Category: Engineering SOP

SOP Title: Cleaning of RO Water Tank

1. Objective:

To define written procedure for Cleaning of RO Water Tank.

2. Scope:

This procedure is applicable for the cleaning of RO Water Tank installed in the Engineering Department.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the RO Water Tank as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexure. To ensure the compliance of procedure.

4. 4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while cleaning the RO Water Tank.
5.2.2	Plan the RO Water Tank cleaning activity prior to the due date of cleaning.
5.2.3	Material Safety Data Sheet for all chemicals is to be collected and use in case of any emergency.
5.2.4	Use proper maintenance tools while cleaning the RO Water Tank.
5.2.5	Ensure that a trained person is carrying out the cleaning activity.
5.2.6	Inform to the user department before the start of cleaning activity.
5.2.7	Ensure that all cleaning activities are supervised by another individual until completed.
	Procedure for the Cleaning of RO Water Tank
5.2.8	Open the top cover of the RO Water Tank.
5.2.9	Ensure that the water tank respective water line valve is closed and the drain valve is open.
5.2.10	Ensure tank is empty before cleaning activity and drain out the water by the bottom valve of the RO Water Tank and get down the inside the tank.
5.2.11	Scrub the internal surface of the RO Water Tank with a nylon scrubber and wash the surface by water.
5.2.12	After scrubbing the walls drain out the water content completely from RO Water Tank with the help of bottom valve of the storage tank.
5.2.13	Sludge and dirty water generated during cleaning are to be disposed of by proper waste disposal procedure.
5.2.14	Again scrub with detergent solution (1% v/v Neutral Liquid Detergent (labolene/extran) thoroughly and then wash out with water.  After removing the traces of detergent give final rinse with water again.
5.2.15	Prepare 10.0 litres of 10 ppm of Chlorine using Sodium Hypochlorite solution as per given formula in the container. Quantity of Sodium Hypochlorite required in mg (Q) in 10.0 litres water =   10 A Where `A` is Assay of Sodium hypochlorite (i.e.  Percentage of available Chlorine in Sodium Hypochlorite )
5.2.16	Wash the RO Water Tank with 10 ppm Sodium Hypochlorite solution.
5.2.17	After treatment with 10 ppm of Chlorine solution, rinse the tank thoroughly with purified water.
5.2.18	Update the “RO Water Tank Cleaning Record” as per Annexure.
5.2.19	Ensure that the RO Water Tank is cleaned at least once in three months.
5.2.20	Intimate Quality Control Department to collect the rinse sample by sending “Water Sample Intimation Slip” to Quality Control Department.
5.2.20	Water Sample Intimation Slip containing two copies (One original and one carbon copy.
5.2.21	After water sample analysis, Quality Control Department sends the carbon copy of “Water Sample Intimation Slip” with result to Engineering Department and original copy retains with Quality Control Department.
5.2.22	After receive the water sample analysis result from Quality Control Department, put the tag “Ready for Use” and start the RO unit and inform the user department.

 

 

6. Abbreviation:

Abbreviation	Expansion
RO	Reverse Osmosis
UTL	Utility

  

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Cleaning of Over Head Raw Water Tank 

 

1. Objective:

To define written procedure for Cleaning of Over Head Raw Water Tank.

2. Scope:

This procedure is applicable for the Cleaning of Over Head Raw Water Tank installed in the Engineering Department.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Cleaning of Over Head Raw Water Tank as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexures. To ensure compliance of the procedure.

4. 4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

  5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while Cleaning the Over Head Raw Water Tank.
5.2.2	Plan the Over Head Raw Water Tank cleaning activity prior to the due date of Cleaning.
5.2.3	Material Safety Data Sheet for all chemicals is to be collected and use in case of any emergency.
5.2.4	Use proper maintenance tools while cleaning the Over Head Raw Water Tank.
5.2.5	Ensure that a trained person is carrying out the cleaning activity.
5.2.6	Inform to the user department before the start of cleaning activity.
5.2.7	Ensure that all cleaning activities are supervised by another individual until completed.
	Equipments and Chemicals Required:
5.2.8	1.     Plastic Brush. 2.     Bucket. 3.     Dusting Cloth & Sponge. 4.     Potassium Permanganate. 5.     Neutral Liquid Detergent (Labolene/Extran). 6.     Water.
	Procedure for the Cleaning of Over Head Raw Water Tank:
5.2.9	Open the top cover of the Water Tank.
5.2.10	Ensure the respective water line valve of the water tank is closed and the drain valve is open.
5.2.11	Ensure tank is empty before cleaning activity and drain out the water by opening the bottom valve of the main storage tank and get down inside the tank.
5.2.12	Scrub the internal surface of the Over Head Raw Water Tank with a nylon scrubber and wash the surface by water.
5.2.13	After scrubbing the walls, drain out the water content completely from over head tank with the help of bottom valve of the main storage tank.
5.2.14	Sludge and dirty water generated during cleaning to be disposed by proper waste management procedure.
5.2.15	Again scrub with detergent solution (1% Volume by Volume Neutral Liquid Detergent (labolene/extran)) thoroughly and then wash out with raw water.  After removing the traces of detergent give final rinse with water again.
5.2.16	Finally dissolve 1 gm of Potassium permanganate in 10 liters of water in bucket and scrub the inner surface and bottom of the tank with brush thoroughly.
5.2.17	Finally flush inside wall of the water tank with Purified Water till the visual inspection is satisfactory.
5.2.18	Update the “Over Head Raw Water Tank Cleaning Record” .
5.2.19	Ensure that the Over Head Raw Water Tank is cleaned at least once in six months.
5.2.20	Intimate Quality Control Department to collect the rinse sample by sending “Water Sample Intimation Slip” to Quality Control Department.
5.2.21	Water Sample Intimation Slip containing two copies (One original and one Carbon copy.
5.2.22	After water sample analysis, Quality Control Department sends the carbon copy of “Water Sample Intimation Slip” with result to Engineering Department and original copy retains with Quality Control Department.
5.2.23	After receiving the water sample analysis result from Quality Control Department, fill the Over Head Raw Water Tank with the Raw Water and put the tag “Ready for Use” and inform the user department.

 

6. Abbreviation:

Abbreviation	Expansion
QAD	Quality Assurance Department
EGD	Engineering Department
UTL	Utility

 

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Cleaning of Underground Water Sump

 

1. Objective:

To define written procedure for Cleaning of Underground Water Sump.

2. Scope:

This procedure is applicable for the Cleaning of Underground Water Sump installed in the Engineering Department.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Cleaning of Underground Water Sump as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexures. To ensure the compliance of the procedure.

4. 4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while Cleaning the Underground Water Sump.
5.2.2	Material Safety Data Sheet for all using chemicals to be collected and use in case of any emergency.
5.2.3	Plan the Underground Water Sump cleaning activity prior to the due date of cleaning.
5.2.4	Use proper maintenance tools while cleaning the Underground Water Sump.
5.2.5	Ensure that a trained person is carrying out the cleaning activity.
5.2.6	Ensure the before cleaning activity, inform to the user department.
5.2.7	Ensure that all manhole / tank covers are opened and are supervised by another individual till the activity is under progress.
	Equipments and Chemicals Required:
5.2.8	1.     Plastic Brush. 2.     Bucket. 3.     Dusting Cloth & Sponge. 4.     Potassium Permanganate. 5.     Neutral Liquid Detergent (Labolene / Eextran). 6.     Water.
	Procedure for the Cleaning of Underground Water Sump:
5.2.9	Open the top cover of the Underground Water Sump.
5.2.10	Ensure the respective water line valve of the water tank is closed and the drain valve is open.
5.2.11	Ensure tank is empty before cleaning activity and drain out the water by using external pump.
5.2.12	Install a Portable Ladder inside the tank with proper supporting and get down the inside the tank.
5.2.13	Scrub the internal surface of the underground tank with a nylon scrubber and wash the surface by water.
5.2.14	After scrubbing the walls drain out the water content completely from underground tank with the help of external water pump and plastic bucket.
5.2.15	Sludge and dirty water generated during cleaning to be disposed by proper waste management procedure.
5.2.16	Again scrub with detergent solution (1% Volume by Volume Neutral Liquid Detergent (labolene/extran)) thoroughly and then wash out with bore well water.  After removing the traces of detergent give final rinse with water again.
5.2.17	Finally dissolve 1 gm of Potassium Permanganate in 10 liters of water in bucket and scrub the inner surface and bottom of the sump with brush thoroughly. Finally flush inside wall of the water tank with Bore well water till the visual inspection is satisfactory.
5.2.18	Ensure that the Underground Water Sump is cleaned at least once in six months.
5.2.19	Update the “Underground Water Sump Cleaning Record” as per Annexure.
5.2.20	Intimate Quality Control Department to collect the rinse sample by sending “Water Sample Intimation Slip” as per Annexure to Quality Control Department.
5.2.21	Water Sample Intimation Slip containing two copies (One original and one carbon copy.
5.2.22	After water sample analysis, Quality Control Department sends the carbon copy of “Water Sample Intimation Slip” with result to Engineering Department and original copy retains with Quality Control Department.
5.2.23	After receive the water sample analysis result from Quality Control Department, fill the Underground Water Sump with the Raw Water and put the tag “Ready for Use” as per Annexure and inform the user department.

 

6. Abbreviation:

Abbreviation	Expansion
SOP	Standard Operating Procedure
UTL	Utility
w.r.t	With Respect To

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Preventive Maintenance of Factory & Buildings

 

1. Objective:

To lay down a procedure for the Preventive Maintenance of Factory & Buildings of the site for Mechanical & Structural Impairment.

2. Scope:

This procedure is applicable for all Buildings and Civil Structures present at site

3. Responsibility:
   • Engineering Department: To prepare and review the SOP. To follow the procedure laid down for the maintenance of all Buildings and Civil Structures as per this SOP.
   • Head of Engineering Shall be responsible for overall compliance to the laid down procedure.

3.3 Quality Assurance Department: To review and approve the SOP and Annexures. To ensure compliance of the procedure.

 

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

5.2.    Operational Procedure:              

	Requirements:
5.2.1	Inputs: Building construction materials & its related Accessories, Paints & Waterproofing. Records: Building maintenance checklist, civil architectural/structural drawings.
	Safety Precautions/Instructions:
5.2.2	Wear appropriate Personal Protective Equipment like Safety shoes, Helmets, Safety belts, relevant safety permits while doing the activity.
	Operation
5.2.3	Check the Factory and Buildings for Civil, Mechanical & Structural impairment. Prepare List of Factory and Buildings.
5.2.4	Fill the checklist for various Buildings & Structures. Prepare Check List for Civil Maintenance of Factory & Buildings.
5.2.5	Check the compound wall of the factory premises for: • Steadiness • Visible cracks • Growth of wild plants
5.2.6	Check the integrity of the Waterproofing of Terraces & Gutters.
5.2.7	Check the opening of Rain water pipes.
5.2.8	Check the integrity of Parapet walls of terraces.
5.2.9	Check the integrity of the Gable wall joints of the Buildings.
5.2.10	Check that the Terraces & Gutters are clean & there is no Fungus formation.
5.2.11	Check that the Storm water drainage channels are clean.
5.2.12	Check the structural Pipe bridges for Integrity and Corrosion.
5.2.13	Check the external surface of the Buildings for structural cracks or any structural impairment.
5.2.14	Check the Fire Hydrant Line for Integrity and Corrosion.
5.2.15	Check the Septic Tank for any cracks and available spare capacity.
5.2.16	Check the MS powder coated Sheets/Insulation of them roofing for Pinholes, Corrosion and Integrity of J hooks.
5.2.17	Check the chequered platforms over pipe bridges for Integrity and Corrosion.
5.2.18	Check the cross over bridges for Integrity and Corrosion.
5.2.19	Check the water tanks for leakages and cracks.
5.2.20	Check the MS Railing of staircases for Steadiness and Corrosion.
5.2.21	Check the structure of MS Staircases of the buildings for Steadiness and Corrosion.
5.2.22	Check the stone pitching for the steadiness of Earth Embankments of the internal roads.
5.2.23	Check the rain water pipes and net for corrosion.
5.2.24	Instruct the Engineering Contractors to carry out the Repairs/Civil works/Paintings etc as per the checklist (if required).
5.2.25	Inform the corrective actions taken to the Site Head.

 

6. Abbreviation:

Abbreviation	Expansion
SOP	Standard Operating Procedure
EGD	Engineering Department
MS	Mild Steel

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Chlorination of Raw Water by Sodium Hypochlorite

 

1. Objective:

To lay down a procedure for the Chlorination of Raw Water by Sodium Hypochlorite.

2. Scope:

This procedure is applicable for the treatment of raw water used as feed water in purified water generation system at site.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the treatment of raw water by sodium hypochlorite solution as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexes. Ensure to the

compliance to the SOP.

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to  perform duties as per this SOP.

5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while treatment of raw water by sodium hypochlorite solution.
5.2.2	Material Safety Data Sheet of sodium hypochlorite is to be used in case of any emergency.
	Chlorination (Sodium Hypochlorite Dosing):
5.2.3	Dosing of chlorine to be done when free chlorine in raw water in the water sump is found to be less than 0.5 ppm as reported by Quality Control Department.
5.2.4	When the raw water content of free chlorine is less than 0.5 ppm. Add sodium hypochlorite as per given formula to obtain the free chlorine content within the limit of 0.5 ppm to 0.8 ppm.
5.2.5	Formula :  Quantity of Sodium hypochlorite required (Q) in ml =            (1-b)  x W 10 x A
5.2.6	Where `A` is assay of sodium hypochlorite (i.e. percentage of available chlorine in sodium hypochlorite), `W` is quantity of water in the sump in litres and  `b` is the initial free chlorine content of water in the sump as reported by  Quality Control Department. Example: When the free Chlorine is found to be 0.2 ppm as   reported by Quality Control Department (initial Chlorine content).  Assay of sodium hypochlorite is 6.54% w/v of available chlorine. Quantity of water in sump is 30,000 litres.
5.2.7	Then quantity of sodium hypochlorite to be added in the sump will be: (1- 0.2) x 30,000    =   366.97 ml. 10 x 6.54
5.2.8	Intimate Quality Control Department to collect the raw water sample by sending “Water Sample Intimation Slip” as per Annexure.
5.2.9	When the free chlorine content is between 0.5 ppm & 0.8 ppm, use the water for further treatments.
5.2.10	Record the details of sodium hypochlorite dosing in the prescribed format.

 

6. Abbreviation:

Abbreviation	Expansion
ppm	Parts Per Million
ml	Millilitre
w/v	Weight By Volume
%	Percent
i.e.	Id est (that is)

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Regeneration of Water Softener

1. Objective:

To lay down a procedure for the Regeneration of Water Softener.

2. Scope:

This procedure is applicable for the Regeneration of Water Softener.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Regeneration of Water Softener as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexes. To ensure compliance to the SOP.

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

5.1.2   Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined            frequency.

 5.2.    Operational Procedure:               

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while operating the Water Softener.
5.2.2	Ensure all the electrical connections are properly earthed. Ensure the power plug of the Water Softener is fixed in the socket properly.
5.2.3	Inspect electrical cables and connectors for any sign of damage.
5.2.4	Ensure that the ON/OFF push button is working properly.
5.2.5	Handle lever must be operated only after switching off the pump.
	Regeneration:
5.2.6	Keep the handle valve on the Service function written on it, start the pump for 5 minutes by pressing one way switch and finally stop the pump.
5.2.7	Keep the handle valve on By Pass Drain function and run the pump for 2 to 3 minutes, so that it will create vacuum inside the container automatically then stops the pump and water inlet line.
5.2.8	Add 10 kg of Sodium Chloride (Salt) and 30 litres of water in NaCl Solution Container and mix well.
5.2.9	Keep the handle valve on Low Rinse function. Put the suction pipe filter body inside the NaCl Solution Container and start the pump by opening the inlet valve into anticlockwise direction with the water pressure at 3 kg/cm2 (40 PSI).
5.2.10	Keep on the regeneration till the end of NaCl solution from the NaCl Solution Container for about 45 minutes then stop the pump.
5.2.11	Close the valve by rotating knob into clockwise direction.
5.2.12	Remove the traces of salt solution from the NaCl Solution Container and take 30 litres of soft water for back washing the bed.
5.2.13	Keep the handle valve lever on Low Rinse function and open the inlet valve in anticlockwise direction and start the pump for 60 minutes.
5.2.14	Keep on the back washing till the end of soft water from the NaCl Solution Container for about 60 minutes then stop the pump.
5.2.15	Record the regeneration details in a specified format as mentioned in Annexure.
5.2.16	After completion of regeneration, Intimate Quality Control Department to collect the post softener water sample by sending “Water Sample Intimation Slip” as per Annexure to Quality Control Department.
5.2.17	Water Sample Intimation Slip containing two copies (One original and one Carbon copy.
5.2.18	After water sample analysis, Quality Control Department sends the carbon copy of “Water Sample Intimation Slip” with result to Engineering Department and original copy retains with Quality Control Department.
5.2.19	After receiving the water sample analysis result from Quality Control Department, keep the handle lever on Service function and open the inlet water valve rotating into anticlockwise direction and start the system for water generation.

 

6. Abbreviation:

Abbreviation	Expansion
UTL	Utility
PSI	Pond per Square Inch
NMT	Not More Than
kg	Kilogram
cm	Centimetre
NaCl	Sodium Chloride
Sr. No	Serial Number

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

SOP Title: Maintenance of Breakdown Equipment

1. Objective:

To lay down a procedure for the Maintenance of  Breakdown Equipment.

2. Scope:

This procedure is applicable for the Maintenance of Breakdown Equipment.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Breakdown Maintenance of Equipment as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexes. To ensure compliance to the SOP.

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

5.1.2  Breakdown Maintenance: Maintenance performed on equipment to restore it in the normal operating condition that has broken down or failed to operate in defined set of parameters suddenly/incidentally.

 

   5.2.    Operational Procedure:               

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while operating the machine.
5.2.2	Ensure that all the electrical connections are properly earthed and the power plug of the machine is fixed in the socket properly.
5.2.3	Inspect electrical cables and connectors for any sign of damage.
5.2.4	Ensure that the ON/OFF push button is working properly.
	Operation:
5.2.5	Breakdown Maintenance is whenever any breakdown is noticed in the equipment used in the Production, Quality Control, Warehouse and Engineering.
5.2.6	For this purpose a trained personnel shall be deputed in the Engineering Department to rectify the problem and provide effective maintenance to the equipment as per the nature of breakdown.
5.2.7	When any breakdown is observed in a section in any equipment the Head of Department gives a written complaint note to the Engineering Department mentioning the nature of complaint as per Annexure.
5.2.8	On receipt of the complaint note the trained personnel is deputed to perform the job.
5.2.9	After completion of the job the complaint note is signed by the complainer confirming that the job is completed.
5.2.10	Before starting the equipment work all the material is removed from that area and after completion of the repair that area is thoroughly cleaned and checked by Functional Department to ensure that it is free from oil, grease or other contaminants.
5.2.11	The signed complaint note also contains the replacements and cause of the fault so that the same could be brought under general maintenance and is kept record in machine history card.
5.2.12	The complaint note after completion of the maintenance is kept in the records of the Engineering Department.
5.2.13	Any maintenance work which is not possible within the company is directed to outside work shop along with a Returnable Gate Pass and the repaired machine or spare parts is checked by the authorised maintenance personnel before installation.
5.2.14	Detail of Breakdown Maintenance carried out is prescribed in the complaint note received by the Engineering Department.
	Recording and Reporting:
5.2.15	The Breakdown Maintenance is logged in the prescribed format as specified in Annexure. The detail of breakdown maintenance performed is recorded in the form of complaint note signed and verified by complainer and kept in file by the Engineering Department.
5.2.16	On the basis of the complaint received and servicing carried out, a report is submitted to the Site Head.

 

6. Abbreviation:

Abbreviation	Expansion
EGD	Engineering Department
UTL	Utility

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

SOP Title: Operation of Diesel Generator Set

 

1. Objective:

To lay down the procedure for the Operation of Diesel Generator Set.

2. Scope:

This procedure is applicable for the Operation of the Diesel Generator Set installed in the Engineering Department.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedures laid down   for Operation of Diesel Generator Set as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexures. To ensure compliance to the procedure.

 

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to

perform duties as per this SOP.

• Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined frequency.

 5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while operating Diesel Generator Set.
5.2.2	Ensure all the electrical connections are properly earthed. Ensure the power plug of the Diesel Generator Set is fixed in the socket properly.
5.2.3	Ensure that the ON/OFF switch is working properly.
	Operation:
5.2.4	Check the Water level in the Radiator Tank using dip stick.
5.2.5	Check the Diesel by plastic tube attached behind the tank.
5.2.6	Check the level of Lubricant in Diesel Generator Set using dip stick.
5.2.7	Check the Diesel Generator Set for any leakages of Diesel, Lubricant Oil and cooling Water etc.
5.2.8	Turn the switch Key to “ON” Position and push the “BLACK” push button of the starter immediately.
5.2.9	After starting the engine, release the push button.
5.2.10	When the engine starts, leave it for few second for warming up.
5.2.11	Check the oil pressure (Pressure should be above 4Kg/Cm²) and then release the switch key.
5.2.12	Increase the engine RPM up to approximately 1500 and maintain throughout running condition.
5.2.13	Turn the control switch Key to “ON” Position of the 250 Kilovolt-amp control panel.
5.2.14	Rotate clockwise the change over switch towards Diesel Generator Set from Main supply in the Low Tension Panel Room.
5.2.15	During running check the Diesel Generator Set for any abnormal sound.
	Generator Shut Down:
5.2.16	While shut down the generator rotate the change over switch to towards Main supply from Diesel Generator Set.
5.2.17	Decrease the RPM of the engine to slow down the oil.
5.2.18	Keep the engine idle for 2 – 3 minute before shut down Diesel Generator Set.
5.2.19	Now turn the switch key to “OFF” position to shut down the engine.
5.2.20	Update the “Diesel Generator Set Usage Log Book” as per Annexure.
	Preventive Maintenance
5.2.21	Perform the Preventive Maintenance as per Annexure.
5.2.22	Affix the “Preventive Maintenance Status Label” on the Diesel Generator Set as per SOP, “Preventive Maintenance Programme for the Equipment”.
5.2.23	If Preventive Maintenance activity is outsourced, the observations are to be transcribed in the Annexure, and external party certificate to be attached.
	Action Plan During Break Down of Diesel Generator Set
5.2.24	If any breakdown occurs, inform to Head of the Department and Quality Assurance Department. Put the tag “Equipment Under Maintenance Do Not Start” and inform to Service Engineer for rectification.

 

6. Abbreviation:

Abbreviation	Expansion
RPM	Revolutions Per Minutes
cm	Centimetre
Kg	Kilogram
UTL	Utility

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

 

Title: Operation of  Boiler

 

1. Objective:

To lay down a procedure for the Operation of Boiler.

2. Scope:

This procedure is applicable for the Operation of Boiler.

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Operation of Boiler as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexure. To ensure   compliance of the SOP.

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

• Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined frequency.

 5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while operation.
5.2.2	Ensure all the electrical connections are properly earthed. Ensure that the power plug of the Boiler is fixed in the socket properly.
5.2.3	Inspect electrical cables and connectors for any sign of damage.
5.2.4	Ensure that the ON/OFF button is working properly.
5.2.5	Ensure that Fuel Temperature Controller setting and Steam Temperature Controller is not altered.
5.2.6	Ensure that the drain valve of Economizer, Fuel, and Strainer Drain valve and coil blow down valves are closed.
5.2.7	During running check the Boiler for any abnormal sound.
5.2.8	During running check the water flow and fuel flow.
5.2.9	Reddish flame indicates that the air supply is insufficient.
5.2.10	During running check the exhaust from the Chimney. It should be almost colourless. If not inform the HOD.
5.2.11	Check the Boiler for any leakages of fuel gases.
5.2.12	Ensure that boiler feed water is meeting the specification of hardness and pH.
	Operation:
5.2.13	Open the water supply line valve by rotating it in anti clockwise direction.
5.2.14	Put the electrical Miniature Circuit Breaker “ON” and the knob pointer should be set above 100C of the saturation temperature of steam.
5.2.15	Close the main steam by rotating the valve in clockwise direction and open the auxiliary steam by rotating the valve in anti clockwise direction.
5.2.16	Open the fuel line by rotating the valve in anti clockwise direction.
5.2.17	Switch “ON” the ‘FILL’ switch to fill up the water in the coil.
5.2.18	Start the boiler by rotating the knob in clockwise direction located at the panel board.
5.2.19	Green Burner lamp will be turned on indicates the fuel spray starts and sparking stops when the flame is established.
5.2.20	When the pressure starts increasing and temperature reached about 130ºC, open the main steam valve by rotating it in anti clockwise direction and simultaneously close the auxiliary steam valve by rotating it in clockwise direction.
	Shut down  of Boiler:
5.2.21	Close the steam valve fully by rotating it in clockwise direction. The pressure switch will be automatically cut-off from the boiler.
5.2.22	Open the coil blow down valve fully by rotating it in anti clockwise direction.
5.2.23	Close the blow down valve by rotating it in clockwise direction.
5.2.24	Open the auxiliary steam valve fully by rotating it in anti clockwise direction.
5.2.25	Finally drain the Economizer by rotating it in anti clockwise direction. Keep its drain valve open till clear water starts coming out.
5.2.26	Close the valve of Economizer by rotating it in clockwise direction after the water drains come out completely then press the ‘FILL’ switch off.
5.2.27	Close the auxiliary valve and put off the electric main switch.
5.2.28	Clean any drip oil, water etc. from the unit.
5.2.29	Close the outlet valves of Soft water, Service tank and Fuel oil service tank.
	Preventive Maintenance
5.2.30	Perform the Preventive Maintenance as per Annexure.
5.2.31	Affix the “Preventive Maintenance Status Label” on the Boiler as per SOP.
5.2.32	If Preventive Maintenance activity is outsourced, the observations are to be transcribed in the Annexure and external party certificate to be attached.
	Action Plan During Breakdown of Boiler
5.2.33	If any breakdown occurs, inform Head of the Department and Quality Assurance Department. Put the tag “Equipment Under Maintenance, Do Not Start” as per SOP and inform to Service Engineer for rectification.

6. Abbreviation:

Abbreviation	Expansion
UTL	Utility
HOD	Head of Department
No	Number
etc	Etcetera
°c	Degree Celsius

 

*Note – Ready to use SOP available in “DOWNLOAD” Section.

 

Title: Operation of Air Compressor

  

1. Objective:

To lay down a procedure for the Operation of Air Compressor.

2. Scope:

This procedure is applicable for the Operation of Air Compressor.

 

3. Responsibility:

3.1 Engineering Department: To prepare and review the SOP. To follow the procedure laid down   for the Operation of Air Compressor as per this SOP.

3.2 Quality Assurance Department: To review and approve the SOP and Annexure. To ensure compliance to the SOP.

4. Accountability:

Head, Engineering Department / Head, Quality Assurance Department.

5. Procedure:
   • Definitions:

5.1.1   Engineering Associate: Executive or Operator of Engineering Department trained to perform duties as per this SOP.

• Preventive Maintenance: Maintenance activity performed to ensure that the equipment will function smoothly and to avoid breakdowns. These activities are performed as per predefined frequency.

 5.2.    Operational Procedure:              

	Safety Precautions/Instructions:
5.2.1	Wear appropriate Personal Protective Equipment while operating the Air Compressor.
5.2.2	Ensure all the electrical connections are properly earthed. Ensure that the power plug of the Air Compressor is fixed in the socket properly.
5.2.3	Inspect electrical cables and connectors for any sign of damage.
5.2.4	Ensure that the ON/OFF push button is working properly.
	Operation:
5.2.5	Drain the accumulated water by opening the drain valve located on the storage tank by rotating it in anti clockwise direction.
5.2.6	Switch on the MCB to ON position.
5.2.7	Push the green button of the starter to start the compressor and lock the Green push button for auto running.
5.2.8	Keep the drain valve open for some time till the water drains completely and then close the valve by rotating it in clockwise direction.
5.2.9	When the compressor gauge reaches about 4 to 6 Kg/cm2 open the valve of the supply line, wherever required.
5.2.10	Check the moisture filter of supply line.
5.2.11	If any water found, drain it completely by rotating screw valve in anti clockwise direction.
5.2.12	Closes the valve by rotating it in clockwise direction after the water is completely drain.
5.2.13	During operation regularly open the drain valve of compressor to drain water.
5.2.14	Check whether the compressor switches off itself automatically when air pressure gauge reaches about 5.0 to 9.0 kg/cm2.
5.2.15	Switch OFF the compressor. If there is any leakage of oil observed from compressor line and inform to concern officer for rectification.
5.2.16	Unlock the Green push button, after completion of work.
5.2.17	Push the Red switch button to switch off the air compressor.
5.2.18	Finally switch off the MCB.
5.2.19	Open the drain valve of the air storage tank by rotating it in anti clockwise direction to remove the air and water from compressor.
	Preventive Maintenance
5.2.20	Perform the Preventive Maintenance as per Annexure.
5.2.21	Affix the “Preventive Maintenance Status Label” on the Air Compressor as per SOP.
5.2.22	If Preventive Maintenance activity is outsourced, the observations are to be transcribed in the Annexure, and external party certificate to be attached.
	Action Plan During Breakdown of Air Compressor
5.2.23	If any breakdown occurs, inform Head of the Department and Quality Assurance Department. Put the tag “Equipment Under Maintenance, Do Not Start” as per SOP and inform to Service Engineer for rectification.

 

6. Abbreviation:

Abbreviation	Expansion
EGD	Engineering Department
MCB	Miniature Circuit Breaker
UTL	Utility
Kg	Kilogram
cm	Centimetre

  

*Note – Ready to use SOP available in “DOWNLOAD” Section.