SOP of Pump Changing Job

STANDARD OPERATING PROCEDURE
Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

SOP No.: WBD/CBN/4.1-01/CB MAINT/ 017 Revision No. 00 Effective Date 15/06/2020
SOP Description: Pump changing job 10/8 Section WASHERY 3
Department :CB Page Page 1 of 11
Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

No. (WHAT) Requirements (WHO) Reference
Hazards/ Impacts
Common hazards and action to be taken
Sl No Hazard Mitigation
1. Maintain proper housekeeping at work area.
2. Follow designated pathway and staircase while going to and from Control Room for work permit issuance.
1 Slip trip and fall at the work area 3. Always maintain 3 Point contact while using any staircase.
4. Remain mindful of the debris accumulated in the staircase.
5. Keep all required spares at a designated place at job site and barricade the working area.
1. Use of Dust Mask is Mandatory
2 Dust Hazard
2. Work to be started only after emptying the belt.
3 Dos and don’ts at working site Do's Don’t
Enter area with mandatory PPE . Do not start job until Proper isolation if required.
For pulling old or new belt use good quality manila rope. Don’t stand near the belt stand.
Use hand gloves before start jobs. Don’t touch any electric cable.
SOP MADE BY: INDRANIL GHOSH SOP CHECKED BY: AK ROUT(Sr. MGR) SOP APPROVED BY: MANISH KUMAR (HEAD W-3)
Date: Date: Date:
Sign. : Sign. : Sign. :

Hazards/ Impacts
1. Safety Induction SAFETY:  Safety  Briefing of the hazards to regarding the area Trained people
Requirement: Awareness of safety Supervisor and about the job. should be involved
rules, Job hazards, work knowledge, & supervisor  Use of safety appliances during the work such as in Job
use of safety appliance, rules about (Safety shoes, Safety Jacket Hand Gloves, safety
working at height, rules about working Helmet, safety Goggles, Dust Masks).
at dusty area, rules about firefighting. Refer safety
standard SS/ENGG-
Hazard: Unawareness about the area, 58 for use of PPE
Slip trip & fall hazard, dusty
environment.
Impact: may cause Injury & accident
ENVIRONMENT: 
 Flying fine dust.
QUALITY:
 Ensure proper Positive Isolation.
Mandatory PPE’s required for this job execution.

Date: Date: Date:

Hazards/ Impacts
List Of PPE’s
Safety Safety Safety Florescent Safety Ear Plug Co Detector Dust Mask Positive Isolation
Helmet Shoe Goggles Jacket Gloves Lock
During Pre Start- √ √ √ √ √ × × √ √

up
During On Job √ √ √ √ √ × × √ √
Any Other PPE Any Other PPE

[Please [Please
List Of PPE’s
Mention] Mention]
Full Body Hardness Gas Welding Eye Glass

Welding Eye Shield Fire Protection Jacket
During Pre Start-up Job √ √ √ ×

activity.
During On Job √ √ √ ×
Date: Date: Date:

Hazards/ Impacts
2. Positive Isolation SAFETY: Trained people

and Work Permit. Requirement: Awareness of safety  Officer 1. Briefing of the hazards to regarding the area and about the should be involved
[De-Energizing the rules, Job hazards, work knowledge,  Foreman job.
 Contractor
in Job
equipment] use of safety appliance, rules about 2. Use of safety appliances during the work such as (Safety
Supervisor
working at height, rules about shoes, Safety Jacket Hand Gloves, safety Helmet, safety
working at dusty area, rules about Goggles, Dust Masks) Refer safety
firefighting. standard SS/ENGG-
58 for use of PPE
Hazard: Unawareness about the
area, Slip trip & fall hazard, dusty Refer safety
environment. standard
EHSMSM/446/4007
Impact: may cause Injury & for work permit
accident
ENVIRONMENT: NA
QUALITY: NA
ENVIRONMENT:
 Flying fine dust.
QUALITY:
 Ensure proper Positive Isolation.
Date: Date: Date:

Hazards/ Impacts
2 Engagement of Requirements: 1. Job should be carried out under the supervision of expert Supervisor. 1. Follow standard:
Manpower Trained People  Officer 2. All persons must have Six days training and PME Certificate. EHSMSM/
 Forman WORKS/446/4007
 Contractor 3. Work Permit should be obtained in prescribed format
Supervisor 4. 6-directional hazard must be identified and fill-up in work permit.
ENVIRONMENT: NA
QUALITY: NA
Date: Date: Date:

Hazards/ Impacts
3 Pre Start - Up SAFETY:  Supervisor 1. Safety induction training by safety supervisor and site in
Job Activities  Injury during the charge must be given to workers before starting the job. 1. Trained
handling of Tools & people should
tackles be involved in
2. Following tools and tackles which is require to executing job. Follow
the job must be accumulated in the working zone area. the SS/GEN –
58 for
ENVIRONMENT: personal
SL. Tools & Tackles Capacity/ Size Nos.
 Dusty Area protective
No. equipment’s
QUALITY: 1 Spanner M36,M30 As standard.
Condition of Tools and requ
Tackles ired
2 Hammer 1 Kg/2 Kg As
requ
ired
3 Allen key As
requ
ired
4 Sling ¾”, 5/8” , 1”
Date: Date: Date:

Hazards/ Impacts
4 Material SAFETY:  Contractor Activity: Refer safety

handling. SAFETY : 1. Physical Supervisor/ 1.Estimate the load and choose means of transportation standard SS/Gen-58
injury from sharp Department accordingly.
edges may occur. representative/ 2.Check the holding position and arrange sling size for carry
2.During sling fixing Contractor such load.
employee. 3.Use trolley, pick and carry, EOT crane whichever is required.
be careful otherwise 4.For transporting with pick and carry type crane hold the job
miscommunication with sling and fix in hook. Take it through rock solid path at Refer safety
between crane speed less than 20m/s. standard SS/Gen-58
operator and rigger 5.Clearance from ground to load should be 1.5 mtr while
can injured rigger. travelling through pick and carry type crane.
3.While lifting load, 6.Position the load as per designated place ,keep it on wooden
swinging action may block to engage sling when necessary.
cause physical injury
to nearby person.
Hence maintain safe
distance.
4. Never overload on
trolley,it may topple
while pulling/pushing.
5.Inspect the ground
level condition for
positioning heavy
vehicle , otherwise it
may topple while
carrying load.
Date: Date: Date:

Hazards/ Impacts
6.While handling load

through stair always 3
point contact theory.
ENVIRONMENT:
 Fine dust.
QUALITY:
 Without damaging
equipment and
without violating
material handling
standard job
should be done.
Date: Date: Date:

Hazards/ Impacts
5 Dismantling of  Contractor Activity: - Follow SS/Gen-25

pump SAFETY: Supervisor/Departm Dismantling & SS/Gen-26
1.Workmen must know the ent 1. For dismantling of pump the vee belts are to be removed
safe use of common safety representative/Contr first from v pulley.
PPEs. actor employee. 2. The adapter is to be then removed using allen key.
2. Unauthorized person not
enter in work place.
3. After adapter removal the v pulley is to be taken out of the
3. Slacking of load may hit shaft.
person hence maintain safe 4. The suction and discharge flanges are to be opened using
distance. M30 spanner.
4.Never come inside load. 5. The base bolts are to be opened using M36 spanner.
5.Never overtight the chain
block.
6.Weak support for chain
block fixing may cause
damage to equipment as
well as workman.
7.Using of EOT crane
without load testing
certification can be
dangerous.
ENVIRONMENT:
Spatter of metal flowing
away from job.
QUALITY: NA.
Date: Date: Date:

Hazards/ Impacts
Step Activity Associated Responsibility Remarks/ Reference
No. (WHAT) Requirements (WHO)
Process/tools/PPEs (HOW)
Hazards/Impacts
7 Erection of new SAFETY:  Contractor Activity: Refer safety standard

pump 1.Use of EOT using Supervisor/ Dept Erection: SS/Gen-58.
remote. representative/ 1. The new pump is to be lifted via sling and kept in base
ENVIRONMENT: Contractor frame. Refer safety standard
NA. employee. 2. Both the suction and discharge flanges are to be fixed using SS/ENGG 03.
QUALITY: NA M30 spanner.
3. The base bolts are then tightened using M36 spanner.
4. The adapter is fixed after which v pulley is fixed in pump’s
input shaft.
5. Vee belts are fixed in the pulley and properly tensioned.
Date: Date: Date:

Hazards/ Impacts
Step Activity Associated Responsibility Remarks/ Reference

No. (WHAT) Requirements (WHO)
Process/tools/PPEs (HOW)
Hazards/Impacts
8 Return work SAFETY: Contractor 1. Ensure all the jobs are completed and no man with tools / Close work permit by
permit  NA Supervisor/ Dept tackles are near the work area.. concern department.
representative/ 2. Any scrap should be removed and put that in designated
ENVIRONMENT: Contractor employee scrap yard.
 NA
QUALITY:
 NA
9 Apply for power SAFETY: Contractor 1 Release field stop.

getting.  NA Supervisor/ Dept 2 Unlock personal lock from group box.
representative/ 4 Release the shutdown of the equipment as per SOP, WBD / CBN /
ENVIRONMENT: Contractor employee 4.1-01/CB-MAINT/1006
 NA
QUALITY:
 NA
Date: Date: Date:

SOP of Pump Changing Job

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SOP of Pump Changing Job

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Verfügbare Formate

STANDARD OPERATING PROCEDURE

Form No.: EHSMSM/446/4013 Form Rev. No.: 00 Effective date: 01-Nov-2009

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Common hazards and action to be taken

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Impact: may cause Injury & accident

Mandatory PPE’s required for this job execution.

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

During Pre Start- √ √ √ √ √ × × √ √

Any Other PPE Any Other PPE

Full Body Hardness Gas Welding Eye Glass

During Pre Start-up Job √ √ √ ×

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

2. Positive Isolation SAFETY: Trained people

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

4 Sling ¾”, 5/8” , 1”

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

4 Material SAFETY:  Contractor Activity: Refer safety

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

6.While handling load

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

5 Dismantling of  Contractor Activity: - Follow SS/Gen-25

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

7 Erection of new SAFETY:  Contractor Activity: Refer safety standard

Step Activity Associated Responsibility Process/tools/PPEs (HOW) Remarks/

Step Activity Associated Responsibility Remarks/ Reference

9 Apply for power SAFETY: Contractor 1 Release field stop.

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