quantity
20 0.3 6 EA
20 0.3 6 EA
20 0.3 6 EA
20 0.3 6 EA
1 3 3 EA
1 3 3 EA
1 3 3 EA
1 3 3 EA
 GURU GOBIND SINGH R
Inspection Requirement (Se
Unit No:-

Driver:-

1 Statutory/ Legal compliance

2 TS Driven

3 Inspection driven

4 Maintenance driven

5 Operation Driven

Summary of inspection requirements:-

Activity type Details Time required

SCAFFOLDING

INTERNAL INSPECTION

EXTERNAL INSPECTION

VISUAL

NDT (DP, Thickness survey)

IN-Situ metallography

Sandblasting, painting

Brief Description of job:-

Inspection task & time requirement:-

S no Activity Description
1

3
 4

Expected repairs during TA:-

Support required for inspection:-

History of Equipment:-

Marked Drawing:-
Planner/Executor
GURU GOBIND SINGH REFINERY
Inspection Requirement (Section - G)
Equipment Tag No:-

Please Tick( wherever

Activity type Details Time required
applicable)
UT

BOROSCOPE

MPT

EDDY CURRENT

RT

OTHERS ( IF ANY )

Time required in
on
Hours
AI
Please Tick( wherever
applicable)

Status
 GURU GOBIND SINGH
Blind Checklist- (Sec
S No Blind No P & ID no Equipment /Pipeline No Blind Size Blind Type (End, Location FLANGE SIZE (INCH) RATING
Tail, Spec)

1 24" 900
2 12" 900
3 24" 900
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
 38
39
40

SAP Wo # : N/A
GURU GOBIND SINGH REFINERY
Blind Checklist- (Section - H)
ACTIVITY STATUS

INSTALLED CONFIRMED REMOVED CONFIRMED

(By Contractor) (By HMEL Operation) (By Contractor) (By HMEL Operation)
DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE NAME SIGN
Equipment Tag No#: 507-R-001 DHDT Reactor
NFIRMED
L Operation)
Remarks
 GURU GOBIND SINGH REFINERY
Electrical Requirement Section- I

Equipment No
Sno Items Required Required Not required
1 Flood light
2 Hand lamp, 24V
3 Extension board
4 Blower
5 1-phase welding machine
6 3-phase welding machine
7 1-phase grinding/ buffing machine
8 Stress relieving machine
9 Hydrojetting machine
10 Air conditioning
11 Air compressor (electric operated)
12 Oven
REFINERY
ection- I

UOM Qty Location Remarks

 GURU GOBIND SINGH REFINE
Cleaning Acceptance Report (TA-2016)
(Attachment-2.1)

EQUIPMENT DETAIL

DATE & TIME OF

INSPECTION

SAP WO NUMBBER N/A PLANT / UNIT NAME

EQIPMENT
EQUIPMENT NUMBER 507-R-001 DESCRIPTION

CLEANING TYPE

HYDROJETTING X WATER WASHING

CHEMICAL CLEANING X DRY CLEANING

MECHANICAL CLEANING NEUTRALIZATION

AIR BLOWING OTHER

CLEANING AREA

INTERNAL CLEANING SHELL SIDE

EXTERNAL CLEANING X TUBE SIDE

RESULT

THE EQUIPMENT HAS BEEN CHECKED FOR CLEANINESS AND FOUND

SATISFACTORY UNSATISFACTORY

COMMENTS

Comment No:01

Comment No:02

CONTRACTOR HMEL INSPECTION

Mech AI

SIGNATURE
 NAME

DESIGNATION

COMPANY NAME
SINGH REFINERY
e Report (TA-2016)
ment-2.1)

DHDT

DHDT Reactor

EANINESS AND FOUND

ACTORY

MEL INSPECTION

TS OPR
 GURU GOBIND SINGH REFIN
Catalyst Loading Certificate (TA-201
(Attachment - 2.4)
DATE
EQUIPMENT DETAIL
SAP WORK ORDER NUMBER N/A
EQUIPMENT / LINE NUMBER 507-R-001
EQUIPMENT / LINE NAME DHDT Reactor
UNIT NAME DHDT

CHECK LIST
ACTIVITY

Screens Are In Place

All Trays, Valves/Bubble Cap & Clamps In Place

All Rings Installed

All Repairs And Hot Work Completed

All Tray'S Manways & Handholes Boxed-Up

Trays Gaskets Renewed

Bolts And Nuts Greased

Internal Lighting Removed

Internals Scaffolding Removed

Others ( If Any )

CLEARANCE
CONTRACTOR INSPECTION MECH
SIGN

NAME

DESIGNATION

DATE & TIME

ALL INTERNAL EQUIPMENT or FIXTURES ARE IN COMPLIANCE WITH DESIGN DOCUMENTS

CATALST MATERIALS IN COMPLIANCE WITH DESIGHN & PROCESS DOCUMENTS

AND ALL TRAYS / INTERNALS ARE IN GOOD CONDITION AND PROPERLY FIXED.

THE EQUIPMENT IS RELEASED FOR CATALYST LOADING

HMEL PROCESS ENGINEERING (TS) HME
SIGN
NAME

DESIGNATION

DATE & TIME

 SINGH REFINERY
g Certificate (TA-2016)
hment - 2.4)
DATE
TAIL

T
ACCEPTED NOT ACCEPTED NOT APPLICABLE

E
AI TS OPR

HMEL OPERATION
 GURU GOBIND SINGH REFI
Boxup Certificate (TA-2016)
(Attachment - 2.5)
DATE
EQUIPMENT DETAIL
SAP WORK ORDER NUMBER N/A
EQUIPMENT / LINE NUMBER 507-R-001
EQUIPMENT / LINE NAME DHDT Reactor
UNIT NAME DHDT

PRE CLEANING INTERNAL CHECK LIST

FINAL INTERNAL INSPECTION CHECK LIST

ACTIVITY
All Debris Removed From Inside
All Nozzles inspected
All Trays, Valves/Bubble Cap & Clamps In Place
All Internals Installed
All Repairs And Hot Work Completed
All Trays Manways Boxed-Up
Gaskets Replaced as per spec
Bolts And Nuts as per spec
Internal Lighting Removed
Equipment has been internally cleaned and cheked
Internals Scaffolding Removed
Others ( If Any )

REMARKS

BOX-UP CLEARANCE
 CONTRACTOR INSPECTION
AI
SIGN

NAME

DESIGNATION

DATE & TIME

SINGH REFINERY
cate (TA-2016)
ment - 2.5)

IL

ACCEPTED NOT ACCEPTED NOT APPLICABLE

 HMEL INSPECTION
TS MECH OPR
 GURU GOBIND SINGH REFINERY
Flange joint Checklist
Attachment 2.6
Flange joint STUDS
SR No. LINE NO/ISO NO.
No SIZE RATING SIZE SPEC

10

CONTRACTOR INSPECTION
AI
SIGN

NAME

DESIGNATION

DATE & TIME

FINERY
t

GASKET Last chance

Checked (Yes or inspection done
TOTAL NO. MATERIAL PERMANENT TEMP. (yes or no)
No)

HMEL INSPECTION
MECH OPR
 GURU GOBIND SINGH REFINERY
Torquing / Bolt Tensioning Checklist (TA-2016)
(Attachment - 2.7)

EQUIPMENT DETAIL
SAP WORK ORDER NUMBER

EQUIPMENT / LINE NUMBER

EQUIPMENT / LINE NAME

UNIT NAME

TORQUING CHECK LIST

S No Nozzle No / Bolt Material Size Rating Torque Pass1 Pass2 Pass3
Spade Tag Value in PSI 30% 60% 100%
No
1 MH 1 36" 900
2 I1 1 24" 900
3 I2 1 12" 1500
4 O1 1 24" 900
5 02/1-6 6 8" 900
6 02/7-9 3 8" 900
7 TW/1-4 4 4" 900
8 PI 1 3" -
9 SV/1-4 4 4" -
10 AO/1-2 2 500ID -
11 S01 1 1060ID -
12 S02/1-3 3 1086ID -
13

14

15

16

17

18

19

20

21

22

23

24

25

ACC = Accepted, Not-ACC = Not Accepted, N / A = Not Applicable

Torquing Value & Sequence Verified

CONTRACTOR INSPECTION HMEL INSPECTION (MECH)
SIGN
NAME

DESIGNATION

DATE & TIME

SINGH REFINERY
ning Checklist (TA-2016)
ment - 2.7)
DATE

N/A
507-R-001
DHDT Reactor
DHDT
ST
Final Torquing Tag No ACC Not- ACC N / A
Check

able

Verified
HMEL INSPECTION (MECH)
 GURU GOBIND SINGH REF
Job Completion Certificate (TA-201
(Attachment - 2.8)

EQUIPMENT DETAIL
SAP WORK ORDER NUMBER

EQUIPMENT / LINE NUMBER

EQUIPMENT / LINE NAME

UNIT NAME

JOB TYPE
CIVIL

STRUCTURAL

MECHANICAL

PIPING

ELECTRICAL

INSTRUMENTATION

AUTHORITIES
EXECUTED BY (Performing Party)

SIGN

NAME

DESIGNATION

DATE & TIME

INSPECTED / VERIFIED BY

AI TS
SIGN

NAME

DESIGNATION

DATE & TIME

ACCEPTED BY
(Operation Engineer)
SIGN

NAME

DESIGNATION

DATE & TIME

D SINGH REFINERY
on Certificate (TA-2016)
chment - 2.8)

Date:-
PMENT DETAIL
N/A

507-R-001

DHDT Reactor

DHDT

OB TYPE
INSPECTION

SCAFFOLDING

INSULATION & REFRACTORY

PAINTING

HVAC

OTHERS ( IF ANY )

THORITIES
) VERIFIED BY (Execution engineer)

Approved by (Maintenance Manager)

TS

Approved by (Operation Manager)

 GURU GOBIND SINGH
Job safety analysis (Risk Hazard
Attachment- 3.2

SAP Work Order No:-

Catalyst Replacement, Internal Inspection
Main Activity
Plant & Location
Sub Activities
List the tasks required to perform the
S.No. activity in the sequence they are carried
out

1 Erection or Removal of Scaffolding

1)Site preparation

2 2) Shifting of materials

3 3) Erection / Removal of scaffold pipes

JSA Done by:

Name

(Note: JSA to be done by issuer and acceptor of work permit. In case required, represent
 GURU GOBIND SINGH REFINERY
Job safety analysis (Risk Hazard Identification)
Attachment- 3.2

Equipment Tag No#: 507-R-001 DHDT Reactor

Catalyst Replacement, Internal Inspection & Rectification Works

Hazards
(Both Existing as well as
potential)Against each task list the Hazards that
could cause injury/damage to people, equipment
or the
environment.

Damages due to use of defective tools and lack of job clarity

Physical Injury to body parts

Fall / Slip of persons from height

Collapse of scaffold

Fire due to breaking of small bore piping

High temp (nearby lines)conditions

damaged to property due to Struck against by materials while lifting

Designation

of work permit. In case required, representative from other discipline can also join the team for JSA)
507-R-001 DHDT Reactor

Control Measures List the control

measures required to eliminate or
minimize the risk of injury arising from
the identified Hazard.

Ensure that Tool box talk is being carried out about the
execution of the jobs and about right tools by the
contractor supervisors

work permit procedures are followed

Ensure that Use of mandatory PPEs

Ensure that Full body harness with double lanyard, safety

net carry tools in bags

Ensure that Use of standard approved scaffolding

materials and procedures, get it approved by concerned
authority and barricading of scaffolding area.

Dont hit/touch/climb/stand on any small bore piping of

instruments & equipments , Mini responder if reqd

Awareness to cover with non asbestos blanket after

wearing kevlar gloves.

Use rope for lifting and lowering pipes, clamps , spanners

Ensure that Escape route education is given to workers

Signature

pline can also join the team for JSA)

 GURU GOBIND
LIFTING PL
(Attach
Notification No.:
* mark fields to be filled by crane operator
Part A and B is must
Part C is required if load is more than 5T and/or more than 50% of rated capacity of mobile crane a
All critical handling(when load is 75% or more of rated capacity of crane) must accompany with a l
operator, rigging team and user deptt HOD.Pl note no handling shall be done if the wind speed is 2

A JOB DESCRIPTION
1 Section/Department
2 Sub section/Unit
3 Exact Location
4 Equipment
5 Lifting Part Description

6 Outer dimensions of Lifting Part{LxBxH(W)}

7 Weight of Lifting Part
8 Weight of part obtained from (the source, eg:Drg/supplier
data/calculated/estimated)
9 Height where Part to be Lifted
10 Part to be released at(site/location)
11 Whether the crane is required at release site?
12 Whether the transport vehicle is required?
13 Are you sure that this lifting cannot be carried with available site Hoist/Crane

14 The above handling task comes under scope of

JOB CONTROL AND SUPERVISION
1 Crane Capacity Required
2 Time and Date of crane requirement at the requested site
3 Crane deputation Time and Date *
4 Expected Duration of crane engegement
5 Actual duration *
6 Expected Time and Date of crane release
7 Actual time of release *
8 Site Incharge controlling the rigging task at both end locations (The mobile
equipment will repot to whom)
9 Work order initiating section Incharge/Mgr
B SITE OPERATION CONTROL
1 Could the load if dropped, release hazardous materials?
2 Is Crane approach pathway is clear?
3 Is Crane swing area is clear or not
4 Is there any underground pipeline/cable beneath the perking area?
5 Is crane parking area has solid compacted smooth ground
6 Is Crane exit pathway is clear?
7 Has the necessary LOTO practice been completed on the equipment and part
being handled?
(plugging/isolating/pressure release/earthing the network line)
8 No. of Workmen engaged
9 Ensure that the part bieng handled has been released out of its clamp/fixrtures
and is vacated/emptied.
10 Ensure part lifting lugs/fixture are securely welded & safe

11 Ensure only skilled manpower at handling site

12 Ensure use of fall arrestor if required
13 Ensure use of life line if required
14 Ensure use of required PPE
15 Ensure use of full body harness
16 Ensure height work permit taken if required
17 Ensure hot work permit taken if required
18 Ensure Electricity isolation permit taken if required
19 Ensure cofined space work permit taken if required
20 Ensure area baricading & no entry for unconcered
21 Ensure sufficient area illumination if required
C RIGGING AND LIFT PLAN
1 Maximum Centre of load to Centre pin of crane Horizontal distance(where part
is lying) (C/C Hz Distance-refer page 2)

2 Height from Horizontal plane

3 * (To be filled by crane operator)
4 Working Radius *
5 Crane Boom Length *
6 Crane capacity at particular radius & boom Length(From chart) *
7 C/C Hz. distance where part to be shifted
10 Sling rated capacity and length *
11 No. of slings *
12 Capacity of D shakles *
13 No. of D shakles *
14 Whether Guide rope tied or not

After Job completion

Contractor Engineer Name & Sign.

Section Supervising Engineer Name & Sign.
 Note:
1
Against a Requisition the Equipment shall be allotted for requested period(M
further use, Requisition extension required with reason.
2
Requisition shall be submitted/sent 24 Hours before the Intended usage. Us
pertaining data as required. Job shall be executed in presence of site inchar
3
Requisition shall remain valid till lapse of Requested Time only if prior cance
4
Allotment subject to availability of Equipment.
5
Without dulyfilled requisition, no equipment will be deputed.
6
Log Book and workorder to be signed by user after completing the job with
Name]
The crane operator may deny the job if he forsee any unsafe situation. In su
7
rigging committee.

Sample Rigging Sketch

ACTUAL RIGGING SKETCH(To be drawn by requestor)

C/C Hz Distance
 C/C Hz Distance

Preliminary Rigging Sketch(To be drawn by requestor)

GOBIND SINGH REFINERY
LIFTING PLAN (TA-2016)
(Attachment - 3.4)
Order No: Time:
Contact no:
Mail id:heshelpdesk@hmel.in
mobile crane at job approach radius.
mpany with a lift plan/sketch and should be pre assessed on site by rigging committee, comprising of cra
wind speed is 20mph(9m/s) or more.

UOM/
Options Qty./ Measurement/Remarks
OFFSITE maintenance
mechanical
offsite area
minitruck

plate

2x1x4
MT 500 kg
-

Mtr.
site
Yes/No yes
Yes/No yes
NA/Yes no

HMEL CONTRACTOR

MT
Date: Time:
Date: Time:
Hrs

Date: Time:

Name: Name:
Mobile No: Mobile No:

Name: Sign/Mobile No::

Yes/No NO
Yes/No YES
Yes/No YES
Yes/No NO
Yes/No YES
Yes/No YES
Yes/No YES

Nos 3
OK/NA OK

OK/NA OK

OK/NA OK
OK/NA OK
OK/NA OK
OK/NA OK
OK/NA NA
OK/NA NA
OK/NA OK
OK/NA NA
OK/NA NA
OK/NA OK
OK/NA OK

Mtr. NA

Mtr.

Deg.
Mtr.
MT
Mtr.

Nos.
MT
Nos.
Yes/
NO{NA)

Crane operator Name & Sign

ted period(Maximum 1o hrs) only, for

d usage. User must request for pre-assessment of job if in doubt and must present th
of site incharge or empowered nominee.
f prior cancellation and /or extension is not done.

the job with starting and closing time [Put Sign. with

uation. In such case, the job shall be evaluated by

H
LOAD:55MT
ei
gh
t
fr
o
m
Hz
Pl
an
e
 Date:

ssed on site by rigging committee, comprising of crane

Actual
Observation

*
*

The site incharge

shall provide two nos
of walky-talky to
crane crew to ensure
safe handling
ment of job if in doubt and must present the

H
ei
gh
t
fr
o
m
Hz
Pl
an
e