Avu&Srlpg Sops

INDIAN OIL CORPORATION LIMITED
PARADIP REFINERY
STANDARD OPERATING PROCEDURES
AVU & SR-LPG TREATMENT UNIT Rev-06 Validity:31-Dec-2022
SOP No : AVU/001 SOP For: PREPARATION FOR LIGHTING UP OF BURNERS Revision No : 06

Department: Equipment involved: Process Unit:
010-F-101 AVU
Production 010-F-201 &
010-F-002 SR-LPG Treatment Unit
PPE’s Required Tools required Think & discuss JSA Requirement

 Helmet  Wheel Key  Location of nearby Eye and safety shower.
 Safety Shoe  Fire Water Hose  Emergency escape route before starting the job.
 Hand Gloves  Fire Extinguisher  Nearby MCP
 Ear plug  Portable Gas Detector  Nearby Fire monitor Not Required
 Gas Detector  Ignitor  Wind direction
 Face Shield  CCTV Camera
 IFR Suit  Fire Tender Approach Route
HAZARDS INVOLVED:
SL.
No Hazards involved Precautions to be taken
.
Furnace draft to be cross checked before opening peep holes & wear face shield
1 Pressurized radiation Box
before opening of peep holes.
Leak Test to be done prior to light up by soap solution and BMS system. Use
2 Hydrocarbon leak from flanges
portable Gas Detector to identify leaks.
Contact with hot surfaces on handling furnace
3 Use heat resistant hand gloves.
inspection doors
Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Page 1 of 732
PARADIP REFINERY
SL.
.
Ensure safety shoes and dry surface before checking ignitor. Check with
4 Electrocution during testing of ignitor.
Electrical Maint.
Do’s & Don’ts:
SL
No Do’s Don’ts
.
1 Inform Panel Officers / Shift in Charge Don’t bypass any process interlocks / approved procedure.
Don’t allow movement of unauthorized personnel in the
2 Use PPEs
nearby area
Use face shield, heat resistance hand gloves, heat resistant suits, Don’t keep open any drains to atmosphere in open
3
IFR suits. condition
PRE START CHECK:

SL Action to be taken by Signature
Potential
No Job description Control measure EA/ EA/
Hazard SIC Panel SIC Panel
. JEA JEA
Ensure all flanges are properly √ √
1 HC Leak Ensure Leak Check.
boxed up.
Ensure all XZVs are in closed HC Ensure Leak check √ √ √
2
position. Ingress with BMS and N2.
HC Ensure Leak check √ √ √
3 Ensure XZVs are not passing.
Ingress with BMS and N2.

Page 2 of 732
PARADIP REFINERY
DETAILED STEPS:
Sl. Action taken by Signature
Potential
No Job description Control Measure Pane EA/ EA/
.
Hazard SIC SIC Panel
l JEA JEA
 Startup
1 Check that all maintenance jobs √
HC Leak Clearance by all
are over. Department.
2 Check all man holes are boxed  Physically check √ √
Man Entry all manholes.
up.
Check stack damper opening by  Carry out stoke
3 Wrong check. Match √ √
operating. It should match with
Indication arrow mark with
panel indication. indication.
 Operate
4 Operate Stack Damper by Stuck Winch √ √
physically by
Winch Cable Cable
winch cable.
 Open to 100%
Pressurizatio
and check
n of Box due
5 Open the furnace stack damper physically. √ √ √
to
to the full open position. incomplete
Match with
counter weight
opening
and arrow.
6 Check oil leakage by Gas Leak  Carry out leak √ √
pressurizing the circuit with check at 5.0

Page 3 of 732
PARADIP REFINERY

Potential
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l JEA JEA
Air / N2. kg/cm2 pressure.
Isolate all FO burners
 Physically check
7 individually. Open FO supply & Fuel Oil √ √
all flanges for
return XZVs & establish FO Leak
leak.
circulation.
Gas
8 Check gas leak by operating  BMS procedure √ √
Leak/Valve
BMS system. Passing
to be followed.
 Nitrogen venting
9 Vent out trapped N2 from FG & Toxic Gas √ √
to be done to safe
PG header. Release
location.
 Ensure Steam
10 Condensate Removal from Box Line √ √
trap/drains are
Purging Steam line Hammering
lined up.
Stuck up for any
11 √ √
Explosion Doors checking Explosion obstruction.
Door Ensure free
movement.
12 Operability of Dampers Stuck  Dampers √ √
dampers operability and
position
checking to be

Page 4 of 732
PARADIP REFINERY

Potential
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l JEA JEA
done with Panel.
Equipment  Ensure all system
13 √ √
Availability of ID / FD Fan Unavailabilit related to ID/FD
y fans are ready.
 Ensure box
purging.
 Check with
Removal of portable gas
14 Box purging with FD fan for at √ √
HC vapors in detector on
least 15 minutes. furnace. completion of
box purging at
multiple
locations.
-***-

Page 5 of 732
PARADIP REFINERY
SOP No : AVU/002 SOP For: PILOT BURNERS LIGHT UP Revision No : 06

010-F-101 AVU

 Gas Detector  Portable Ignitor  Wind direction
HAZARDS INVOLVED:
SL.
.
2 Hydrocarbon leak from flanges/passing valves portable Gas Detector to identify leaks/ gas inside box. Ensure sufficient box
Contact with hot surfaces on handling furnace purging.
inspection doors

Page 6 of 732
PARADIP REFINERY
SL.
.
Ensure safety shoes, gloves and dry surface before using ignitor. Check with
4 Electrocution during USE of ignitor.
Electrical Maint.
Do’s & Don’ts:
SL
No Do’s Don’ts
.
Use PPEs, Inform Panel Officers / Shift in Charge before light
1 Don’t bypass any process interlocks / approved procedure.
up.
Ensure box purging and check the box for HC before trying to Don’t allow movement of unauthorized personnel in the nearby
2
light up. area
Use face shield, heat resistance hand gloves, heat resistant
3 Don’t keep open any drains to atmosphere in open condition
suits, IFR suits.
4 Follow BMS procedure for lighting up of burners.
PRE START CHECK:

Potential
. JEA JEA
boxed up.
2

Page 7 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
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l JEA JEA
1 Stuck closed  MSD operation √ √ √
Open MSD 100%
MSD. physically.
2 Ensure furnace lighting  Ensure readiness √ √ √
Leaks
preparation is done
Close the burner secondary air
3 √ √
control damper 100% and 
primary air 75%.
Flammable  Physically Check
4 Make sure that individual gas √ √ √
mixture in Valves and
valves to the pilots are closed. Box XZVs position.
5 Reset shutdown valves in pilot  Ensure Leak √ √ √
Gas Leak
gas line. check complete.
6 Open PG valve & get 0.5 – 0.8 √ √ √

Kg / cm2g header pressure.

Page 8 of 732
PARADIP REFINERY

Potential
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l JEA JEA
 Bleeding to be
done under
7 Bleed out N2 from system at far supervision and √ √
Gas Leak
end drain point. to safe location.
Ensure no HOT
JOB nearby.
Insert portable igniters lance  Ensure proper
8 √ √
through the ignition port Fall pedestal for
provided. ignitor insertion.
Open slowly the pilot isolation  Follow BMS.
valve and then press the push  Pilot XZV closes
button on the ignition control in 10 sec if no
9 Explosion √ √ √
flame detected.
unit. The pilot should light
instantly. Adjust air flow of PG
burner when required.
10 If Pilot burner is not ignited try Explosion  Do not attempt > √ √ √
again. 3 unsuccessful
attempt.
 If pilot is not
light up within
10 minutes of
successful BMS

Page 9 of 732
PARADIP REFINERY

Potential
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l JEA JEA
leak check than
BMS leak check
to start again.
 Purge the furnace
again before light
up to remove
accumulated HC.
11 Adjust the pilot pressure to the  √ √
design operating pressure.
12 Take all PG burners in line.  √ √
SOP No : AVU/003 SOP For: FUEL GAS BURNERS LIGHT UP Revision No : 06

010-F-101 AVU


Page 10 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
inspection doors
Ensure safety shoes, gloves and dry surface before using ignitor. Check with
4 Electrocution during USE of ignitor.
Electrical Maint.
Do’s & Don’ts:
SL
No Do’s Don’ts
.
up.
2
light up. area

Page 11 of 732
PARADIP REFINERY

suits, IFR suits.
PRE START CHECK:

Potential
. JEA JEA
boxed up.
2
DETAILED STEPS:
Potential
.
l JEA JEA
1 Ensure that Pilot Gas burners are Explosive  Cross Check √ √
on. Mixture physically.
2 Ensure that FG system leak test Valve  Follow BMS √ √ √
is done by BMS method. Passing procedure.
3  Check arch zone √ √
Ensure FD fan is in operation. Low Oxygen
Analyzer

Page 12 of 732
PARADIP REFINERY

Potential
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l JEA JEA
4 Make sure the individual burner FG ingress to for close position √ √ √
firing valves are closed. Furnace of all IVs before
light up.
5 Open burner primary air fully & √ √ √
Low Oxygen 
50% secondary air.
Reset FG SDV & maintain FG
6 High FG  Monitor FG √ √ √
pressure 1.5 kg/cm2 through
Pressure pressure.
C/V.
 Light up with
low opening of
7 Take gas burner in line where √ √
Explosion Isolation valves
Pilot burner is on. in controlled
rate.
 Check flame
8 High / Low physically and √ √
Adjust air flow as required.
Air avoid high / low
air.
Similarly light other FG burner 
9 √ √ √
consulting panel as per
requirement.
10 Light up main FG burner only Un burnt gas.  Physically check √ √ √

Page 13 of 732
PARADIP REFINERY

Potential
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l JEA JEA
Pilot Flame
where PG burner is on.
before light up.
 Stroke checking
to be ensured
CV
Take Fuel Gas Pressure malfunction before taking in
11 line. √ √
Controller in auto after sufficient
 FG Pressure
nos. of burners are in line. High / Low
High/Low
FG pressure
Interlock to be in
line.

Page 14 of 732
PARADIP REFINERY
SOP No : AVU/004 SOP For: FUEL OIL BURNERS LIGHT UP Revision No : 06

010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
inspection doors

Page 15 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
up.
2
light up. area
suits, IFR suits.
PRE START CHECK:

Potential
. JEA JEA
boxed up.
2

Page 16 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
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l JEA JEA
Ensure that all FO burner valves  Physically check
1 are closed. Oil ingress
all XZVs and √ √
IVs before
startup.
2 Establish FO circulation. Set oil High / Low  Monitor √ √
pressure between 4-6 kg/cm2. Pressure pressure.
Drain condensate completely  Ensure steam
3 Condensate
temp and √
from atomizing steam header. Carry over
pressure.
Line up atomizing steam C/V &
 Monitor pressure
4 maintain @ 1.5 kg/cm2 Improper √ √ √
/ differential
differential pressure. Ensure that atomization. pressure.
the steam is dry.
5 Set the burner air requirement Low / High  Physically check √
Air the box.

Page 17 of 732
PARADIP REFINERY

Potential
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l JEA JEA
to the required position for oil
firing.
Open the steam valve and flush
atomizing steam and (purge) the  Ensure
Condensate
condensate
6 oil gun until both oil and steam carry over √ √
draining before
lines to each burner is inside
opening steam
condensate free and also furnace.
XZV.
completely warmed up.
After informing panel, activate
the burner FO XZV. Ensure that  Ensure oil
isolation valve is
7 it is opened & flushing steam √ √
Oil ingress closed position
XZV is closed both in field & before opening
panel. Ensure that Pilot gas XZV.
burner is on in this burner.
8 Open oil valve gradually until High / Low  Open the valve √ √
ignition is established. opening slowly.
After burner lights up, adjust oil  Monitor
High / low pressure.
9 valve for capacity required and √ √ √
flame /  Ensure interlock
adjust steam valve to achieve pressure is in line.
clean, bright flame.

Page 18 of 732
PARADIP REFINERY

Potential
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l JEA JEA
With a stable oil flame High / Low  Monitor coil
10 established, the gas firing can be COT & Skin outlet & Skin √ √ √
shut off or turned down if Temperature temperatures.
required. s
Light all additional burners in High COT &  Monitor coil
11 the furnace following above Skin outlet & Skin √ √
procedure as per requirement of Temperature temperatures.
panel. s
12 Flame should not impinge on High Skin  Physically √ √
heater tube. temperature monitor.
Adjust air in such a way that it  Physically
13 Insufficient monitor box for √
should not be excess or burner
Air smoke / haziness.
should not be hazy.
Close main stack damper after  Monitor furnace
14 draft and control. √ √ √
consulting Shift in Charge and Low Draft
Panel
SOP No : AVU/005 SOP For: FUEL OIL BURNERS HANDOVER FOR MAINTENANCE Revision No : 06
Production 010-F-101 AVU

Page 19 of 732
PARADIP REFINERY
010-F-201 &

 Gas Detector  Wind direction
HAZARDS INVOLVED:
SL.
.
Ensure proper PPEs. Tracing steam to be isolated in FO line for the particular
1 Hot Oil / Condensate spill
burner.
2 Hydrocarbon leak from flanges/passing valves Depressurize the system and check for passing valve before flange opening.
inspection doors.
4 Trip and Fall Ensure proper platforms for carrying out the work.
Do’s & Don’ts:

SL Do’s Don’ts

Page 20 of 732
PARADIP REFINERY
No
.
Use PPEs, Inform Panel Officers / Shift in Charge before
starting activities.
Use face shield, heat resistance hand gloves, heat resistant Don’t allow movement of unauthorized personnel in the nearby
2
suits, IFR suits. area
3 Ensure availability of required tools. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
1 Ensure other burners are available. Low COT Consult Panel √
Ensure work permits are available √ √

2 Read Permit Copy
and permit conditions are met.
Ensure proper platforms for carrying √ √
3
out the work.
DETAILED STEPS:

Page 21 of 732
PARADIP REFINERY

Potential
.
l JEA JEA
Isolate fuel oil valve at the
1 burner which is to be handed  Adjust firing in √ √
Low COT
over for maintenance job. Keep other burners.
steam valve open.
Adjust fuel gas/ fuel oil firing in
2 the heater at other burners if High / Low  Adjust firing in √ √
required. (Confirm with control COT other burners.
room).
Pinch steam main I/V.
Activate its XZV from panel.
This will lead closing FO XZV &
3 opening purging steam XZV. Condensate  Arch pressure to √ √
Open flushing steam to the fuel ingress be monitored
oil line slightly and carefully
watch arch pressure and excess
air (O2) and Heater outlet temp.
Ensure complete removal of Fuel
4 Residual oil  Ensure sufficient √ √ √
oil from the FO line. ( it is to be
in burner. steam flushing.
flushed properly)
5 Then isolate main steam valve. Oil / Steam  Depressurize √
Ensure that FO / steam valves spill. before flange

Page 22 of 732
PARADIP REFINERY

Potential
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l JEA JEA
are holding. opening.
6 Hand over the Fuel oil gun for √ √

maintenance

Page 23 of 732
PARADIP REFINERY
SOP No : AVU/006 SOP For: FUEL GAS BURNERS HANDOVER FOR MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Gas leak/Oil leak/Condensate spill.
burner.
inspection doors.

Page 24 of 732
PARADIP REFINERY
SL.
.
4 Trip and Fall Ensure proper platforms for carrying out the work.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
3 Ensure availability of required tools. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA

2 Read Permit Copy

Page 25 of 732
PARADIP REFINERY

Potential
. JEA JEA
3
out the work.
DETAILED STEPS:
Potential
.
l JEA JEA
Isolate pilot, FG, fuel oil valve at
1 the burner which is to be  Adjust firing in √ √
Low COT
handed over for maintenance other burners.
job. Keep steam valve open.
Adjust fuel gas/ fuel oil firing in
2 the heater at other burners if High / Low  Adjust firing in √ √
required. (Confirm with control COT other burners.
room).
3 Pinch steam main I/V. Condensate  Arch pressure to √ √
Activate its XZV from panel. ingress be monitored
This will lead closing FO XZV &
opening purging steam XZV.
Open flushing steam to the fuel
oil line slightly and carefully

Page 26 of 732
PARADIP REFINERY

Potential
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l JEA JEA
watch arch pressure and excess
air (O2) and Heater outlet temp.
Ensure complete removal of Fuel
4 Residual oil  Ensure sufficient √ √ √
oil from the FO line. ( it is to be
in burner. steam flushing.
flushed properly)
Then isolate main steam valve.  Depressurize
5 Oil / Steam √
Ensure that FO / steam valves before flange
spill.
are holding. opening.
6 Isolate and depressurize the FG Valve  Depressurize √ √
and Steam valves. passing before handover.
7 Hand over the Fuel oil gun for √ √

maintenance

Page 27 of 732
PARADIP REFINERY
SOP No : AVU/007 SOP For: FUEL OIL BURNERS TAKEOVER AFTER MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Oil leak/Condensate spill.
burner.
inspection doors.

Page 28 of 732
PARADIP REFINERY
SL.
.
4 Back firing of oil on burner lineup. Ensure no chokage and proper cleaning of burners.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
Ensure proper cleaning before box up. Ensure all flanges are
tightened.
4 Check for damage of oil and steam hose before lining up.
PRE START CHECK:

Potential
. JEA JEA

2 Read Permit Copy

Page 29 of 732
PARADIP REFINERY

Potential
. JEA JEA
3
out the work.
DETAILED STEPS:
Potential
No Job description Control Measure EA/ EA/
.
JEA JEA
1 Check FO gun tip for any Back firing √
blockage. of burner
2 Insert the gun & tighten the  Ensure new O √
O ring leak
holder with new O ring. ring
3 Open gun purging steam &  Ensure proper √
Flange leak
check leakage at holder joint. gasket box up.
4 Isolate purging steam & keep as √

standby.
5 √
Adjust firing according to COT High COT  Monitor COT.

Page 30 of 732
PARADIP REFINERY
SOP No : AVU/008 SOP For: FUEL GAS BURNERS TAKEOVER AFTER MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Gas leak Ensure proper PPEs. Use Gas detector. Ensure correct boxup.
2 Burner back firing on line up Ensure no chokage and proper cleaning of burners.
inspection doors.

Page 31 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
Ensure proper cleaning before box up. Ensure all flanges are
tightened.
4 Check for damage of hose before lining up.
PRE START CHECK:

Potential
. JEA JEA

2 Read Permit Copy

Page 32 of 732
PARADIP REFINERY

Potential
. JEA JEA
3
out the work.
DETAILED STEPS:
Potential
.
JEA JEA
1 Check FG gun tip for any Back firing √
blockage. of burner
2 Allow to box up gun assembly &  Ensure new O √
Gasket leak
FG line to it with new gasket. ring
3 Ensuring PG gas burner is in √

line, take FG burner in line.
4 √
Check for any leakage. 
5 √
Adjust firing according to COT High COT  Monitor COT.

Page 33 of 732
PARADIP REFINERY
SOP No : AVU/009 SOP For: EXCESS AIR ADJUSTMENT IN FURNACE Revision No : 06

010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 High Arch pressure. Air adjustment to be done in small steps. Monitor draft in furnace.
Very low air will result in insufficient burning. Monitor box and oxygen
2 Insufficient burning
analysers.
3 Use heat resistant hand gloves and face shield.
inspection doors.

Page 34 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
Always confirm heater draft from panel before opening peep
holes
Inform panel before light up of new burners & adjusting of Don’t allow movement of unauthorized personnel in the nearby
2
flame pattern & follow BMS area
3 Use face shield while opening the peep holes Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Check draft of furnace before High √
1 Consult Panel
adjusting air. Pressure
Wrong
Physically cross check furnace draft √ √
2 Indicatio Check Physically
in local PG.
n

Page 35 of 732
PARADIP REFINERY

Potential
. JEA JEA
Arch
Ensure availability of ID fan (at √ √
3 Pressure Ensuring running
least 1)
Adj
DETAILED STEPS:
Potential
.
JEA JEA
1 Check furnace condition from  Low COT  Physical check. √ √
the field and observe following  High Skin
points if there is not sufficient Temp
air for combustion in the heater
Smoky Flame: - When fuel oil
not burn completely it produces
smoke. Oil firing usually
requires 15% excess air for
proper mixing and combustion
& proper steam oil ratio for
atomizing.
Flame pattern:- Then the fuel

will search for air elsewhere in

Page 36 of 732
PARADIP REFINERY

Potential
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JEA JEA
the firebox to complete
combustion process. This will
cause the flames to move around
the furnace uncontrollably and
they will not appear straight and
stiff.
Instability:- Then the oil fire

become unstable. The instability
will exhibit itself as a pulsing
flame or it may just flame out.
Also verify arch zone O2  Check physically

2 Insufficient √
content: - in case of insufficient  Cross check with
Burning
air, it will also show less value. analyzer
Monitor skin temperatures:- in  Cross check skin
3 High Skin √
case of insufficient air, skin temperature and
Temp
temperatures may also increase. COT.
4 After observing all this, if it High Draft  Adjust in small √
indicates that there is Explosion steps.

Page 37 of 732
PARADIP REFINERY

Potential
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JEA JEA
insufficient air in the heater, and due to
then air can be increased in sudden
heater. burning
Please also watch arch pressure
5 √ √
when adjusting air (O2) in the 
heater.
Excess air should be optimized at
6 minimum value possible √

considering all above
constraints.
SOP No : AVU/010 SOP For: BURNER FLAME ADJUSTMENT IN FURNACE Revision No : 06

010-F-101 AVU


Page 38 of 732
PARADIP REFINERY
HAZARDS INVOLVED:
SL.
.
1 High Arch pressure. Air adjustment to be done in small steps. Monitor draft in furnace.
Very low air will result in insufficient burning. Monitor box and oxygen
2 Insufficient burning
analyzers.
3 Use heat resistant hand gloves and face shield.
inspection doors.
Contact with hot gases due to draft fluctuation
4 Cross check furnace draft. It should be negative.
on opening peep holes.
Do’s & Don’ts:
SL
No Do’s Don’ts
.
holes
Inform panel before light up of new burners & adjusting of Don’t allow movement of unauthorized personnel in the nearby
2
flame pattern & follow BMS area

Page 39 of 732
PARADIP REFINERY
PRE START CHECK:

Potential
. JEA JEA
Check draft of furnace before High √
1 Consult Panel
adjusting air. Pressure
Wrong
Physically cross check furnace draft √ √
2 Indicatio Check Physically
in local PG.
n
Arch
Ensure availability of ID fan (at √ √
3 Pressure Ensuring running
least 1)
Adj
DETAILED STEPS:
Potential
.
JEA JEA
 Ensure
1 Miscommuni availability of √ √
Inform Panel Engineer.
cation communication
device

Page 40 of 732
PARADIP REFINERY

Potential
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JEA JEA
2 Manually inspect stack for any Low Excess √

smoke. Air
3 Confirm draft in the furnace and  Check PI as well √
High Draft
tally it with Panel engineer. as PG.
Use special PPE like furnace face
 Ensure
4 shield / anti-glare glasses for Personal √
availability of
furnace inspection along with injury
PPEs.
mandatory PPEs.
 Do not stand
5 Stand sidewise near peep hole Direct Heat √ √
directly in front
and slowly open the peep hole. Exposure
of peep hole.
6 Inspect the following through  √
peep hole with minimum
exposure of body to furnace for
physical monitoring /
healthiness check and necessary
adjustments: -
 Fire box for any haziness
 Flame characteristic for
height/ shape/ orientation/
impingement/ colour/ lift /

Page 41 of 732
PARADIP REFINERY

Potential
.
JEA JEA
sparklers/ pulsation/
turbulence etc.
 Burner block for deposition/
clinker formation.
 Gun tip for
erosion/orientation.
 Tubes & support for leakage/
hot spot/ loose support.
 Burner heat balance (equal
distribution of burners).
 Skin thermocouples.
 Refractory condition of
walls/floor
Adjust air register according to
 Slow changes to
7 flame pattern. If required, High Arch √ √
be done. Monitor
inform panel to increase air flow Pressure
draft.
as per demand.
8 Manual observation from Heat  Physical √
furnace bottom for any hot Exposure checking

Page 42 of 732
PARADIP REFINERY

Potential
.
JEA JEA
spots/ leakages.
9 Check pilot burners for any Heat  Physical √
leakages. Exposure checking
10 Manual observation for any hot Heat  Physical √
spots on furnace walls. Exposure checking
Manual observation of peep hole
11 refractory and ensure all peep Heat  Physical √
holes are in closed condition. Exposure checking

Page 43 of 732
PARADIP REFINERY
SOP No : AVU/011 SOP For: SOOT BLOWING OPERATION IN FURNACE Revision No : 06

010-F-101 AVU

 Ear plug  Soot blowing wheel & key  Nearby Fire monitor Not Required
HAZARDS INVOLVED:
SL.
.
1 High Arch pressure. Ensure MSD is in open condition.
2 High Arch Pressure Ensure condensate removal before soot blowing.

Page 44 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
holes
Don’t allow movement of unauthorized personnel in the nearby
2 Ensure soot blower panel energized.
area
PRE START CHECK:

Potential
. JEA JEA
Condensa Confirm steam √
1 Ensure dry steam
te temperature
2

Page 45 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
Contact panel engineer and get
stack damper opened fully.
1 High Arch  Cross verify in √ √
Check from the field that the
Pressure field physically.
stack damper has actually
opened
Open trap bypass & drain
2 condensate completely from SB Condensate  Check steam √
steam line. Commission SB carry over temperature
steam header.
Check the local panel if any soot
3 blower is kept on bypass Inadvertent  Ensure it is √
enquires from field log book for run skipped
reasons of the same.

Page 46 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Check soot blower panel, all the
soot blowers in home position
lamp should be glowing.
4 √
Operation sequence switch 
should be on remote, individual
soot blower switch should be in
“on” and “auto” position.
5 Report to shift in charge if any √ √

abnormality is found.
After satisfying that all
conditions are ok start sequence
6 for soot blowers in automatic √

and ensure from panel that it has
started and steam flow increase
is observed on panel.
7 After about soot blowers  √ √
operation is complete, start soot
blowers from panel sequence
start button and remain around
furnace to ensure that soot
blower operation progresses

Page 47 of 732
PARADIP REFINERY

Potential
.
JEA JEA
without any disturbance.
When soot blowing is over,
hooter starts signaling that the
8 automatic sequence is complete, √

acknowledge the same and
terminate soot blowing from
panel.
Contact panel engineer, inform
him about sequence completion
9 √
and get the stack damper closed. 
Enquire about steam flow and
ensure that soot blowing is over.
During soot blowing operation
take round of the soot blowers
on platform to find out any
10 √
abnormality such a steam leak, 
abnormal sound etc and if found
report the same to shift in
charge.
11 During soot blowing operation if  √
there is any problem in

Page 48 of 732
PARADIP REFINERY

Potential
.
JEA JEA
particular soot blower there will
be sequence interruption alarm,
bypass the particular soot blower
so that sequence can go ahead
and try to find out the problem
of the particular soot blower and
inform shift in charge.
12 When soot blower operation is Overheating  Mechanically √
over and if steam flow does not remove soot
return to normal as soot blowing blower.
results in increased steam flow,
most likely the soot blower
where sequence interruption
alarm had come is stuck inside
furnace and has not retracted.
This is serious and in such an
eventuality steam valve should
be kept open and mechanical
help should be called to retract
the blower. Shift in charge
should be immediately

Page 49 of 732
PARADIP REFINERY

Potential
.
JEA JEA
informed.

Page 50 of 732
PARADIP REFINERY
SOP No : AVU/012 SOP For: SOOT BLOWING HANDOVER FOR MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Condensate spill Ensure steam XZV is closed and isolated.
2 Electrical Safety Ensure soot blower panel is de-energized using LOTO system.

Page 51 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Physically isolate steam header. Don’t bypass any process interlocks / approved procedure.
2 Close Steam XZV. Open drain XZV.
area
3 Electrically de-energize the soot blower. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Condensa Ensure √
1 Ensure steam header is isolated.
te depressurization
Ensure drain valve is OPEN. Condensa Ensure √
2
te depressurization
Ensure soot blower is de- √ √
3 Follow LOTO.
energised.

Page 52 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Isolate soot blower steam &
1  Ensure complete √ √
depressurize the SB line. Open Hot Surface
depressurization
all trap bypasses.
De-energize electrically of all
2 Electrical  Follow LOTO to √ √
panels from substation. Check &
Shock de-energise.
Tag it.
3 √ √
Release for maintenance. 
After maintenance job is over,

4 physically check the job. Check √

electrical connection properly
fitted.
After job completion clearance
5 from maintenance department is √ √

received, & LOTO clock is
opened, energize all panels.
6 √
Open steam trap and bypass. 

Page 53 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Slowly charge steam. Allow
draining of total condensate
7 √ √
from the line. When dry steam 
comes out of the trap bypass,
slowly close the trap bypass.
SOP No : AVU/013 SOP For: ROUTINE CHECKING OF RUNNING FORCED DRAFT FANS Revision No : 06
010-F-101 AVU


Page 54 of 732
PARADIP REFINERY
HAZARDS INVOLVED:
SL.
.
1
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Do not operate the Electrical switch. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Page 55 of 732
PARADIP REFINERY

Potential
. JEA JEA
1 Take temperature gun. √
2 √
3 √ √
DETAILED STEPS:
Potential
.
JEA JEA
Approach running fan in routine
round fully focused and stand
there for some time for any
1 √
abnormal sound / vibration feel 
in the fan. Note down if there is
any abnormality and inform it to
shift in charge.
2 Check oil level in inboard as  √
well as outboard bearing house,
feel the temperature and sound
of the bearings, visually check

Page 56 of 732
PARADIP REFINERY

Potential
.
JEA JEA
the colour and quality of lube
oil. If required top up LO.
3 Check cooling water flow and √

temperature
4 Check the load of the fan its √

ampere.
Take full round around the fan
5 √
to check any vibration in any 
part of the fan
Check IGV opening and
compare with your previous day
6 √
round and if there is any 
discrepancy in your view, share
the same with panel engineer.
Take reading of the temperature
and other parameters, compare
with previous record and your
7 √ √
memory of previous reading, in 
case of deviation contact panel
and shift charge and inform
them about abnormality.

Page 57 of 732
PARADIP REFINERY

Page 58 of 732
PARADIP REFINERY
SOP For: ROUTINE CHECKING OF RUNNING INDUCED DRAFT

SOP No : AVU/014 Revision No : 06
FANS
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1

Page 59 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Do not operate the Electrical switch. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA
1 Take temperature gun. √
2 √

Page 60 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √ √
DETAILED STEPS:
Potential
.
JEA JEA
Approach running fan in routine
round fully focused and stand
there for some time for any
1 √
abnormal sound or feel in the 
fan. Note down if there is any
abnormality and inform it to
shift in charge.
Check oil level in inboard as
well as outboard bearing house,
2 √
feel the temperature and sound 
of the bearings, visually check
the color and quality of lube oil.

Page 61 of 732
PARADIP REFINERY

Potential
.
JEA JEA
3 Check cooling water flow and √

temperature
4 Check the load of the fan its √

ampere.
Take full round around the fan
5 √
to check any vibration in any 
part of the fan
Check IGV opening and
compare with your previous day
6 √
round and if there is any 
discrepancy in your view, share
the same with panel engineer.
Take reading of the temperature
and other parameters, compare
with previous record and your
7 √ √
memory of previous reading, in 
case of deviation contact panel
and shift charge and inform
them about abnormality.

Page 62 of 732
PARADIP REFINERY

Page 63 of 732
PARADIP REFINERY
SOP No : AVU/015 SOP For: FORCED DRAFT (FD) FAN START UP Revision No : 06
010-F-101 AVU

 Safety Shoe  Emergency escape route before starting the job.
 Hand Gloves  Nearby MCP
 Ear plug  Nearby Fire monitor Not Required
HAZARDS INVOLVED:
SL.
.
1 High Arch pressure due to excess air flow IGV to be operated slowly.
2 High Excess Air Monitor excess oxygen analyzers.

Page 64 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure FD fan is energized. Don’t bypass any process interlocks / approved procedure.
Check CW Supply and return line up and ensure CW header Don’t allow movement of unauthorized personnel in the nearby
2
pressure. area
3 Check lube oil in bearings, both DE and NDE side. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Ensure operation of Dampers Stuck Physically see √
1
before start of fan. Dampers operation.
Malfuncti Physically see IA √
2 Ensure no air leakage in dampers
on leak.
Ensure CW line up and bearing Bearing √ √
3 Physically check.
lube oil. Damage

Page 65 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 High Arch open position √ √
Open MSD 100%.
Pressure and feed back in
Panel.
2 Drain out accumulated water  Drain out the √
Vibration
from casing. casing
Check oil level in inboard as Bearing  Physically check
3 well as outboard bearing house, damage due lube oil quantity √
visually check the colour and to low lube as well as
quality of lube oil. oil. quality.
4 Check cooling water flow and High bearing  Physically see √
temperature oil temp. CW valve lineup.
5 Stuck Closed  Match field & √ √
Open discharge damper fully.
damper. Panel indication.
6 High Air  Ensure 100% √ √
Close inlet damper.
flow close damper.
7 Take power clearance & start the High no load  Stop fan if √
motor. Wait till starting load current amperage does

Page 66 of 732
PARADIP REFINERY

Potential
.
JEA JEA
reduces. not come down.
Slowly increase load by opening High
8 Amperage  Gradually √ √
inlet damper (as per
High Arch increase load.
requirement). Pressure
9 Observe inlet damper opening Mismatch √ √
and match with
from field. with Panel
panel.
Observe for any abnormal sound
10 √
/ vibration. If it is there, inform 
SI & take corrective action.

Page 67 of 732
PARADIP REFINERY
SOP No : AVU/016 SOP For: INDUCED DRAFT (ID) FAN START UP Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Low Arch pressure due to excess air flow IGV to be operated slowly.
2 High Excess Air Monitor excess oxygen analyzers.

Page 68 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure ID fan is energized. Don’t bypass any process interlocks / approved procedure.
2
pressure. area
PRE START CHECK:

Potential
. JEA JEA
1
on leak.
3 Physically check.
lube oil. Damage

Page 69 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Ensure that MSD is kept 100%  Physically check
1 open. Match with field High Arch open position √ √
indication. Pressure and feed back in
Panel.
2 Drain out accumulated water  Drain out the √
Vibration
from casing. casing
Check oil level in inboard as Bearing  Physically check
3 well as outboard bearing house; damage due lube oil quantity √
visually check the colour and to low lube as well as
quality of lube oil. oil. quality.
4 Check cooling water flow and High bearing  Physically see √
temperature oil temp. CW valve lineup.
5 Open discharge damper fully. Stuck Closed  Match field & √ √
Match field & CR indication. damper. Panel indication.
6 Close inlet damper. High Air  Ensure 100% √ √
flow close damper.
7 Take power clearance & start the High no load  Stop fan if √
motor. Wait till starting load current amperage does

Page 70 of 732
PARADIP REFINERY

Potential
.
JEA JEA
reduces. not come down.
Slowly increase load by opening High
8  Gradually √ √
inlet damper (as per Amperage
increase load.
requirement).
Observe inlet damper opening  Physically check
9 Mismatch
and match with √ √
from field. with Panel
panel.
Observe for any abnormal sound
10 √
/ vibration. If it is there, inform 
SI & take corrective action.

Page 71 of 732
PARADIP REFINERY
SOP For: FORCED DRAFT (FD) FAN HANDOVER FOR

MAINTENANCE
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Low Arch pressure IGV to be operated slowly.
2 Low Excess Air Monitor excess oxygen analyzers.

Page 72 of 732
PARADIP REFINERY
SL.
.
3 Insufficient combustion Adjust air flow. If required reduce plant load / furnace duty.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure ID fan is energized. Don’t bypass any process interlocks / approved procedure.
2
pressure. area
PRE START CHECK:

Potential
. JEA JEA
1
on leak.

Page 73 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 Physically check.
lube oil. Damage
DETAILED STEPS:
Potential
.
JEA JEA
Inform panel engineer and
High Arch
1 request him to close IGV of the  Operation to be √ √
Pressure
fan & increase 2nd FD load as Low Oxygen
done gradually.
required for furnace.
Stop the 1st FD. Observe furnace
2 Low Low Air  Ensure other FD √ √
box & adjust air requirement as
flow is running
per requirement.
3 Reverse  Ensure physical √ √
Close discharge damper and IGV
rotation. closure.
4 De-energized motor with LOTO Energized  Follow LOTO √ √ √
is done. That the motor is de- Motor  Confirm with
energized must be confirmed by Substation
 Ensure healthy

Page 74 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pressing the start button in
presence of substation Interlock
technician.
The agency which is supposed to
work must also check the status
 Follow LOTO
5 of motor and their engineer Energized √ √
 Confirm with
must apply lock on the panel Motor Substation
before requesting permit to
work.
However for very small external
6 jobs like changing oil or working  Ensure Fan is not √
to de-chock cooling water line, rotating
de-energisation is not necessary.
If there is man entry
requirement in FD casing
7 √ √
manually operated shut off  Ensure blind
blinds (OSB) must be closed and
area completely isolated.

Page 75 of 732
PARADIP REFINERY
SOP For: INDUCED DRAFT (ID) FAN HANDOVER FOR

MAINTENANCE
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 High Arch pressure IGV to be operated slowly.
2 Low Excess Air Monitor excess oxygen analyzers.

Page 76 of 732
PARADIP REFINERY
SL.
.
3 Insufficient combustion Adjust air flow. If required reduce plant load / furnace duty.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure other ID fan is healthy. Don’t bypass any process interlocks / approved procedure.
2
pressure. area
PRE START CHECK:

Potential
. JEA JEA
1
on leak.

Page 77 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 Physically check.
lube oil. Damage
DETAILED STEPS:
Potential
.
JEA JEA
Inform panel engineer and
High Arch
1 request him to close IGV of the  Operation to be √ √
Pressure
ID fan & increase 2nd ID load as done gradually.
required for furnace.
Stop the 1st ID fan. Observe
2 Low Low Air  Ensure sufficient √ √
furnace box & adjust air
flow air flow.
requirement as per requirement.
3 Reverse  Ensure physical √ √
Close discharge damper and IGV
rotation. closure.
4 De-energized motor with LOTO Energized  Follow LOTO √ √ √
is done. That the motor is de- Motor  Confirm with
energized must be confirmed by Substation
 Ensure healthy

Page 78 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pressing the start button in
presence of substation Interlock
technician.
The agency which is supposed to
work must also check the status
 Follow LOTO
5 of motor and their engineer Energized √ √
 Confirm with
must apply lock on the panel Motor Substation
before requesting permit to
work.
However for very small external
6 jobs like changing oil or working  Ensure Fan is not √
to de-chock cooling water line, rotating
de-energisation is not necessary.
If there is man entry
requirement in ID casing
7 √ √
manually operated shut off  Ensure blind
blinds (OSB) must be closed and
area completely isolated.

Page 79 of 732
PARADIP REFINERY
SOP No : AVU/019 SOP For: FO STRAINER CHANGE OVER Revision No : 06

010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 High FO pressure Control valve to be kept in manual.
2 High / low COT Monitor FO pressure and adjust.
3 High / Low FO-Steam DP Monitor differential pressure and adjust.

Page 80 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure proper box up. Don’t bypass any process interlocks / approved procedure.
2 Ensure drains are closed.
area
3 Inform SIC and Panel before start of job. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Ensure that the standby strainer is Flange Physically see all √
1
properly boxed up. Leak flanges.
Ensure that LPD/HPVs are boxed Physically see all √
2 Oil Leak
up. drains / vents.
Miscomm Start job only after √
3 Inform Panel before start of job.
unication informing.

Page 81 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Mis-
1  Start job only √
Inform panel engineer. communicatio
after informing.
n
Before changing over of FO
strainer, ensure that standby
2  Check √
strainer is properly cleaned, Flange leak
Physically.
flushed & boxed-up with proper
gasket.
3 Ensure its inlet / outlet / drain /  Check √
Oil leak
vent valves are closed. Physically.
Then by opening one of the inlet
isolation valves, fill it with FO &
vent air from the vent. This  Ensure hose
4 Air pocket √ √
activity to be carried out at very connection for
Oil Spill
slow rate in order to avoid safe air removal.
pressure fluctuation in the
system or FO spillage.

Page 82 of 732
PARADIP REFINERY

Potential
.
JEA JEA
5 After filling the standby strainer  Ensure proper √ √
Oil Spill
close vent valve & plug it. box up.
Then slowly open outlet
6 √
isolation valve & allow building Oil leak  Check physically
pressure in the standby strainer.
After achieving equilibrium
pressure in the standby strainer  Monitor FO
7 line up both (i.e. upstream & High FO pressure and √ √
downstream valve) of the pressure Control through
standby strainer. Open fully control valve.
inlet & outlet valves.
 Monitor FO
8 Isolate on-line strainer for Low FO pressure and √
further maintenance. pressure Control through
control valve
9 Check about flow/pressure from  Adjust as per √ √
Low COT
panel. requirement.
 Ensure proper
10 Depressurize and drain to safe Valve √
closure of inlet
location passing
and outlet valves.

Page 83 of 732
PARADIP REFINERY

Page 84 of 732
PARADIP REFINERY
SOP No : AVU/020 SOP For: FG STRAINER CHANGE OVER Revision No : 06

010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 High FG pressure Control valve to be kept in manual.
2 High / low COT Monitor FG pressure and adjust.
3 High Arch pressure Monitor arch pressure and adjust.

Page 85 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1
2 Gas Leak
up. drains / vents.

Page 86 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Mis-
1  Start job only √
Inform panel engineer communicatio
after informing.
n
Ensure that the standby strainer
2  Check √
is properly cleaned, flushed & Flange leak
Physically.
boxed-up with proper gasket.
3 Ensure its inlet / outlet / drain /  Check √
Gas leak
vent valves are closed. Physically.
Slowly open inlet valve & vent
 Ensure hose
4 the strainer air content to Air pocket √ √
connection for
atmosphere by opening the vent Gas leak
safe air removal.
valve.
Ensuring air is totally vented,
5 close vent valve & allow gaining  Ensure proper √ √
Gas leak
FG header pressure in the box up.
strainer. Check for any leakage.
6 Slowly open outlet valve. Check √
Gas leak  Check physically
for any pressure fluctuation.

Page 87 of 732
PARADIP REFINERY

Potential
.
JEA JEA
 Monitor FG
7 Isolate former strainer & H/O for High FG pressure and √ √
cleaning pressure Control through
control valve.
 Monitor FG
8 Check about flow/pressure from Low FG pressure and √
panel. pressure Control through
control valve
9 Check about flow/pressure from  Adjust as per √ √
Low COT
panel. requirement.
 Ensure proper
10 Depressurize and drain to safe Valve √
closure of inlet
location passing
and outlet valves.

Page 88 of 732
PARADIP REFINERY
SOP No : AVU/021 SOP For: FO STRAINER HAND OVER FOR MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.

Page 89 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1
2 Oil Leak
up. drains / vents.

Page 90 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Inform panel engineer 
2 Change over Strainer as per √


SOP.
3 Isolate upstream & downstream  Ensure complete √
Valve Passing
isolation valves. closure.
4 √
Drain to CBD. 
5 Open vent valve in order to have √


effective draining.
Check & ensure that isolation
6 √
valves are holding by opening 
drain to OWS.
After ensuring complete
7 √
draining, hand over FO strainer 
for cleaning.

Page 91 of 732
PARADIP REFINERY
SOP No : AVU/022 SOP For: FG STRAINER HAND OVER FOR MAINTENANCE Revision No : 06
010-F-101 AVU

 Safety Shoe  Gas detector  Emergency escape route before starting the job.
HAZARDS INVOLVED:
SL.
.

Page 92 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1
2 Gas Leak
up. drains / vents.

Page 93 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Mis-
1  Start job only √ √
Inform panel engineer communicatio
after informing.
n
2 √ √
Change over strainer as per SOP. 
3 Isolate upstream & downstream √


isolation valves.
4 Exposure to  Ensure safe √ √
Depressurize to safe location.
Gas location.
5 Exposure to  Ensure safe √ √
Provide N2 connection & purge.
Gas location.
6 Exposure to √
Close vent valve & open drain.  Use gas detectors
Gas
7 √
Ensure isolations are holding. 
8 Exposure to √
Check H2S  Use gas detectors
Gas
Now, strainer can be handed  Use non sparking
9 √ √
over to maintenance for tool for
cleaning. maintenance.

Page 94 of 732
PARADIP REFINERY
SOP No : AVU/023 SOP For: FO STRAINER TAKE OVER AFTER MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.

Page 95 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1

Page 96 of 732
PARADIP REFINERY

Potential
. JEA JEA
2 Oil Leak
up. drains / vents.
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Ensure proper cleaning of filter. 
2 Ensure filter is not in damage √


condition.
3 √
Ensure proper box up of filter. 
Visually check whether all the

4 √
nut bolts are properly tightened 
and area is cleaned properly.
5 Ensure filter drain and vents are √

closed.

Page 97 of 732
PARADIP REFINERY

Potential
.
JEA JEA
6 Slowly open inlet valve and √

remove air by opening vent.
7 √
Check for any leakage. 
8 Keep it in stand by position 

Page 98 of 732
PARADIP REFINERY
SOP No : AVU/024 SOP For: FG STRAINER TAKE OVER AFTER MAINTENANCE Revision No : 06
010-F-101 AVU

HAZARDS INVOLVED:
SL.
.

Page 99 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1
2 Gas Leak
up. drains / vents.

Page 100 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Ensure proper cleaning of filter. 
2 Ensure filter is not in damage √


condition.
3 √
Ensure proper box up of filter. Flange Leak  Check physically
Visually check whether all the

4 √
nut bolts are properly tightened Flange Leak  Check physically
and area is cleaned properly.
5 Ensure filter drain and vents are √
Gas Leak  Check physically
closed.
6 Slowly open inlet valve and  Ensure safe √
Gas Leak
remove air by opening vent. location
7 √
Check for any leakage. Flange Leak  Use Gas Detector
8 √
Keep it in stand by position 

Page 101 of 732
PARADIP REFINERY

Page 102 of 732
PARADIP REFINERY
SOP No : AVU/025 SOP For: ATOMIZING STEAM COMMISSIONING Revision No : 06

010-F-101 AVU

HAZARDS INVOLVED:
SL.
.
1 Hot condensate Ensure draining with pre caution. Use PPEs.
2 FO burner fluctuations Monitor FO pressure and adjust.
3 COT fluctuations Monitor COT and adjust.

Page 103 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure condensate draining. Don’t bypass any process interlocks / approved procedure.
2 Ensure insulation on hot surface
area
PRE START CHECK:

Potential
. JEA JEA
Ensure steam header is lined up at Loss of √
1 Physically check.
battery limit. Steam
Ensure that hot surface is √
2 Injury Physically check.
insulated.
3 Inform Panel before start of job. Ensure √

Page 104 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Isolate individual FO burner
1 Valve Passing  Physically √
atomizing steam main isolation
High Arch Pr. ensure
valve.
2 Open all individual burners Hot √
 Use PPEs
atomizing steam drain condensate
3 √
Open 20% steam C/V. 
4 √
Line up one set of strainer. 
5 Open drains at D/s of steam C/V, √


strainer
Crack open steam main isolation
valve & allow to drain out
6 condensate from all above √

mentioned drain points. Wait till
dry steam comes out from above
drains.
7 COT  Monitor and √ √
Start FO burner and adjust DP
fluctuations Control

Page 105 of 732
PARADIP REFINERY

Potential
.
JEA JEA
8 COT  Monitor and √ √
Gradually take in all FO burners.
fluctuations Control
SOP No : AVU/026 SOP For: VELOCITY STEAM COMMISSIONING Revision No : 06

010-F-101 AVU

 Safety Shoe   Emergency escape route before starting the job.
HAZARDS INVOLVED:

Page 106 of 732
PARADIP REFINERY
SL.
.
1 Hot condensate Ensure draining with pre caution. Use PPEs.
2 Pass flow fluctuations Monitor Pass flow
3 COT fluctuations Monitor COT and adjust.
4 Coil Vibration Physically see and monitor.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure condensate draining. Don’t bypass any process interlocks / approved procedure.
2 Ensure insulation on hot surface
area
PRE START CHECK:

Page 107 of 732
PARADIP REFINERY

Potential
. JEA JEA
Ensure steam header is lined up at Loss of √
1 Physically check.
battery limit. Steam
Ensure that hot surface is √
2 Injury Physically check.
insulated.
3 Inform Panel before start of job. Ensure √
DETAILED STEPS:
Potential
.
JEA JEA
1 Isolate velocity steam inlet to all  Physically √
Valve Passing
passes ( convection + radiation) ensure
2 Open condensate drains at C/v & Hot √
 Use PPEs
at u/s of inlet isolation valve. condensate
3 Open main line trap bypass. Hot
 Use PPEs
√
condensate
4 Open individual pass steam C/V √

10%.
5 Crack open steam main isolation Hot  Use PPEs √
valve & allow to drain out condensate
condensate from all above

Page 108 of 732
PARADIP REFINERY

Potential
.
JEA JEA
mentioned drain points. Wait till
dry steam comes out from above
drains.
6 Pinch drains & slowly open Hot √
 Use PPEs
(fully) main isolation valve. condensate
Close all above mentioned drains
7 Coil  Monitor and √ √
& introduce steam after
vibration Control
consulting panel officer.
8 Gradually take in all passes Coil  Monitor and √ √
velocity steam vibration Control
SOP No : AVU/027 SOP For: CONTROL VALVE HANDOVER FOR MAINTENANCE Revision No : 06
AVU
Production Respective Control Valves &
SR-LPG Treatment Unit


Page 109 of 732
PARADIP REFINERY
 Safety Shoe  Gas Detector  Emergency escape route before starting the job.
HAZARDS INVOLVED:
SL.
.
1 Process Fluid Leak Ensure PPEs.
2 Gland leak. Ensure gland tightening.
3 Hot surface Ensure PPEs.
4 Hot liquid. Ensure cooling before draining.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure PPEs. Don’t bypass any process interlocks / approved procedure.
2 Monitor vibration of the line.
area

Page 110 of 732
PARADIP REFINERY
PRE START CHECK:

Potential
. JEA JEA
Gland Cross Check with √
1 Check bypass valve glands.
leak MM
2 √
3 √
DETAILED STEPS:
Potential
.
JEA JEA
Mis
1 Inform panel engineer about  Start only after √
communicatio
isolating the control valve. communicating.
n
Check the bypass valve of the  Cross Check
2 √
control valve for any gland leak / Gland Failure with help of
bonnet leak. MM.

Page 111 of 732
PARADIP REFINERY

Potential
.
JEA JEA
If gland leak / bonnet leak is  Cross Check
3 √ √
there get it attended by Mech Gland Failure with help of
Maint. MM.
After ensuring all is OK, crack  Flow control
4 open the bypass valve in High flow through CV. √ √
consultation with Panel. Vibration  Monitor
vibration.
Coordinate with Panel and
5 ensure steady flow. Panel officer √ √

to control flow using control
valve.
If control valve is not operable,
6 adjust flow by operating √ √

upstream isolation valve of the
CV.
When sufficient flow is  Adjust bypass in
7 √ √
achieved, then close the Low flow coordination
CV/upstream isolation valve. with Panel
Lock tight the bypass control
8 √ √
valve and monitor for any 
vibration.

Page 112 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Once flow is steady, isolate both
9 √
upstream and downstream CV. 
For Gas/LPG service control

valve depressurize to flare
10 header through permanent line.  Ensure proper √
Gas Leak
If flare line not available, use hose connection.
temporary hose. Ensure CV full
open.
For liquid service control valve
depressurize to CBD (if  Ensure sufficient
available) or OWS header cooling.
11 √
through permanent line. If Hot liquid  If required
permanent line not available, remove
use temporary hose. Ensure CV insulation.
full open.
Check for complete
depressurization by opening
12  Ensure sufficient √
LPD to open. For hot service Hot liquid
cooling.
ensure liquid is cold before
opening to atmosphere.

Page 113 of 732
PARADIP REFINERY

Potential
.
JEA JEA
On complete draining and
13 ensuring no valve passing √

handover control valve for
maintenance job.
If CV is required to be dropped
14 ensure brass tools for √

FG/H2/LPG service. After
dropping CV ensure blinds.

Page 114 of 732
PARADIP REFINERY
SOP No : AVU/028 SOP For: CONTROL VALVE TAKEOVER AFTER MAINTENANCE Revision No : 06
AVU
Production Respective Control Valves &

HAZARDS INVOLVED:
SL.
.

Page 115 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Monitor vibration of the line.
area
PRE START CHECK:

Potential
. JEA JEA
Check inlet/outlet/bypass valve Gland Cross Check with √
1
glands. leak MM
Ensure that the control valve is
Flange √
2 properly boxed-up with proper Check Physically
Leak
gasket.
Leak Check Physically √
3 Close drain to CBD/OWS.

Page 116 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Mis
1 Inform panel engineer about  Start only after √
communicatio
taking the control valve inline. communicating.
n
Do stroke check of the control
2 CV Reverse  Cross Check √
valve in inlet and outlet valves
Operation with help of IM.
isolated condition.
3 Full open the C/V in inlet and √ √

outlet valves isolated condition.
Crack open the inlet valve &  Ensure air
4 vents air to flare. Ensure Explosive removal to flare. √ √
complete air removal by mixture.  Else connect
observing vent line temperature. permanent hose.
5 Close vent to flare & allow √ √

pressurizing the loop.
6 Check for any leakage. Attend if √ √

any.
7 For liquid CV connect hose and Oil Spill  Crack open the √ √
route to safe location for air inlet and vent
valve.

Page 117 of 732
PARADIP REFINERY

Potential
.
JEA JEA
removal. For hot liquid take  Hose to be
routed to
precaution in very small opening
CBD/Safe
of inlet and vent valve. location.
8 Close CV and Open sufficient Flange Leak  Monitor closely √ √
inlet valve. High Flow  Monitor closely
 Activity to be
9 Slowly open outlet valve to High / Low √
done very
avoid flow disturbance. Flow
slowly.
Ask panel to open C/V as per Vibration /
10  Closely monitor √
requirement & simultaneously gland leak in
the bypass valve.
close bypass slowly. bypass valve
11 Handover C/V to panel √

engineer.

Page 118 of 732
PARADIP REFINERY
SOP No : AVU/029 SOP For: PUMPING OUT OF CBD VESSELS LIQUID TO SLOP TANK Revision No : 06
Respective CBD Vessels and Pumps AVU
Production 010-P-610/611/612/613/614 &
010-V-610/611/612/613/614 SR-LPG Treatment Unit

HAZARDS INVOLVED:
SL.
.

Page 119 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure CBD Pumps are not run in dry conditions. Don’t bypass any process interlocks / approved procedure.
Monitor vibration of the line / pump / seal leak during pump Don’t allow movement of unauthorized personnel in the nearby
2
running. area
PRE START CHECK:

Potential
. JEA JEA
Cross Check with
Ensure wet slop tank is lined up for √
1 No Flow DHDT Shift in
receiving slop. Charge
Ensure AVU battery limit wet slop Cross Check with √
2 No Flow
valve is lined up. Area JEA.
Ensure that CBD is floated with √
3 Leak Check Physically
flare.

Page 120 of 732
PARADIP REFINERY

Potential
. JEA JEA
Ensure CBD pump is available and Equipmen Cross Check with √ √
4
not under any maintenance. t Damage SIC
Ensure LG/LT, PG/PT, FT, TT are Cross Check with
SIC and Panel √ √ √
5 working and not under
maintenance. Officers.
DETAILED STEPS:
Potential
.
JEA JEA
1 Inform panel engineer before Miscommuni  Start after √
staring the operation cation confirmation.
Panel officer to inform DHDT
2 Tank  Start after √
Panel about starting the pump
Availability confirmation.
and confirm line up of the tank.
Ensure that the temperature of
3 the vessel is below the tripping High  Ensure √
value in High High Temperature Temperature Compliance
trip logic.

Page 121 of 732
PARADIP REFINERY

Potential
.
JEA JEA
4 Check Local Level reading and √ √

cross check with DCS.
Start pump and observe its  Ensure all
5 Flange Leak flanges are boxed √
performance.
up / not leaking.
6 √
Ensure that there is no leakage. Flange Leak  Physically check.
7 Stop pump when desired level is √


achieved.
Pump can be put in remote for  Ensure LTs are
8 working and √ √
tripping automatically when Dry Run
interlock is also
level comes down. working.
 To be present
near pump till
9 Do not allow dry run of the CBD Pump √
running.
pump. Damage
 Observe for any
abnormal flow.
10 Inform panel engineer when √ √

operation gets over

Page 122 of 732
PARADIP REFINERY

Page 123 of 732
PARADIP REFINERY
SOP No : AVU/030 SOP For: PSV TAKE OVER AFTER MAINTENANCE Revision No : 06
AVU
Production Respective PSVs. &

HAZARDS INVOLVED:
SL.
.

Page 124 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure PSVs are properly calibrated. Don’t bypass any process interlocks / approved procedure.
Cross check PSV tag no with P&ID for ensuring correct location Don’t allow movement of unauthorized personnel in the nearby
2
of box up. area
3 Cross check PSV set point with P&ID. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Cross Check with
Ensure PSV tag no with that of the √ √
1 No Flow P&ID and PSV Tag
P&ID. no.
Cross Check
Ensure PSV is correctly calibrated √
2 No Flow Inspection / Mech
as per test pressure.
Maint.

Page 125 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
1 Miscommuni  Start after √
Inform panel engineer.
cation confirmation.
Observe physically boxing up of
2  Start after √
PSV with proper gasket & are Flange Leak
confirmation.
properly tightened.
3  Ensure √
Close drain.
Compliance
 Ensure all
4 √
Open d/s isolation valve first. Flange Leak flanges are boxed
up / not leaking.

Page 126 of 732
PARADIP REFINERY

Potential
.
JEA JEA
 Ensure all
5 √
Line up pilot line. Flange Leak flanges are boxed
up / not leaking.
 Ensure all
6 √
Open U/s valve Flange Leak flanges are boxed
up / not leaking.
Check leakage physically &
7 √
check that PSV B/Vs are not 
passing.

Page 127 of 732
PARADIP REFINERY
SOP No : AVU/031 SOP For: PSV HAND OVER FOR MAINTENANCE Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.

Page 128 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure stand by PSV is lined up. Don’t bypass any process interlocks / approved procedure.
Cross check PSV tag no with P&ID for ensuring correct PSV is Don’t allow movement of unauthorized personnel in the nearby
2
isolated. area
PRE START CHECK:

Potential
. JEA JEA
Cross Check with
Ensure PSV tag no with that of the In correct √ √
1 P&ID and PSV Tag
P&ID. PSV
no.
Cross Check
Ensure no leak from any flanges of √
2 Inspection / Mech
stand by PSV.
Maint.

Page 129 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
1 Miscommuni  Start after √
Inform panel engineer.
cation confirmation.
 Confirm PSV not
2 Line up stand by PSV & lock it PSV pop up. popping. √
with chain. Flange leak  Ensure no
flange leak.
3  Ensure √
Isolate the former one.
Compliance
4 De-blind PSV U/S & D/S line Valve  Ensure correct √
bleeder. Passing isolation.

Page 130 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Open both inlet & outlet drains Valve  Ensure correct
5 √
& depressurizes the line. Stand Passing isolation.
at opposite wind direction.
6 Ensure that both valves are √
holding.
Give clearance for dropping the
7 √
PSV. Ask to wear gas mask if
required. Use non sparking tools.

Page 131 of 732
PARADIP REFINERY
SOP No : AVU/032 SOP For: SOUR WATER SAMPLING Revision No : 06

AVU

 Face MASK  CCTV Camera
HAZARDS INVOLVED:
SL.
.
1 Sour Water Leak Ensure PPEs.
2 H2S Exposure Ensure PPEs. Gas Detector to be used.

Page 132 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
Do not go alone for sample. Always minimum two persons
should be present for sour water sampling.
2 Carry personal gas detector.
area
3 Check wind direction and stand up stream side. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Inform Shift in Charge and Panel
1 officers and fellow JEAs about √ √
sampling.
Check surrounding are for any √
2 H2S Leak
smell / leak with gas detectors.
Ensure that there is not any leak of
3 H2S Leak
H2S / sour water nearby.

Page 133 of 732
PARADIP REFINERY

Potential
. JEA JEA
Ensure that there is a closed loop
4 for sour water sampling. Take H2S Leak
sample in Bomb if possible.
5
DETAILED STEPS:
Potential
.
JEA JEA
1 Inform panel engineer before √

starting the job.
2 Carry gas meter and walkie- √

talkie along with you.
3 Open Inlet and Outlet valves for √

starting circulation
 Ensure valve is
After circulation is established crack open.
4 √
for sufficient time, open drain H2S Leak  Carry gas
valve slightly to collect sample. detector.
 Use face mask.

Page 134 of 732
PARADIP REFINERY

Potential
.
JEA JEA
5 During sampling stand upstream  √
side of the wind direction.
6 Collect sample and close the √
circulation.
7 Inform SIC and Panel about √
completion of sample collection.

Page 135 of 732
PARADIP REFINERY
SOP No : AVU/033 SOP For: PRODUCT ROUTING PROCEDURES Revision No : 06

AVU
Production Respective products/tanks/units &

 Hand Gloves  Temperature Gun  Nearby MCP
HAZARDS INVOLVED:
SL.
.
1 High Product Temperature Ensure PPEs. Ensure TI indication are working.
2 H2S Exposure Ensure PPEs. Gas Detector to be used.

Page 136 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
Do not go alone for sample. Always minimum two persons
should be present for sour water sampling.
2 Carry personal gas detector.
area
3 Check wind direction and stand up stream side. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
1 Inform ISC, Panel Officers √
2 Check line integrity. √

Check all FT/PT/TT/TG/PG are
3 √
boxed up.

Page 137 of 732
PARADIP REFINERY

Potential
. JEA JEA
Check required insulation are
4 √
provided.
5 Check valves have wheel keys. √

Page 138 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Inform panel engineer and shift
1 Miscomm  To start after √
in-charge before start of
unication confirmation.
operation.
For changeover of routing,
2 confirm receiving tank / unit Miscomm  To start after √
line up from Shift in Charge / unication confirmation.
Panel Officer.
3 Inform panel officer about Miscomm  To start after √
change over. unication confirmation.
Confirm battery limit pressure /  Ensure rundown
4 High Temp AFC and Water √ √
temperature from Panel.
Cooler is in line.
Ensure LPD/HPVs are isolated
5  Check √
and boxed up before changing Leak
Physically.
routing.
Open rundown valve, where to
6 Low/High  To be opened √
be routed first. Slowly close
Flow gradually.
formerly routed rundown valve.
7 Be constantly in touch with Low/High  To be opened √
panel engineer about rundown Flow gradually.

Page 139 of 732
PARADIP REFINERY

Potential
.
JEA JEA
flow.
8 Inform Shift in charge. Record √

in log book.
SOP No : AVU/034 SOP For: WATER SPRINKLER CHECKING PROCEDURE Revision No : 06

AVU
Production Respective Deluge Systems &

HAZARDS INVOLVED:

Page 140 of 732
PARADIP REFINERY
SL.
.
1
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Page 141 of 732
PARADIP REFINERY

Potential
. JEA JEA
2 √
3 √
DETAILED STEPS:
Potential
.
JEA JEA
Ensure no maintenance activity,
1 Injury to  Check √
especially electrical job, is going
Personnel Physically
on in the area.
First drain through the header
drain point, if available, till
2 √
water sediments are cleared so as Chokage 
to avoid chock-age of sprinklers
due to poor fire water quality.
3 Isolate the drain valve once √

water quality improves.

Page 142 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Open sprinkler isolation valve
4 fully and check sprinkler √ √

performance in shortest time
possible in hot equipment area.
Isolate the sprinkler header B/V
5 √
and drain out the header where 
drain line available.
Log locations of chocked
6 √
sprinkler points for 
maintenance.
7 Get the chocked sprinklers de- √

chocked
SOP No : AVU/035 SOP For: COOLING WATER SAMPLING FOR OIL CHECKING Revision No : 06
AVU
Production Respective CW Header &

Page 143 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
1
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 144 of 732
PARADIP REFINERY

2
area
PRE START CHECK:

Potential
. JEA JEA
2 √
3 √
DETAILED STEPS:
Potential
.
JEA JEA
Take CWR sample of the
1 √
condenser/cooler in a clean 
sample bottle.
2 See if it has any lighter √

hydrocarbon smell.

Page 145 of 732
PARADIP REFINERY

Potential
.
JEA JEA
3 Give it 2-5 minutes settling time √

to float oil, if present.
Compare the sample with that of
4 CWS sample to visually assess √ √

any leakage in the
condenser/cooler.
Send fresh samples of CWS &
CWR to QC lab for HC
5 √
checking, if any leakage is 
suspected, to assess the severity
of leakage.

Page 146 of 732
PARADIP REFINERY
SOP No : AVU/036 SOP For: SAFETY SHOWER CHECKING Revision No : 06

AVU

HAZARDS INVOLVED:
SL.
.
1 Hot Water due to idle liquid Ensure water is drained till cold water is available.

Page 147 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure water is at normal temperature. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA
2 √
3 √

Page 148 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Ensure body shower chain is in √

good condition.
2 Ensure eye wash unit operating √

valve is operable.
3 Ensure safety shower area is not √

slippery and proper drainage.
Ensure proper
4 flow/pressure/quality of water √ √

from body shower & eye
shower.
5 Ensure that there is no leakage. 
√
6 Ensure that drinking water B/L


valve is open.

Page 149 of 732
PARADIP REFINERY
SOP No : AVU/037 SOP For: MONTHLY PSV CHECKING FOR PASSING Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.
1 Hc Spill Due to flange / LPD leak Ensure no leak is there.

Page 150 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure no HC leak. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA
2 √
3 √

Page 151 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 All PSV to be checked on √

Alternate Sundays.
Check if these are passing by
2 √
touching. It will be hot / cold 
than normal temperature.
3 Ensure all those are in line are √

locked with chain.
4 If anyone is passing, change over √

it & lock the new one.
5 Isolate passing one & inform SI √

to hand over to maintenance

Page 152 of 732
PARADIP REFINERY
SOP No : AVU/038 SOP For: COLD LIQUID SAMPLING PROCEDURE Revision No : 06

AVU
Production Respective Sampling Point &

 Hand Gloves  Sample Bottle  Nearby MCP
HAZARDS INVOLVED:
SL.
.
1 HC Spill Ensure boxup.

Page 153 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure OWS is dechoked. Don’t bypass any process interlocks / approved procedure.
2 Ensure PPEs.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 Ensure OWS is de-choked. Oil Spill Check Physically √
3 √

Page 154 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Use appropriate hand glove and  Open valve √
Oil Spill
goggles. slowly.
2 Crack open 2nd isolation valve  Open valve √
and then root valve. slowly.
3 √
Flush dead line content. 
4 Flush the sample bottle √


thoroughly 2-3 times.
Fill up the sample bottle and
5 √
close the isolation valves. Ensure 
that bottle lid is properly closed.
6 Tag the sample appropriately √

and keep it on sample point.

Page 155 of 732
PARADIP REFINERY
SOP No : AVU/039 SOP For: HOT LIQUID SAMPLING PROCEDURE Revision No : 06

AVU
Production Respective Sampling Point &

HAZARDS INVOLVED:
SL.
.
1 HC Spill Ensure proper box up.
2 Hot liquid spill Ensure adequate PPEs.

Page 156 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure OWS is de-choked. Don’t bypass any process interlocks / approved procedure.
2 Ensure PPEs.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 Ensure OWS is de-choked. Oil Spill Check Physically √
3 √

Page 157 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Use asbestos gloves for sampling.  Open valve √
Oil Spill
slowly.
Start CW to sample cooler and
2 check whether CW flow is there  Open valve √
or not. If flow is not observed slowly.
get the CW line de-chocked.
After confirming the CW flow
through sample cooler, Crack
3 √
open 2nd isolation valve and then 
root valve. Adjust valve opening
if liquid is very hot.
4 √
Flush dead line content. 
5 Flush the sample bottle √


6 Fill up the sample bottle and √

close the isolation valves.
7 Tag the sample appropriately  √

Page 158 of 732
PARADIP REFINERY

Potential
.
JEA JEA
8 Flush the sample point with
 √
steam
9 Place the sample into sample
 √
cage.

Page 159 of 732
PARADIP REFINERY
SOP No : AVU/040 SOP For: SAMPLING OF FLUE GAS Revision No : 06

AVU
Production Respective Stacks. &

HAZARDS INVOLVED:
SL.
.
1 Flue Gas Exposure Ensure adequate PPEs.
2 Height Work Ensure height permit and Ensure adequate PPEs for the same.

Page 160 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure sampling personnel are healthy & fit for height work. Don’t bypass any process interlocks / approved procedure.
2 Ensure PPEs. Ensure availability of permits.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 161 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Use appropriate hand gloves. √

Stand against air direction.
2 Crack open 2nd isolation valve √

and then root valve.
Flush the sampling bladder
3 √
thoroughly 2-3 times using 
aspirator.
Fill up the bladder and lock it
4 √
with locking pin and close the 
isolation valves.
Tag the sample indication
5 sample name, date & time of √

sampling and analysis required

Page 162 of 732
PARADIP REFINERY
SOP No : AVU/041 SOP For: SAMPLING OF FUEL GAS Revision No : 06

AVU
Production Fuel Gas Sample Point &

 Hand Gloves  Sample Bladder  Nearby MCP
HAZARDS INVOLVED:
SL.
.
1 H2S Exposure Ensure adequate PPEs. Ensure Gas Detector is available.
2 Height Work Ensure height permit and Ensure adequate PPEs for the same.

Page 163 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Ensure sampling personnel are healthy. Don’t bypass any process interlocks / approved procedure.
2 Ensure PPEs..
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 164 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Use appropriate hand gloves. 
Stand against air direction.  Carry H2S

2 H2S
Responder/Mul √
Check for any gas leak
Exposure
with gas detector. ti gas detector.
3 Crack open 2nd isolation valve √

and then root valve.
4 Flush the sampling bladder √

Fill up the bladder and lock it
5 √
with locking pin and close the 
isolation valves.
6 sample name, date & time of √


Page 165 of 732
PARADIP REFINERY

Page 166 of 732
PARADIP REFINERY
SOP No : AVU/042 SOP For: CLOSED LOOP SAMPLING OF OIL / GAS SAMPLES. Revision No : 06
AVU
Production Respective Sample Point &

 Hand Gloves  Sample Collection Device  Nearby MCP
HAZARDS INVOLVED:
SL.
.
1 H2S Exposure / Hot liquid. Ensure adequate PPEs. Ensure Gas Detector is available.

Page 167 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Do not vent HC to atmosphere.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 168 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Use appropriate hand gloves. 
 Carry H2S
2 Place sample bomb & fix H2S √
Responder/Mul
properly in the point. Exposure
ti gas detector.
3 √
Open cylinder valves 
 Ensure no hose
4 √
Open supply and return valves Hose Leak leak. If leaks
then isolate.
Flow sample through the
5 cylinder for a sufficient time in √

order to obtain a representative
sample
6 √
Close supply and return valves 
7 Close cylinder valves  √
8 Open vent valve to flare to

 √
reduce the pressure.

Page 169 of 732
PARADIP REFINERY

Potential
.
JEA JEA
9 Close vent valve  √
10 sample name, date & time of
 √
11 For liquid sample through bottle
 √
follow the following procedure.
Open inlet / outlet valves from
12 upstream / downstream and  √
establish circulation.
13 Ensure sample coolers are in  Ensure proper
Hot liquid √
line. cooling.
After sufficient circulation, open
14  Ensure slow
intermediate drain to Liquid Spill √
opening.
OWS/CBD.
15  Ensure slow
Drain hold up to CBD/OWS. Liquid Spill √
opening.
16 Collect sample and close
 √
circulation valves.

Page 170 of 732
PARADIP REFINERY

Page 171 of 732
PARADIP REFINERY
SOP No : AVU/043 SOP For: NORMAL OPERATION OF HEAT EXCHANGERS Revision No : 06

AVU
Production HEAT EXCHANGERS &

HAZARDS INVOLVED:
SL.
.
1

Page 172 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 173 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Check Inlet/Outlet temp. gauges,
1 √
Tis, pressure gauges, PIs for 
healthiness
Check inlet/Outlet temp.
2 √
indicator in control room for 
healthiness
Check bypass valve of Heat For VGO
 Consult VGO-
exchanger is open or not. If open exchanger
3 HDT Panel √
after consulting SIC, bypass VGO-
before pinching
HDT DP
valve to be closed. bypass valve.
increases
Check leak from floating
head/channel cover/  Monitor
4 regularly √ √
flanges/valve glands if observed Fire Hazard
 Hot bolting to be
keep steam lancer & inform shift done
in charge
5 Check for insulation damage if  Heat Loss  Insulation to be √ √
not found ok get it attended  Safety done.

Page 174 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Abnormal temperatures of I/L
6 and O/L temp to be observed √

and to be informed to shift in
charge.
Abnormal change in pressure
drop to be informed to shift in
7 charge for getting cleaned heat
 √
exchanger and open bypass valve
slightly if restriction is observed
in that stream
If excessive leak from exchanger
8 is observed, immediately contact
 √
shift in charge and get it
bypassed

Page 175 of 732
PARADIP REFINERY
SOP No : AVU/044 SOP For: NORMAL OPERATION OF COOLERS / CONDENSORS Revision No : 06

AVU
Production COOLERS & CONDENSORS &

HAZARDS INVOLVED:
SL.
.
1

Page 176 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 177 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Check Inlet/Outlet temp. gauges,
1 √
pressure gauges for 
healthiness(CW)
Observe products run down
2 temperature and log in log sheet 
√
kept in Control Room.
Observe product outlet temp if
high check cooling water outlet
temperature. Open inlet/outlet
3 √
water valves if throttled and 
then observe run down temp of
product. Inform to shift in
charge
4 Observe cooling water outlet  √ √
temperature if high, throttle
water outlet valve. Collect
sample of water ex-cooler outlet
and check for leak. Inform shift

Page 178 of 732
PARADIP REFINERY

Potential
.
JEA JEA
in charge about cooler leak or
for getting it attended by
Maintenance. Bypass cooler if
required after consultation with
shift in charge.
Leak from flanges/ channel
5 cover/valves. Inform shift in √ √
 
charge to get attended by
Maintenance.
Observe for excessive leak -If
required, call furnace, pump
6 √
house operator for assistance and 
immediately bypass & isolate the
coolers.

Page 179 of 732
PARADIP REFINERY
SOP For: HANDOVER PROCEDURE FOR EXCHANGER (NON

CONGEALING LIGHT HYDROCARBONs)
AVU
Production Respective Heat Exchangers &

HAZARDS INVOLVED:
SL.
.
1

Page 180 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √

Page 181 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √
DETAILED STEPS:
Potential
.
JEA JEA
Inform panel officer about the
1 operation. Panel officer to √

inform downstream units if
required.
 Check bypass
valve gland
Gland
2 Open bypass valve of hot side before opening. √ √
Leak
first.  Control Flow
High Flow
through flow
control valves.
3 Open bypass valve of cold side Gland  Check bypass √ √
next. Leak valve gland
High Flow before opening.
 Control Flow

Page 182 of 732
PARADIP REFINERY

Potential
.
JEA JEA
through flow
control valves.
4  Ensure valves are √
De-blind both side CBD/OWS Flange Leak
not passing.
Isolate both side & immediately  Open valve to
5  Hot liquid √
Crack open drain to CBD. This is only depressurize
to CBD.
to avoid leak due to expansion. the exchangers.
6 Allow to cool less than 100 deg  Check with √ √
C. temperature gun.
 1st drain to OWS
to check if drain
7 √
Drain both sides to CBD. Choked CBD is de-choked or
not, then drain to
CBD.
Work at
8  Ensure safety √
Open vent to drain completely. Height
belt
Operation
9 Open vent to drain completely. Back flow  While vent is √ √
from CBD opened, ensure
that drain is
routed to OWS
and NOT to
CBD. Else back

Page 183 of 732
PARADIP REFINERY

Potential
.
JEA JEA
flow of gas from
CBD will
happen.
Ensure that its isolation valves
10 √ √
are holding. Check by draining 
to OWS.
11 After draining is over, provide
 √
steam connection in both sides.
12 Steaming to be done thoroughly.
 √
Initially to CBD & than to OWS.
Stop steaming and close draining
13 of both tube and shell side to  √
CBD / OWS
Wait 2 hr. & Check the pressure
14 of both sides, if it is increasing.
 √
Check OWS drain. If not coming
exchanger can be handed over.
Confirm complete draining of
15 Condensate  Ensure slow √
tube and shell side by checking
spill operation.
in OWS.

Page 184 of 732
PARADIP REFINERY

Potential
.
JEA JEA
16 √ √
Handover exchange for blinding 

Page 185 of 732
PARADIP REFINERY
SOP For: HANDOVER PROCEDURE FOR EXCHANGER

(CONGEALING HEAVY HYDROCARBONs)
AVU

HAZARDS INVOLVED:
SL.
.
1 Spill of hot liquid. Use PPEs.

Page 186 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √

Page 187 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √
DETAILED STEPS:
Potential
.
JEA JEA

required.
 Check bypass
valve gland
Gland
2 Open bypass valve of hot side before opening. √ √
Leak
first.  Control Flow
High Flow
through flow
control valves.
3 Open bypass valve of cold side Gland  Check bypass √ √
next. Leak valve gland
High Flow before opening.
 Control Flow

Page 188 of 732
PARADIP REFINERY

Potential
.
JEA JEA
through flow
control valves.
not passing.
Isolate both side & immediately  Open valve to
5  Hot liquid only depressurize √
Crack open drain to CBD. This is
to CBD. the exchangers
to avoid leak due to expansion. and then close.
6 Allow to cool less than 150 deg  Check with √ √
C. temperature gun.
to check if drain
7 √
Drain both sides to CBD. Choked CBD is de-choked or
not, then drain to
CBD.
Work at
8  Ensure safety √
Open vent to drain completely. Height
belt
Operation
9 Open vent to drain completely. Back flow  While vent is √ √
from CBD opened, ensure
that drain is
routed to OWS
and NOT to

Page 189 of 732
PARADIP REFINERY

Potential
.
JEA JEA
CBD. Else back
flow of gas from
CBD will
happen.
10 √ √
to OWS.
11 After draining is over, flush both
 √
side with FLO & drain to CBD.
 √
steam connection in both sides.
 √
CBD / OWS
Wait 2 hr & Check the pressure
15 Condensate  Ensure slow √
of both sides, if it is increasing. If
spill operation.
not increasing then OK.
16 Confirm complete draining of  √
tube and shell side by checking

Page 190 of 732
PARADIP REFINERY

Potential
.
JEA JEA
in OWS
17 √ √
Handover exchange for blinding 

Page 191 of 732
PARADIP REFINERY
SOP No : AVU/047 SOP For: HANDOVER PROCEDURE FOR TRIM COOLERS Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.
1 Spill of hydrocarbons Use PPEs.

Page 192 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 193 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA

required.
 Check bypass
valve gland
Gland
2 Open bypass valve of hot before opening. √ √
Leak
hydrocarbon side first.  Control Flow
High Flow
through flow
control valves.
 Check bypass
valve gland
Gland
3 Open bypass valve of cold CW before opening. √ √
Leak
side next.  Control Flow
High Flow
through flow
control valves.
not passing.
5 Isolate both side & immediately  Hot liquid  Open valve to √
Crack open drain to CBD. This is to CBD. only depressurize

Page 194 of 732
PARADIP REFINERY

Potential
.
JEA JEA
the exchangers
to avoid leak due to expansion.
and then close.
6 Allow for 2 hours for liquid to Cool  Check with √ √
cool. sufficiently temperature gun.
to check if drain
7 √
Drain HC side to CBD. Choked CBD is de-choked or
not, then drain to
CBD.
8 Start draining of cooling water

side to open.
Work at
9 Open HC side vent to drain the  Ensure safety √
Height
exchanger completely. Operation
belt
 While vent is
opened, ensure
that drain is
routed to OWS
10 Open HC side vent to drain the Back flow √ √
and NOT to
exchanger completely. from CBD
CBD. Else back
flow of gas from
CBD will
happen.

Page 195 of 732
PARADIP REFINERY

Potential
.
JEA JEA
11 √ √
to OWS.
 √
steam connection in HC side.
 √
CBD / OWS
15 Condensate  Ensure slow
of both sides, if it is increasing. If √
spill operation.
16 √
tube and shell side by checking 
in OWS
17 Handover exchanger for √

blinding.

Page 196 of 732
PARADIP REFINERY
SOP No : AVU/048 SOP For: HANDOVER PROCEDURE FOR CW CONDENSOR Revision No : 06

AVU

HAZARDS INVOLVED:
SL.
.

Page 197 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 √
3 √

Page 198 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA

required.
 Check bypass
valve gland
Gland
2 Open bypass valve of before opening. √ √
Leak
hydrocarbon side first.  Control Flow
High Flow
through flow
control valves.
 Check bypass
valve gland
Gland
3 Open bypass valve of cold CW before opening. √ √
Leak
side next.  Control Flow
High Flow
through flow
control valves.
not passing.
5 Isolate both side & immediately  Hot liquid  Open valve to √
Crack open drain to CBD. This is to CBD. only depressurize

Page 199 of 732
PARADIP REFINERY

Potential
.
JEA JEA
the exchangers
to avoid leak due to expansion.
and then close.
6 Allow for 2 hours for HCs to Cool  Check with √ √
cool. sufficiently temperature gun.
to check if drain
7 √
Drain HC side to CBD. Choked CBD is de-choked or
not, then drain to
CBD.
8 Start draining of cooling water

side to open.
Work at
9 Open HC side vent to drain the  Ensure safety √
Height
exchanger completely. Operation
belt
 While vent is
opened, ensure
that drain is
routed to OWS
10 Open HC side vent to drain the Back flow √ √
and NOT to
exchanger completely. from CBD
CBD. Else back
flow of gas from
CBD will
happen.

Page 200 of 732
PARADIP REFINERY

Potential
.
JEA JEA
11 √ √
to OWS.
 √
steam connection in HC side.
 √
CBD / OWS
15 Condensate  Ensure slow
of both sides, if it is increasing. If √
spill operation.
16 √
tube and shell side by checking 
in OWS
17 Handover exchanger for √

blinding.

Page 201 of 732
PARADIP REFINERY
SOP No : AVU/049 SOP For: TAKE OVER PROCEDURE FOR HEAT EXCHANGERS Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.

Page 202 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
Ensure Exchanger is properly

2 √
boxed up.
Ensure all PG/TG are boxed up
3 √
and hydro test water is drained.

Page 203 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Inform panel officer. Panel
1 officer to inform downstream 
√
units.
2 De-blind FLO. 
√ √
3 Provide hose connection at both Height √ √

side vents.  Use PPEs.
Work
4 Fill both side with FLO & Height Work √

displace air through vents.  Use PPEs.
HC Spill
Drain both side material to OWS
to endure that it is free from
5 water. If water exists, drain  
√
more & subsequently fill with
FLO.
6 Close vents & Pressurize both HC Spill  Physically check. √ √
sides with FLO, 7 kg / cm2
pressure. Do leak test of both

Page 204 of 732
PARADIP REFINERY

Potential
.
JEA JEA
side de-blinded flanges.
7 Close & end blind both sides’  Ensure proper √

vents. HC Spill
box up.
8 Blind FLO 
Slowly line up cold side. 1st

9 outlet valve and then inlet valve. 
√
Do not close its bypass.
Slowly line up hot side. 1st outlet
10 valve and then inlet valve. Do 
√
not close its bypass.
11 Now slowly close cold side √ √

bypass. (80%). Monitor in Panel. 
After above step, slowly close

12 hot side bypass (80%). Take √
sufficient time for closing hot  √
side bypass. Monitor in Panel.
13 Rest 20% bypass valves to be  √

Page 205 of 732
PARADIP REFINERY

Potential
.
JEA JEA
closed in two shift & slowly.
14 Drain to CBD/OWS to be
blinded.  √
15 Hot bolting to be done as per

requirement.  √

Page 206 of 732
PARADIP REFINERY
SOP No : AVU/050 SOP For: TAKE OVER PROCEDURE FOR CONDENSORS Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.

Page 207 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √

2 √
boxed up.
3 √

Page 208 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Inform panel officer. 
2 Ensure that it is handed over by √ √


maintenance.
3 Surrounding area checked for √ √

oil, rags, debris etc.
4 Check that water side is de- √

blinded
5 Check that hydrocarbon side is √
 
de-blinded
6 Fill tube side with water and √ √
Water Spill  Physically check.
remove air from HPV
7  Ensure proper √
Line up cooling water side. Water Spill
box up.
Provide N2 connection in shell
8 side. Pressurize shell side to 3-4 
kg / cm2.
9 Check leakage of inlet / outlet √

flange where blind was put.

Page 209 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Bleed out N2 by opening shell
10 √
outlet drain. Hold a little 
pressure.
11 Slowly open outlet valve. √ √

Monitor temperature.
12 Slowly open inlet valve. Monitor
 √ √
temperature.
13 Remove N2 connection & cap /
 √
blind both vent drain points.
14 Hydrocarbon side to CBD/OWS
 √
to be blinded.

Page 210 of 732
PARADIP REFINERY
SOP No : AVU/051 SOP For: TAKE OVER PROCEDURE FOR TRIM COOLERS Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.

Page 211 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √

2 √
boxed up.
3 √

Page 212 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Inform panel officer. 
2 Ensure that it is handed over by √ √


maintenance.
3 Surrounding area checked for √ √

oil, rags, debris etc.
4 Check that water side is de- √

blinded
5 Check that hydrocarbon side is √
 
de-blinded
6 Fill tube side with water and √ √
Water Spill  Physically check.
remove air from HPV
7  Ensure proper √
Line up cooling water side. Water Spill
box up.
Provide N2 connection in shell
8 side. Pressurize shell side to 3-4 
kg / cm2.
9 Check leakage of inlet / outlet  √

Page 213 of 732
PARADIP REFINERY

Potential
.
JEA JEA
flange where blind was put.
Bleed out N2 by opening shell
10 √
outlet drain. Hold a little 
pressure.
11 Slowly open outlet valve. √ √

Monitor temperature.
12 Slowly open inlet valve. Monitor
 √ √
temperature.
13 Remove N2 connection & cap /
 √
blind both vent drain points.
14 Hydrocarbon side to CBD/OWS
 √
to be blinded.

Page 214 of 732
PARADIP REFINERY
SOP No : AVU/052 SOP For: NORMAL OPERATION OF FIN FAN COOLERS Revision No : 06
AVU
Production Respective AIR FIN COOLERS &

HAZARDS INVOLVED:
SL.
.
2 Hot Air Check air direction while taking round.

Page 215 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
Check if Deluge system is in line or not. Take in line if not in
line.
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
2 Ensure AFC is properly boxed up. √

3 √

Page 216 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Check amperage of fin fan  Cross Check
1 cooler. If amperage is high, then Motor with EM / √
motor amperage at substation to Damage Substation
be checked. Operation.
Check for any abnormal Fan /
2  PDM to be done
√
vibrations or sound in fan and Motor
motor. Damage
3 Reverse  Compare DOR √
Check rotation of fan.
Rotation with other fans.
4 Check cage guard is proper and Personnel √

locked. Injury
Check belt healthiness. If belt
 Improper
5 found broken or slipped from √
rotation  Check regularly.
pulley, stop motor and attend /cooling
with maintenance department.
6 Check fin fan outlet  √
temperature. Always maintain
the temperature within

Page 217 of 732
PARADIP REFINERY

Potential
.
JEA JEA
operating range, by starting
spare fans or stopping excess
fans.
Proper sequencing of fans should
7 √
be done, to avoid localized 
cooling.
Check for any leakages in
8 process side fin tubes, flanges, or √
HC Spill  Regular checking
any other places, if the process
side is corrosive.
Safety fire water sprinklers over Fire
9 √ √
fin fans may be checked every Protection  Regular checking
month. Availability

Page 218 of 732
PARADIP REFINERY
SOP No : AVU/053 SOP For: HAND OVER OF FIN FAN COOLERS FOR MAINTENANCE Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.
2 Hot Air / Hydrocarbon / Gas Check air direction while taking round.

Page 219 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
line.
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √
3 Ensure all PG/TG are boxed up. √

Page 220 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
 Ensure
1 Miscomm
communication √
Inform Panel officer.
unication
before job.
Isolate fin cooler inlet valves. Panel officer to
Allow to run fans for 30 minutes monitor outlet
& than stop. temperature and
pressure and
High adjust operation of
2 Outlet other fans to bring √ √ √
temp down temperature.
If temperature
cannot be reduced
downstream units
to be informed.
3 √
De-blind its drain to CBD/OWS. 
High CBD  Monitor CBD
4 Isolate AFC outlet valves. Start √ √ √
Temp/Pressur temperature &
draining to CBD. e Pressure
Provide N2 connection at inlet  High  Ensure CBD
5 √ √ √
D/S of inlet isolation valve vent CBD floated with
point. Pressure flare.

Page 221 of 732
PARADIP REFINERY

Potential
.
JEA JEA
 High  Ensure CBD
6 Drain the entire hydrocarbon to √ √ √
CBD floated with
CBD under N2 pressure. Pressure flare.
 Ensure AFC is
7 Ensure complete draining by √
N2 Exposure depressurized to
opening drain to OWS. CBD
Stop N2 & check that isolation
8 √
valves are through drain to 
OWS.
Provide water connection at
9 √ √
vent. Flush it with water till it is 
oil free.
For heavy HC service, do FLO √
10 flushing followed by steaming 
and water flushing.
De-energize the motor of Air √
11 Fin cooler from sub-station. Do Electrical √
 Ensure LOTO
LOTO. Check by switching on Safety
from field.
12 Ensure that "DO NOT  √
OPERATE, MEN AT WORK"

Page 222 of 732
PARADIP REFINERY

Potential
.
JEA JEA
board is put on the switch.
Blind inlet and outlet nozzles  Ensure hot air is √
(Tube side and shell side) of the not coming from
13 Hot Air from
other fans, else √
Air fin cooler. other fans
they need to be
stopped.
Clearance to be given to hand √
14 √
over for clearing maintenance 
job or for inspection jobs.

Page 223 of 732
PARADIP REFINERY
SOP For: TAKE OVER OF FIN FAN COOLERS AFTER

MAINTENANCE
AVU

HAZARDS INVOLVED:
SL.
.
2 Hot Air / Hydrocarbon / Gas Check air direction while taking round.

Page 224 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
line.
PRE START CHECK:

Potential
. JEA JEA
1 Inform SIC. √

Page 225 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 Ensure all PG/TG are boxed up. √
DETAILED STEPS:
Potential
.
JEA JEA
 Ensure all
1 Confirm from maintenance that Miscomm related work √
job is over & de-blinded. unication permits are
closed.
 Physical
2 Check that cage guard is √
checking
installed properly and locked. required.
Check that earthing connections  Physical
3 checking √
and electrical connections are Loose cable
done. required.
4 All the belts are installed and  Check through √ √
Loose belt
OK. MM.
Strictly follow
5 Check and follow LOTO for Electrical √ √
LOTO system for
energization. Safety
energization.

Page 226 of 732
PARADIP REFINERY

Potential
.
JEA JEA
6 √
Energize motor.  
Provide N2 connection at inlet

7 √
D/S of inlet isolation valve vent  
point.
8 Purge with N2 to OWS. Purge  Ensure Gas √
N2 exposure
for ½ hr. Detectors
Close drain to OWS. Pressurize
9 √
the system to 7 kg/cm2 & do leak 
test.
Close N2 & remove connection.
10 √
De-pressurize to minimum 
pressure.
11 Line up cooler inlet & outlet. Flange Leak  √
12 Start the fin & observe sound & √

 √
vibration.
13 Inform shift in-charge if there is
 √
any abnormal sound/problem.
14 Blind drain to CBD/OWS. Hot Air from  Ensure hot air is √ √
other fans not coming from

Page 227 of 732
PARADIP REFINERY

Potential
.
JEA JEA
other fans, else
they need to be
stopped.

Page 228 of 732
PARADIP REFINERY
SOP No : AVU/055 SOP For: LP STEAM HEADER COMMISSIONING IN ISBL OF AVU Revision No : 06
AVU
Production LP Steam header and associated piping. &

HAZARDS INVOLVED:
SL.
.
1 Hammering. Drain condensate.
2 Hot Surface Insulation to be ensured.

Page 229 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Monitor hammering. Drain condensate properly. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA
1 Ensure trap bypass are opened. √
2 Ensure all flanges are boxed up. √

Ensure insulation has been
3 √
provided.

Page 230 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Take clearance from TPS for √

commissioning
2 Make sure all flanges were boxed √

up/de-blinded properly.
Open all condensate trap by-
3 Condensate  Ensure PPE √
passes in the header and isolate
Spill during operation.
all traps.
4 Drain condensate through trap Condensate  Ensure PPE √ √
bypass before charging. Spill during operation.
5 √ √
Inform Panel engineer.
Crack open B/L isolation B/V so
6 √
that condensate start coming  
from trap by-passes
Ensure there is no hammering in
7 √
the lines. Take sufficient time for  
this operation

Page 231 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Slowly increase B/L B/V opening
8 with adequate cushion time so √

that header line gets warm up
slowly.
Take all Traps in line when dry
steam start coming out and close
9 √
trap by-pass valves one by one 
from B/L side. Ensure steam
traps are in line and working.
When all steam traps are in line
and all its by-passes are closed
10 √
header pressure will increase. 
When operating pressure
attained, check for any leakage.
When the header pressure floats
11 with B/L condition open the B/L  √
block valve fully.
12 Attend leakages if any and LP √
 √
steam now stands commissioned

Page 232 of 732
PARADIP REFINERY

Page 233 of 732
PARADIP REFINERY
SOP No : AVU/056 SOP For: MP STEAM HEADER COMMISSIONING IN ISBL OF AVU Revision No : 06
AVU
Production MP Steam header and associated piping. &

HAZARDS INVOLVED:
SL.
.

Page 234 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

3 √
provided.

Page 235 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA

commissioning

up/de-blinded properly
all traps.
Drain condensate through trap
4 Condensate  Ensure PPE √ √
bypass in the battery limit
before charging.
5 Inform Panel engineer. √ √
Crack open bypass of B/L

6 √
isolation B/V so that condensate  
start coming from trap by passes.
7 √
this operation.

Page 236 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Slowly increase B/L B/V opening
8 with adequate cushion time so √

that header line gets warm up
slowly.
9 √
trap by-pass valves one by one 
10 √
block main valve fully.
12 Attend leakages if any and MP √
 √

Page 237 of 732
PARADIP REFINERY

Page 238 of 732
PARADIP REFINERY
SOP No : AVU/057 SOP For: HP STEAM HEADER COMMISSIONING IN ISBL OF AVU Revision No : 06
AVU
Production HP Steam header and associated piping. &

HAZARDS INVOLVED:
SL.
.

Page 239 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

3 √
provided.

Page 240 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA

commissioning

up/de-blinded properly.
all traps.
Drain condensate through trap
4 Condensate  Ensure PPE √ √
bypass in the battery limit
before charging.
5 Inform Panel engineer √ √
Crack open bypass of B/L

6 √
isolation B/V so that condensate  
start coming from trap by-passes.
7 √
this operation.

Page 241 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Slowly increase B/L Bypass/V
8 opening with adequate cushion √

time so that header line gets
warm up slowly.
9 √
trap bypass valves one by one 
10 √
main block valve fully.
12 Attend leakages if any and HP √
 √

Page 242 of 732
PARADIP REFINERY

Page 243 of 732
PARADIP REFINERY
SOP No : AVU/058 SOP For: STEAM TRACING COMMISSIONING Revision No : 06

AVU
Production Steam tracing commissioning &

HAZARDS INVOLVED:
SL.
.

Page 244 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

3 √
provided.

Page 245 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Open trap bypass of steam outlet √

at condensate recovery station.
Drain condensate from steam
supply line & than open traced
steam supply valve.
Line up trap after closing its
3 √
bypass when dry steam appears 
at recovery station.

Page 246 of 732
PARADIP REFINERY
SOP For: LP STEAM IMPORT–EXPORT INTEGRATION &

SUPERHEATED STEAM LINE UP IN CDU FURNACE.
AVU
LP Steam header and associated piping in CDU furnace, E-151 ABC, E-
Production &
251 ABC, E-150 Steam export circuit.

HAZARDS INVOLVED:
SL.
.

Page 247 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 PSVs should be in line.
area
PRE START CHECK:

Potential
. JEA JEA

Page 248 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √
provided.
DETAILED STEPS:
Potential
.
JEA JEA
Commission LP steam in AVU
ISBL as per SOP. This step is not
required if the AVU LP Steam is
1 already commissioned. Ensure 
√ √
that the Battery Limit LP Steam
valve is fully opened and traps are
in line.
Cond.
Check LP Steam (Refinery) in
Spill
CDU furnace battery limit if it is
2 isolated (Valve-A). If it is isolated
Flange
 Use PPEs.
√
Leak
crack open and open low point
Hammerin
drains to remove condensate.
g
3 After ISBL of furnace LP Steam Cond.  Use PPEs. √
header is warmed up gradually Spill

Page 249 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Flange
fully open the isolation Valve – Leak
A. Hammerin
g
Cond.
Spill
After warm up, open Valve-F to
4 warm up steam header of F-201.
Flange
 Use PPEs.
√
Leak
Remove condensate from drains.
Hammerin
g
After warm up of header ensure
5 the following 
√
Valve –B, C,D,G,H,I are closed.
Ensure steam from E-151 ABC,
6 E-251 ABC, E-150 is vented
High
 Use PPEs
√ √
Noise
locally.
Cond.
Crack open Valve-B & C in F-101
Spill
and Valve-G & H in F-201.
7 Flange
 Use PPEs.
√ √
Leak
This will warm up the header
Hammerin
from Furnace to E-151/251/150
g
8 Allow sufficient time for warm up Cond.  Use PPEs. √
of the header and draining of Spill

Page 250 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Flange
condensate. Drain condensate
Leak
from low point near each of the 7
Hammerin
steam generators.
g
Cond.
After warm up fully open the
Spill
globe valves Valve-C and G in F-
9 101/201 respectively. Keep the
Flange
 Use PPEs.
√
Leak
valves B and G in crack opened
Hammerin
condition.
g
Gradually crack open valves-D &
I in F-101/201 respectively and
10 warm up the header towards

√
superheating coil. Warm up the
header through coils as well as
bypass.
Open valves-E & J (at least 70-
11 80%) as well as vent XZV-9301 Over  Ensure PSVs are √
and 1528 to vent the steam locally pressure inline
through silencer.
 Ensure PSVs are
E-151/251/E-150 local vent can
12 Over inline in furnace √ √
be stopped and fully routed to F-
pressure as well as
101/201.
exchangers

Page 251 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Cond.
Spill
13 Drain condensate from all Flange
 Use PPEs.
√
available low points. Leak
Hammerin
g
When the steam header is Cond.
sufficiently warmed up, route Spill
14 steam from E-151/251 ABC and Flange
 Use PPEs.
√
E-150 to LP steam header towards Leak
furnace and vent through silencer. Hammerin
Close vent in exchangers. g
Ensure valve B and Valve G are
High
crack opened else refinery header  Panel Officer to
15 steam will be vented from the
Steam
monitor and √ √
consumpti
silencer. Check battery limit take action.
on
steam flow and adjust the valves.
Cond.
Open XZV-9302 and XZV-1529
Spill
to route steam towards the CDU
16 column and Strippers. Ensure
Flange
 Use PPEs.
√
Leak
drains are opened so that
Hammerin
condensate is removed.
g

Page 252 of 732
PARADIP REFINERY

Potential
.
JEA JEA
When header is warmed up,
17 stripping steam can be charged to 
√
C-001/2/3/8.
After opening of stripping steam
18 to C-001/2/3/8 gradually pinch

√
Valve E and Valve J to
atmosphere.
Gradually open valve B and
19 Valve G to allow sufficient flow 
√
of LP Steam.
When valve B and G are
20 sufficiently opened (> 60-70%),

√ √
close XZV-9301 and XZV-1528
to atmosphere.
On confirmation of closure of
21 XZV-9301 and XZV-1528, fully 
√ √
open the isolation valves E and J.
22 Adjust valve B and G as per

√ √ √
steam requirement.
Schematic Diagram in next Page

Page 253 of 732
PARADIP REFINERY
LP STEAM SUPERHEATER CIRCUIT

Refinery LP Steam header to To Atm thru Silencer
F-101/201 XZV-9301
TV-1134
B
D E
8"
A
XZV-9302 To CDU Column and
12"
F-101 LP STEAM Strippers
F 10" SUPERHEATING COIL
C
10"
To CDU Column and
Strippers
H 10"
LP Steam
from E-151
ABC, E-251
ABC, E-150 TV-1634 To CDU Column and
Strippers
XZV-1529
12" 8"
F-201 LP STEAM J
SUPERHEATING COIL To Atm thru Silencer
G 8"
F-101 F-201
A LP Steam header Main valve to F-101/201 F LP Steam from header to F-201 XZV-1528
B LP Steam from Refinery Header to Superheater (8") G LP Steam from Refinery Header to Superheater (8")
C LP Steam from E-151,E-251 A,B,C, E-150 to Superheater H LP Steam from E-151,E-251 A,B,C, E-150 to Superheater
D Common Valve at inlet of LP Steam Super Heater I Common Valve at inlet of LP Steam Super Heater
E Isolation valve to Silencer J Isolation valve to Silencer

Page 254 of 732
PARADIP REFINERY
SOP For: LP STEAM IMPORT–EXPORT INTEGRATION &

SUPERHEATED STEAM LINE UP IN VDU FURNACE.
AVU
LP Steam header and associated piping in VDU furnace, E-151 ABC, E-
Production &
251 ABC, E-150 Steam export circuit.

HAZARDS INVOLVED:
SL.
.

Page 255 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 PSVs should be in line.
area
PRE START CHECK:

Potential
. JEA JEA

Page 256 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √
provided.
DETAILED STEPS:
Potential
.
JEA JEA
Commission LP steam in AVU
ISBL as per SOP. This step is not
required if the AVU LP Steam is
1 already commissioned. Ensure 
√
that the Battery Limit LP Steam
valve is fully opened and traps are
in line.
Cond.
Check LP Steam (Refinery) in
Spill
VDU furnace battery limit if it is
2 isolated (Valve-A). If it is isolated
Flange
 Use PPEs.
√
Leak
crack open and open low point
Hammerin
drains to remove condensate.
g
3 After ISBL of furnace LP Steam  √
header is warmed up gradually

Page 257 of 732
PARADIP REFINERY

Potential
.
JEA JEA
fully open the isolation Valve –
A.
After warm up of header ensure
4 the following Valve –B, C, are 
√
closed.
Ensure steam from E-151 ABC,
5 E-251 ABC, E-150 is vented 
√
locally.
Cond.
Crack open Valve-B & C in F- Spill
6 002. Flange
 Use PPEs.
√
This will warm up the header Leak
from Furnace to E-151/251/150 Hammerin
g
Cond.
Allow sufficient time for warm up
Spill
of the header and draining of
7 condensate. Drain condensate
Flange
 Use PPEs.
√
Leak
from low point near each of the 7
Hammerin
steam generators.
g
8 After warm up fully open the Cond.  Use PPEs. √
valve Valve-C. Keep the valves B Spill
in crack opened condition. Flange
Leak

Page 258 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Hammerin
g
Cond.
Gradually crack open valves-E
Spill
warm up the header towards
9 superheating coil. Warm up the
Flange
 Use PPEs.
√
Leak
header through coils as well as
Hammerin
bypass.
g
Open valves-E (at least 70-80%)
10 as well as vent XZV-3003 to vent 
√
the steam locally through silencer.
Cond.
Spill
11 Drain condensate from all Flange
 Use PPEs.
√
available low points. Leak
Hammerin
g
Cond.
When the steam header is
Spill
sufficiently warmed up, route
12 steam from E-151/251 ABC and
Flange
 Use PPEs.
Leak
E-150 to LP steam header towards
Hammerin
furnace and vent through silencer.
g

Page 259 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Ensure valve B is crack opened
else refinery header steam will be High
13  Panel Officer to √ √
vented from the silencer. Check Steam
monitor.
battery limit steam flow and flow
adjust the valves.
Cond.
Open XZV-3002 to route steam Spill
14 towards the VDU column. Ensure Flange
 Use PPEs.
drains are opened so that Leak
condensate is removed. Hammerin
g
When header is warmed up,
15 stripping steam can be charged to 
√
C-007.
After opening of stripping steam Over
16 to C-007 gradually pinch Valve E pressurisat  PSV to be in line
√ √
to atmosphere. ion
17 Gradually open valve B to allow

√ √
sufficient flow of LP Steam.
When valve B is sufficiently Over
18 opened (> 60-70%), close XZV- pressurisat  PSV to be in line
√ √
3003 to atmosphere. ion
19 On confirmation of closure of  √
XZV-3003, fully open the

Page 260 of 732
PARADIP REFINERY

Potential
.
JEA JEA
isolation valves E.
20 Adjust valve B as per steam

√
requirement.
Schematic Diagram in next Page

Page 261 of 732
PARADIP REFINERY

Page 262 of 732
PARADIP REFINERY
SOP For: MP STEAM EXPORT INTEGRATION & SUPERHEATED

STEAM LINE UP IN CDU FURNACE.
AVU
Production MP Steam commissioning. &

HAZARDS INVOLVED:
SL.
.

Page 263 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Check PSVs are inline or not. PSVs should be in line.
area
PRE START CHECK:

Potential
. JEA JEA

Page 264 of 732
PARADIP REFINERY

Potential
. JEA JEA
3 √
provided.
DETAILED STEPS:
Potential
.
JEA JEA
When Steam generator pressure
1 (V-024) increases up to 6-7

√
kg/cm2 steam can be vented to
atmosphere through silencer vent.
Crack open the export valve at V-
2 24 to steam super heater to warm 
√
up the header.
3 Crack open the valves at inlet of

√
FV-1085 and FV-1585.
Remove condensate from LPDs of
4 FV-1085 and FV-1585 in F-
Condensat
 Ensure PPEs.
√
e Spill
101/201 respectively.
Ensure HV-1030 and HV-1032
(local vent to silencer) is in Open  Ensure
5 condition. Isolation valve
Hammerin
condensate √
g
upstream of the HVs are also to draining
be kept open condition.

Page 265 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Gradually fully open export valve
 Ensure
6 at V-24 and isolation valves Hammerin
condensate √
upstream of FV-1085 and FV- g
draining
1585.
Slowly open FV-1085 and FV-
 Ensure
7 1585 and route steam to silencer Hammerin
condensate √ √
after super heater. Ensure drains g
draining
are open to remove condensate.
When dry steam starts coming,
8 gradually close the local vent of Overpress  Ensure PSVs are √ √ √
V-024. Monitor for pressure of ure inline
the vessel.
When super heater outlet steam
9 temperature reaches > 300 Deg C, 
√
steam can be routed to header.
Open HV-1031 and HV-1040 and
 Ensure
10 route steam up to the final Hammerin
condensate √
isolation valve. Remove g
draining.
condensate through drains.
When condensate is removed  Ensure
11 gradually open the 10” isolation
Hammerin
condensate √
g
valve. draining.
12 When valve is fully open, close Overpress  Ensure PSVs are √ √ √
HV-1030 and HV-1032. ure inline

Page 266 of 732
PARADIP REFINERY

Potential
.
JEA JEA
For commissioning E-149 header
13 steam following procedure to be 
followed.
14 Crack Open the steam valve at F-

√
101/201 coming from E-149.
Warm up the steam header by
15 back flowing steam up to E-149. Condensat
 Ensure PPEs.
√ √
Drain condensate from LPDs/ trap e Spill
bypass.
 Ensure
16 After sufficient warm up fully Hammerin
condensate √ √
open the valve near furnace. g
draining.
 PSVs should be
High
17 Close vent valve of E-149 and in line √ √
Pressure in
route steam to export header.  Monitor
E-149
Pressure.

Page 267 of 732
PARADIP REFINERY

Page 268 of 732
PARADIP REFINERY
SOP For: MP STEAM EXPORT INTEGRATION & SUPERHEATED

STEAM LINE UP IN VDU FURNACE.
AVU
Production MP Steam Super heater commissioning and export. &

HAZARDS INVOLVED:
SL.
.

Page 269 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Check PSVs are inline or not. PSVs should be in line.
area
PRE START CHECK:

Potential
. JEA JEA
Ensure all flanges are boxed up.

2 Ensure insulation has been √
provided.

Page 270 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
When Steam generator pressure
1 (V-022) increases up to 6-7

√
kg/cm2 steam can be vented to
atmosphere through silencer vent.
Crack open the export valve at V-
2 22 to steam super heater to warm 
√
up the header.
3 Remove condensate from LPDs.
Condensat
 Ensure PPEs.
√
e Spill
Ensure HV-3031 (local vent to
silencer) is in Open condition.  Ensure
4 Isolation valve upstream of the
Hammerin
condensate √
g
HVs are also to be kept open draining
condition.
 Ensure
5 Gradually fully open export valve Hammerin
condensate √
at V-22. g
draining
When dry steam starts coming,
6 gradually close the local vent of Overpress  Ensure PSVs are √ √ √
V-022. Monitor for pressure of ure inline
the vessel.

Page 271 of 732
PARADIP REFINERY

Potential
.
JEA JEA
When super heater outlet steam
7 temperature reaches > 300 Deg C, 
√
steam can be routed to header.
Open HV-3031 and route steam
 Ensure
8 up to the final isolation valve. Hammerin
condensate √
Remove condensate through g
draining.
drains.
When condensate is removed  Ensure
9 gradually open the 6” isolation
Hammerin
condensate √
g
valve. draining.
10 When valve is fully open, close Overpress  Ensure PSVs are √ √ √
HV-3031 and HV-3030. ure inline

Page 272 of 732
PARADIP REFINERY

Page 273 of 732
PARADIP REFINERY
SOP No : AVU/063 SOP For: CWS and CWR Header Commissioning. Revision No : 06
AVU
Production CW Circuit and associated exchangers. &

HAZARDS INVOLVED:
SL.
.
1 Water leak Ensure Box up.

Page 274 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Water leak to be checked. Don’t bypass any process interlocks / approved procedure.
2 Check TSVs are inline or not. TSVs should be in line.
area
PRE START CHECK:

Potential
. JEA JEA
1 Ensure proper box up. √
2 Ensure drains are closed. √
DETAILED STEPS:

Page 275 of 732
PARADIP REFINERY

Potential
.
JEA JEA
1 Isolate all water coolers & √

condensers. (inlet / outlet)
2 Line up all structure CWS/CWR Height √
 Use PPEs
jump over. Work
3 Inform water block about this √

operation.
Keeping CWS battery limit valve
4 √
closed, open 3-4 thread CWR 
B/L valve.
Bleed out air from CWS B/L
5 √
valve D/S drain till clear water 
comes out.
6 Bleed out air from individual √

structure highest point vent.
7 Full open CWS/CWR battery √

limit valve.
Take CW in individual cooler /
condenser. Crack open CWR
8 √
valve & vent out air from the 
cooler & condenser. After that
full open CWS & CWR valves.

Page 276 of 732
PARADIP REFINERY
SOP No : AVU/064 SOP For: NITROGEN HEADER COMMISSIONING. Revision No : 06

AVU
Production Nitrogen Header and associated equipments. &

HAZARDS INVOLVED:
SL.
.
1 Nitrogen leak Ensure Boxup. Use Gas Detectors

Page 277 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Nitrogen leak to be checked. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA

Page 278 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Isolate N2 make up to all CBD / √

ABD.
2 Isolate N2 make up to all vessel / Height √
 Use PPEs
columns. Work
3 Isolate N2 to flare header (all √

points).
4 √
Make a list of point no 1-3 
5 Ensure that all confine area Asphyxiati  Ensure vessel √

man-entry permit is withdrawn. on box up
 Area
barricading to
6 Purge the entire N2 circuit from Low be done with √ √
drains of all supply point. Oxygen Man watcher
and gas
Detector.
Pressurize the circuit with N2 to
7 Nitrogen √
7 kg/cm2 & do leak test. Rectify 
Leak
the leaky one.
8 √
Do hold up test. 

Page 279 of 732
PARADIP REFINERY

Potential
.
JEA JEA
9 Send sample to Lab for O2 √

content.
10 √
Open battery limit valve fully. 

Page 280 of 732
PARADIP REFINERY
SOP No : AVU/065 SOP For: FLARE HEADER COMMISSIONING Revision No : 06

AVU
Production Flare Header and associated equipments. &

HAZARDS INVOLVED:
SL.
.
1 HC leak Ensure Box up. Use Gas Detectors

Page 281 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 HC leak to be checked. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA
DETAILED STEPS:

Page 282 of 732
PARADIP REFINERY

Potential
.
JEA JEA
1 √
Isolate flare line at B/L 
Isolate all control v6alves /

2 Height
 Use PPEs
√
vessels / columns and instrument
Work
releasing to flare.
3 √
Close flare KOD drain to CBD 
4 √
5 Charge N2 from furthest points √


of all flare headers.
 Area
Low barricading to
6 Purge out through flare KOD to Oxygen be done with √ √
OWS. Nitrogen Man watcher
Leak and gas
Detector.
7 Do leak test at 0.5 Kg/cm2 g √

pressure.
8 √

Page 283 of 732
PARADIP REFINERY

Potential
.
JEA JEA

content.
10 √
Open battery limit valve fully. 
11 Line up point 1-2 whichever is √


required.

Page 284 of 732
PARADIP REFINERY
SOP No : AVU/066 SOP For: FG SUPPLY HEADER COMMISSIONING Revision No : 06

AVU
Production FG Supply Header and associated equipments. &

HAZARDS INVOLVED:
SL.
.

Page 285 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
3 Stop all hot jobs during FG header commissioning. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
2 Ensure HPV/ drains are closed. √
DETAILED STEPS:

Page 286 of 732
PARADIP REFINERY

Potential
.
JEA JEA
1 Ensure that flare line is √

commissioned.
2 Isolate FG make up to all CBD /  Check √
HC Leak
ABD. Physically
3 Isolate FG make up to all vessel / √

columns.
4 Isolate FG to flare header (all √

points).
5 √
6 Ensure that F101/201 & F02 FG √ √


at B/L is blinded.
7 √
Close V4 drain to flare / OWS. 
8 Provide N2 connection at D/S of √


FG battery limit valve.
 Area
Low barricading to
9 Purge the entire FG circuit from Oxygen be done with √ √
drains of all supply point. Nitrogen Man watcher
Leak and gas
Detector.

Page 287 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Pressurize the circuit with N2 to
10 √
6 kg & do leak test. Rectify the 
leaky one.
11 √


content.
13 Depressurize to 0.2 kg/cm2. 
Open 2-3 thread FG battery  To be done with

limit valve & open V4 drain to continuous
14 Gas Leak
supervision. √ √
OWS. Keep a LEL meter there.
 Use HC
Detector.
When gas comes out at V4
15 drain, close drain to OWS &

open drain to flare. Allow to
vent to flare for 10 minutes.
16 Bleed our N2 from all CBD Gas Leak  To be done with
/ABD FG make up line bleeder continuous
till gas comes out. supervision.
 Use HC

Page 288 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Detector.
17 Ensure that no hot job is taking Fire  Strictly Ensure √ √
place during this operation. Hazard No Hot Job.
Purge out through flare header  To be done with
(from all points) for at least 10 continuous
18 Gas Leak
supervision. √ √
minutes each.
 Use HC
Detector.
19 Now full open battery limit √

valve.
20 Check for any leakage. Rectify if √

any.
21 Line up point no 2-4 
√

Page 289 of 732
PARADIP REFINERY
SOP No : AVU/067 SOP For: FG RETURN HEADER COMMISSIONING Revision No : 06

AVU
Production FG Return Header and associated equipments. &

HAZARDS INVOLVED:
SL.
.

Page 290 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
3 Stop all hot jobs during FG header commissioning. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
DETAILED STEPS:

Page 291 of 732
PARADIP REFINERY

Potential
.
JEA JEA
1 Ensure that flare line is √

commissioned.
Purge out 010-V-16, 010-C-010
2  Check √
and V-017 with nitrogen to flare N2 Leak
Physically
header.
 To be done with
Drain Nitrogen at Battery Limit continuous
3 Gas Leak
supervision. √
Return header PG to safe
location with a hose.  Use HC
Detector.
After sufficient purging, send
4 sample for oxygen. If O2 % is √

less than 0.5% HC can be
charged.
5 Depressurize Nitrogen from the √

header to minimum.
6 Charge fuel gas to the header √

and purge from V-17 PSV.
7 Check PSV LPD with HC Gas Leak  To be done with √
Detector if FG is coming. When continuous
FG comes stop purging to Flare. supervision.
 Use HC

Page 292 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Detector.
Open export valve at battery
8 √
limit and route FG to export 
header.
SOP No : AVU/068 SOP For: COMPRESSOR NORMAL OPERATION Revision No : 06

AVU
Production Off Gas Compressor. &


Page 293 of 732
PARADIP REFINERY
HAZARDS INVOLVED:
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
PRE START CHECK:

Page 294 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
Carry H2S meter during
1 √
normal / periodic round of 
checking
2 Check lube oil level in the  Check √
Low Oil
reservoir and its quality. Physically
Check lube oil cooler
3 √
performance by touching / temp 
gun.
4 Check LO pressure.  Check √
Low Oil
Physically
5 Check DM water vessel level 
√

Page 295 of 732
PARADIP REFINERY

Potential
.
JEA JEA
6 Check tempered water pump √

condition
7 Check lubricator reservoir level. √

Top up as per requirement.
8 Check N2 flow to all 4 seal 
√
Check for any abnormal sound

9 & temperature (Touch) of loader  √
valves.
Check & note vibration /
10 temperature data from local  √
panel in log book.
11 Any abnormality to be reported
 √
to SI.

Page 296 of 732
PARADIP REFINERY
SOP No : AVU/069 SOP For: COMPRESSOR START UP AFTER MAINTENANCE Revision No : 06

AVU

HAZARDS INVOLVED:
SL.
.

Page 297 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
PRE START CHECK:

Potential
. JEA JEA

Confirm again that all mounting
3 bolts, connection bolts and flanges √
are tightened firmly.

Page 298 of 732
PARADIP REFINERY

Potential
. JEA JEA
Check lube oil level in the
4 √
reservoir and its quality.
Confirm instrument air supplied
5 √
sufficiently in motor.
Commission cooling water to
6 tempered water and the lube oil √
cooler.
Confirm the electrical power √
7 √
supply.
Confirm total draining of the
8 √
process piping and volute bottles.
DETAILED STEPS:
Potential
.
JEA JEA
Keeping suction & discharge
1 √
valve closed, purge compressor 
with N2.
2 Pressurize with N2 to 1.5 kg & √
HC leak  Use Detectors
do leak test. Rectify if any

Page 299 of 732
PARADIP REFINERY

Potential
.
JEA JEA
3 Commission nitrogen flow as the √
primary and secondary seal gas. 
Supply and adjust the primary

4 √
and secondary seal gases to the 
shaft seal portion.
Start tampered water pump.
5 Maintain jacket CW pressure > √

3.5 kg/. Keep stand by pump in
auto start mode.
6 Start lube oil pump. Lube Oil  Check √
Leak Physically
7 After the oil pump has started,  √
make air venting from the oil
system and check these items.
a. Oil pressures and
temperatures (should be
within the specified ranges.)
b. Oil levels of the oil reservoir.
c. Oil leakage of piping or
equipment.

Page 300 of 732
PARADIP REFINERY

Potential
.
JEA JEA
d. Oil flows through the sight
glasses to confirm all of the
equipments are properly
lubricated.
e. Maintain LO pressure > 3.5
kg.
Commission instrument air to

8 √
motor, to keep it pressurize. 
Check for healthy pressure.
9 Commission instrument air to
 √
local panel, to keep it pressurize
Line up suction drum (10V6) &
drain out liquid from it. Also
10 drain condensate from V6 to  √
compressor suction &
compressor discharge header
11 Confirm valve positions.  √ √ √
a. Fully open the suction main

Page 301 of 732
PARADIP REFINERY

Potential
.
JEA JEA
valve.
b. Fully open the discharge
valve.
c. Confirm other valve positions
according to the P & I
diagrams.
d. Check a smooth action of the
discharge check valve.
e. Line up the pressure safety
valves for both stages.
f. Take spill back is lined up.
Check stroking of this valve.
g. Check & match compressor
load position in field & panel.
h. Set compressor load to 0%
Make manual turning (Barring)

12  Ensure barring
√
to confirm the smooth rotation Shaft Jam √
of the rotors.

Page 302 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Prepare for starting of the main
13 driver and check if it is ready to  √
start.
Start lubricator pump &
maintain its pressure > 8 kg/cm2.
14 Ensure LO drops from all points  √
& LO level in reservoir is
maintained.
Bypass interlock for no load run.
15 (Compressor will trip if load is √ √

not given within 20 minutes of
switch-on.)
16 Confirm start up clearance is √

obtained.
17 Open spill back 100%. 
√
Start the main motor in 0% load.

18 Check for any abnormal noise, √
 √
vibration and gas and bearing
temperatures.

Page 303 of 732
PARADIP REFINERY

Potential
.
JEA JEA
19 After the compressor has  √ √ √
reached a steady states, increase
load to 17.9% and close spill
back. Run for about 1 hour
under the specified conditions,
and check or confirm the
followings.
a. No leakage from the
process gas line.
b. Gas pressures
c. Gas temperatures
d. Vibration and noise of
compressor.
e. Bearing temperatures of
compressor, speed-up
gear and main driver.
f. Cooling water inlet and
outlet temperatures.
g. Oil system pressures,

Page 304 of 732
PARADIP REFINERY

Potential
.
JEA JEA
temperature and oil
levels.
If no problems appear on the

20 √ √
machines and the system,  √
increase load as per requirement.
21 Check the operating conditions. √
 √
Continue to operate the
22 compressor for about one hour
 √
under the normal operating
conditions and observe.
Check for noise, vibration and
23 take a periodic reading on
 √
process gas, lube oil and seal
gas supply systems.
All readings should be reviewed
24 and checked whether they are
 √
normal and within allowable
ranges.

Page 305 of 732
PARADIP REFINERY

Potential
.
JEA JEA
During the first several days,
make frequent checks to be sure
25 that all conditions and readings  √
remain reasonably steady and
within allowable ranges.

Page 306 of 732
PARADIP REFINERY
SOP No : AVU/070 SOP For: COMPRESSOR HANDOVER FOR MAINTENANCE Revision No : 06

AVU

 Ear plug  Nearby Fire monitor No
HAZARDS INVOLVED:
SL.
.

Page 307 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
PRE START CHECK:

Potential
. JEA JEA


Page 308 of 732
PARADIP REFINERY

Potential
. JEA JEA
Check lube oil level in the
4 √
reservoir and its quality.
DETAILED STEPS:
Potential
.
JEA JEA
1 √
Reduce load to zero in step. 
2  Use Detectors
√
Stop compressor. HC leak
Lube oil AOP should start
3 automatically. If not start √

manually & continue to run for
at least 2 hrs for cooling.
4 √
Stop lubricator pump. 

Page 309 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Stop the cooling water and L oil
5 √
pump, after system is cooled 
down.
6 Valve
 Check Pressure
√
Isolate suction & discharge.
Passing
Drain out liquid from both stage
volute bottles. De-pressurize
compressor to flare. Check both
7 isolation valves are holding by √

closing flare valve. If system gets
pressurized, it means that one of
the valves is passing. Act
accordingly.
8 Purge 3-4 times the system with √

N2.
Do JSA & blind suction &
9 H2S
 HC Detector
discharge. Keep a H2S detector √
Exposure
nearby.
10 Blind both stage PSV bypass &
 √
drain to CBD.

Page 310 of 732
PARADIP REFINERY

Potential
.
JEA JEA
De-energize the compressor &
11 isolate lube oil & jacket CW to
 √
it. Ensure that these are not
passing.

Page 311 of 732
PARADIP REFINERY
SOP No : AVU/071 SOP For: LUBE OIL FILTER CHANGE OVER IN COMPRESSORS Revision No : 06
AVU
Production Off Gas Compressors. &

HAZARDS INVOLVED:
SL.
.

Page 312 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
PRE START CHECK:

Potential
. JEA JEA


Page 313 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Ensure that stand by filter is √

filled. Else fill with lube oil.
Check that stand by filter is not
2  Use Hose/PPEs
√
vapor lock, by opening vent HC leak
valve.
Ensure that drained line and
3 √
vent line both closed before 
taking in line
4 Filling line to be closed before √

taking filter in line
5 Inform panel to bypass inter lock √

if required.
6 Slowly open outlet valve of the Pressure  Monitor √
filter. fluctuation Pressure
All the lube oil filter to get  Ensure physical
7 Flange
checking of √
pressurized. Leak
flange.
8 On no leak, gradually open the Flow  Monitor flow √
outlet valve of the lube oil filter. fluctuation and pressure.

Page 314 of 732
PARADIP REFINERY

Potential
.
JEA JEA
9 Fully open inlet outlet valve of
 √
the stand by filter.
10 Gradually close inlet valve of the Flow  Monitor flow
√
1st filter. fluctuation and pressure.
11 After full close, close outlet
 √
valve of the filter.

Page 315 of 732
PARADIP REFINERY
SOP No : AVU/072 SOP For: LUBE OIL FILTER HAND OVER IN COMPRESSORS Revision No : 06
AVU

HAZARDS INVOLVED:
SL.
.

Page 316 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Ensure box up.
area
PRE START CHECK:

Potential
. JEA JEA


Page 317 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Ensure that filter is properly √

isolated by pulling lever
2 Ensure that equalization valve √

closed
3 √
Depressurized the filter. 
4 Inform panel to observe LO √


pressure.
5 Make sure that filter is drained √

and vent is open

Page 318 of 732
PARADIP REFINERY
SOP No : AVU/073 SOP For: COMPRESSORS SUCTION STRAINER CLEANING Revision No : 06

AVU

HAZARDS INVOLVED:
SL.
.

Page 319 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Activity should be closely supervised till completion.
area
3 Use non sparking tools. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA


Page 320 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Isolate the compressor and purge √
HC Leak 
with nitrogen for 8 hours.
After sufficient purging and
ensuring all valves to
2 √
CBD/OWS/Flare is closed 
strainer cleaning activities can
be started.
Open PG point near strainer and
3 check for LEL/H2S. If LEL/H2S H2S  Use Gas √
is coming purge with nitrogen Exposure Detector
again.
4 When LEL / H2S is zero, allow H2S  Use Gas √
for strainer flange opening. Exposure Detector
5 Check for any trapped gas. Use H2S  Use Gas √ √
BA set if required. Exposure Detector
6 Remove all bolts and clean the

strainer.
7 On cleaning, box up and check

leak with Nitrogen pressure.

Page 321 of 732
PARADIP REFINERY

Page 322 of 732
PARADIP REFINERY
SOP No : AVU/074 SOP For: TURBINE DRIVEN VR PUMP START UP PROCEDURE Revision No : 06
AVU
Production TURBINE DRIVEN VR PUMP (010-P-025 A) &

HAZARDS INVOLVED:
SL.
.
1 Hot Surface Ensure proper insulation.
2 HP steam leak. Ensure proper boxup

Page 323 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Drain condensate and warm up header before start up. Don’t bypass any process interlocks / approved procedure.
2 VR Pump side to be in warmed up condition.
area
3 All HPVs/LPDs are closed. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA


Page 324 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Charge HP steam at B/L and open
the 2” bypass valve across the 8”
 Take
1 isolation valve keeping XZV- Condensat
precaution. √
3018 close, open the drain valve e Spill
 Use PPEs
provided 2” bypass line.
Open turbine exhaust 8” MP

steam line drain & open its valve  Take
2 Condensat
precaution. √
slowly to heat up and gradually e Spill
open exhaust valve fully  Use PPEs
3 Ensure cooling water is lined up


√
Ensure lube oil level is healthy  Replace if

4 Bearing
suspected to be √
and quality is good. Damage
contaminated.
Ensure turbine casing drains are  Take
5 Condensat
precaution. √
open. e Spill
 Use PPEs
6 Ensure turbine leak-off vent and Condensat  Take √
drain are open. e Spill precaution.

Page 325 of 732
PARADIP REFINERY

Potential
.
JEA JEA
 Use PPEs
7 Latch the turbine (mechanically). Hot
 Use PPEs
√
Surface
Ensure following and reset turbine
from HWC.
 Emergency trip from LCP

should be released condition
 Local panel turbine stop
8 should be in released condition 
√ √
 Emergency trip from HWC
should be released condition
 WWG (Woodward Governor)
trip command should be
healthy
9 Check IZ-305 (vacuum column Sudden  Use PPEs √

level: healthy) & IZ-332 (XZV at Condensat
VR pump suction: Open) are e Spill
healthy then open HP steam inlet
XZV 3018 from field slowly and
bring the temperature/pressure to

Page 326 of 732
PARADIP REFINERY

Potential
.
JEA JEA
the start permissive condition 320
deg C/ 35kg/cm2g.
Check other start permissive

condition like.
 Vibration ( should be <3mils,

10 trip value) √

 Bearing temperature (<117
deg C, trip value) and
 Turbine is in Zero speed
condition
When turbine start permissive

condition are satisfied SOV will
11 
√ √
energize and 3way valve at DCS
becomes green
After SOV energization, latching

12 to be done manually from field by

√ √
raising the SOV lever.

Page 327 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Close the turbine trap bypass
13 
√
isolation valves.
Don’t close the 40mm leak off

14 vent /drain valves provided in

√
turbine
HP steam isolation valves to be

open slowly to 30% from field.
15 Check pump healthiness like seal √


pot /lube oil cup level/seal fluid
(VGO)/cooling water to be lined
up
Pump discharge valve to be kept

16 close & and equalization & warm

up valve to be kept open
17 Reset following button in field &  √

HWC

Page 328 of 732
PARADIP REFINERY

Potential
.
JEA JEA
 Turbine reset button at HWC
 Trip reset button from LCP
Start the turbine from filed by

pressing start button from LCP,
18 
√
turbine will start with minimum
RPM 1000.
Check MOP pressure should be

>0.2 kg/cm2g @1000RPM & at
19 
√
full RPM MOP pressure should
be 0.5-0.7 kg/cm2g.
Increase the RPM from field or

from DCS panel slowly to 2970
RPM and keep watch on pump
20 discharge pressure and slowly

√ √
open the pump discharge isolation
valve to maintain discharge
pressure 20kg/cm2g.

Page 329 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Open HP steam inlet valve fully
from field or from panel turbine
21 
√ √
maximum RPM can be increased
to 3100 RPM.
Turbine over speed

22 instrumentation trip set point is

√ √
3360 RPM
Turbine mechanical over speed

23 
√
trip set point is 3460RPM.
In case turbine is getting tripped

due to HH vibration or bearing
Temperature HH then asked the
24 instrument person to reset the 
MMS panel provided in SRR and
then follow the startup procedure
to start the turbine again]

Page 330 of 732
PARADIP REFINERY
SOP No : AVU/075 SOP For: TURBINE DRIVEN VR PUMP SHUT DOWN PROCEDURE Revision No : 06
AVU
Production TURBINE DRIVEN VR PUMP (010-P-025 A) &

HAZARDS INVOLVED:
SL.
.
2 HP steam leak. Ensure proper boxup

Page 331 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 All HPVs/LPDs are closed. Don’t bypass any process interlocks / approved procedure.
2
area
PRE START CHECK:

Potential
. JEA JEA


Page 332 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Decrease RPM to 1000 either
1 
√ √
from field or from LCP
Close pump discharge valve

2 
√
accordingly.
Press turbine stop button from

field, in case of any emergency,
3 emergency push button is

√
provided both in LCP and as well
as in HWC.
4 HP steam XZV-3018 will close


√
Isolate P-25A discharge isolation

5 valve /seal fluid. Keep it under

√
warm up condition.
6 Isolate MP steam exhaust valve


√

Page 333 of 732
PARADIP REFINERY

Page 334 of 732
PARADIP REFINERY
SOP For: NORMAL OPERATING PROCEDURE FOR CENTRIFUGAL

PUMP
AVU
Production All Centrifugal Pumps &

HAZARDS INVOLVED:
SL.
.
2 Ensure proper boxup

Page 335 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

Page 336 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
Check amperage of pump.
a. High or low amperage may
be due to high discharge flow
than design flow. To be
1 
√ √
brought to the notice of shift
in-charge for counter
checking (from sub-station)
b. Note in log book
2 Check discharge pressure and  √

flow. If the pump is developing
less head, then check causes

Page 337 of 732
PARADIP REFINERY

Potential
.
JEA JEA
a. Suction conditions like
cavitations of pump.
Cavitations can be avoided
by maintaining suction
pressure at a high enough
level and suction
temperature low to increase
NPSH available.
b. Suction strainer may be
chocked. Inform S/I to clean
the strainer.
c. Wrong direction of rotation.
Check rotation.
NOTE: If the pump is not

primed, this can be known by
low and fluctuating discharge
pressure, fluctuating amperage
and typical sound indicating dry

Page 338 of 732
PARADIP REFINERY

Potential
.
JEA JEA
running of pump.
Check pump and motor
temperature.
a. High bearing temperature
3 
√
may be due to improper
lubrication or low CW flow.
Check it.
4 Check pump & motor sound and  √

vibrations. Excessive vibration
may be due to
a. Excessive amount of gas/air
in the system. Sufficient
venting should be done to
remove air
b. Excessively high discharge
head. High discharge can be
caused by obstruction in
discharge side. All valves to

Page 339 of 732
PARADIP REFINERY

Potential
.
JEA JEA
be wide open or in a
predetermined throttle
position and the discharge
piping should not be blocked
in any way.
c. Operating at very low
capacity. Minimum
circulation line may be
opened for maintaining
proper flow.
d. Cavitation of pump. This can
be noticeable as a “pumping
gravel “noise.
e. Or mechanical troubles.
5 Check lube oil level,  √

temperature, pressure
a. If lube oil level in oil cup is

Page 340 of 732
PARADIP REFINERY

Potential
.
JEA JEA
low, makeup lube oil
b. If there any change in lube
oil color or contamination of
lube oil with water, then
drain and replace it. Check
lube oil cooler for leakage.
c. If any lube oil leak from oil
cup or bearing housing is
found, then to be attended
with maintenance deptt.
d. High temperature of lube oil
may be due to low oil level,
or chocked lube oil cooler.
e. If auxiliary lube oil pump is
there, then it should be in
AUTO position, so that AOP
can automatically start if
pressure becomes low.

Page 341 of 732
PARADIP REFINERY

Potential
.
JEA JEA
f. Lube oil suction line
strainers (if any) should be
checked and cleaned if lube
oil pressure becomes low.
In pumps having seal system,

check seal pot level and buffer
pressure(if any)
a. Seal snuffing line should be
always open if the pump is
running.
6 b. Increase in seal pot level or 
√
pressure may be the
indication of primary seal
failure and process liquid is
coming in seal pot. Inform SI
to attend.
7 Check cooling water flow to seal  √

flush cooler, mechanical seal,

Page 342 of 732
PARADIP REFINERY

Potential
.
JEA JEA
bearing house, and glands.
a. If flow is low, ask
maintenance for
rectification.
b. Seal flush cooler leakages or
blocks to be checked
c. Rusting of bearings due to
water getting into housing
8 Check for any leakages from  √

mechanical seal, flanges/valve
glands or any other places.
a. If any small leakages found,
then steam lancer (for hot
products)/water hose (for
cold products) to be provided
at the place of leak.
b. If heavy leakages found, then
change over the pump and

Page 343 of 732
PARADIP REFINERY

Potential
.
JEA JEA
isolate suction & discharge of
leaky pump. . Inform SI to
attend
Check functioning of pressure

gauges, temperature gauges, flow
9 meters. √

a. If damaged, attend with
maintenance deptt
Check for any mechanical

troubles. If any, then change
over the pump
10 a. Rotating part rubbing on √

stationary part. Coupling
touching coupling guard
b. Foundations not rigid
11 Check readiness of standby  √

pump. Standby pumps may be
put in warm-up mode, for hot

Page 344 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pumps. Standby pump should
be in AUTO-Remote mode, if
any interlock for auto start is
there. Changeover of pumps
should be done at scheduled
intervals.
12 Check all seal plan system is √

having sufficient flow.

Page 345 of 732
PARADIP REFINERY
SOP For: NORMAL OPERATING PROCEDURE FOR SUNDYNE

PUMP
AVU
Production All Sundyne Pumps &

HAZARDS INVOLVED:
SL.
.

Page 346 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

Page 347 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
1 √ √
Check gear box oil 
2 Check discharge pressure 

√
3 Check motor amperage 

√
Check motor sound. If abnormal

4 √
inform SI to get it checked by 
E/M.
Check pumps sound. If abnormal
5 √
inform SI to get it checked by 
M/M.
6 Check any leakage from seal, √

flanges etc. Report to SI if any.

Page 348 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Check CW flow & temperature
7 √
of gear box oil & seal 
temperature.
Check seal pot level & pressure.
8 √
If abnormal then check for 
possible seal leak. Report to SI.

Page 349 of 732
PARADIP REFINERY
SOP For: NORMAL OPERATING PROCEDURE FOR TURBINE

DRIVEN PUMP
AVU
Production Turbine Driven Pump (010-P-25 A) &

HAZARDS INVOLVED:
SL.
.

Page 350 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Drain condensate and warm up header before start up. Don’t bypass any process interlocks / approved procedure.
2 VR Pump side to be in warmed up condition.
area
3 All HPVs/LPDs are closed. Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA

Page 351 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
1 Check inlet steam pressure and  √ √
temperature.
a) Reduction in temperature
may be caused by poor
condensate removal. Ensure
steam traps are working well.
b) Low inlet steam pressure and
temperature can result in
excessive steam usage, low
speeds.
c) Steam strainer may be
checked and cleaned if it is

Page 352 of 732
PARADIP REFINERY

Potential
.
JEA JEA
choked.
2 Check speed of turbine and √

record it.
Check for any unusual noise,
3 √
rubbing, overheating or 
excessive vibrations in turbine.
4 Check lube- oil level,  √
temperature, pressure.
a) If lube oil level in oil sump is
low, makeup lube oil
b) If there any change in lube
oil color or contamination of
lube oil with water, then
drain and replace it. Check
lube oil cooler for leakage.
c) High temperature of lube oil
may be due to low oil level,
or chocked lube oil cooler.
d) Lube oil suction line strainers

Page 353 of 732
PARADIP REFINERY

Potential
.
JEA JEA
(if any) should be checked
and cleaned if lube oil
pressure becomes low.
Check for any steam leakages at
governor valve system, trip valve
system, or past carbon rings, or
any other places.
 Ensure that sealing steam to
turbine is not blowing out of
the packing case or along the
turbine shaft. If sealing steam
5 
√
is allowed to leak into
bearing housing, then
lubricating oil may become
contaminated. Adjust the
sealing steam valve, so that
only slight amount of steam
is discharged from packing
case drain lines.

Page 354 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Check cooling water flow to
bearing house, glands and lube
oil cooler.
 If flow is low, remove
6 
√
obstruction in water flow by
gently hammering the line.
Still flow is not improving,
inform S/I to rectify.
Pump side checking should be
done like process side discharge
7 √
pressure and flow, gear oil level 
in oil cup, seal plan system
level / flow.
Check functioning of pressure
8 gauges, temperature gauges, flow √

meters. If damaged, attend with
maintenance department.

Page 355 of 732
PARADIP REFINERY
SOP For: NORMAL OPERATING PROCEDURE FOR DOUBLE SEAL

PUMP
AVU
Production All Double Seal Pumps &

HAZARDS INVOLVED:
SL.
.

Page 356 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

Page 357 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
Lube oil level in oil cup is to be
1 √ √
checked regularly, if less it is to 
be make up
If lube oil gets
colored/contaminated, it is to be
2 √
notified to shift in-charge and it 
is to be get replaced by M/M. If
required, change over the pump.
If lube oil leakage observed, it is
3 to be notified to shift in-charge √

and it is to be get attended by
M/M

Page 358 of 732
PARADIP REFINERY

Potential
.
JEA JEA
If lube oil is getting quickly
4 topped up, pump is to be √

changed over consulting shift in-
charge
If high vibration/abnormal
sound are observed in any part
of the pump/motor it is to be
5 √
notified to shift in-charge. The 
cause is to be identified and
rectified with the help of
concerned department.
If high temperatures are
observed in bearing housing of
pump, it is to be notified to shift
6 √
in-charge and it is to be get 
attended by M/M. If it is
abnormally very high, pump is
to be changed over immediately
7 Discharge pressure and suction  √
pressure to be monitored. If
pressure gauges are faulty, it is to

Page 359 of 732
PARADIP REFINERY

Potential
.
JEA JEA
be notified to shift in-charge and
it is to be get attended by I/M
Cooling water flow to bearing
house/mechanical seal/gland to
8 be monitored. If less/or no flow, √

it is to be notified to shift in-
charge and it is to be get
attended by M/M
Seal flush cooler pot level is to
be monitored. If level is high,
there are chances of primary seal
failure. Pump is to be changed
9 over consulting shift in-charge.  √ √
If level is low there are chances
of secondary seal failure. Pump
is to be changed over consulting
shift in-charge.
10 Seal pot pressure is to be  √
monitored. High pressure in seal
oil pot indicates Lighter gases
going to flare. Immediately

Page 360 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pump changeover to be carried
out consulting shift in-charge.
CW system to be monitored, if
11 leak it is to be notified to shift
 √
in-charge and it is to be get
attended by M/M
Amperage of motor to be
12 monitored. If abnormal, load to
 √
be adjusted by adjusting
discharge valve.
Pumps to be observed for seal
leakage, if observed it is to be
notified to shift in-charge and it
13 is to be get attended by M/M. If  √
leak is heavy, pump is to be
changed over immediately
consulting shift in-charge.
14 Seal plan flow to be monitored  √

Page 361 of 732
PARADIP REFINERY

Page 362 of 732
PARADIP REFINERY
SOP For: NORMAL OPERATING PROCEDURE FOR

RECIPROCATING PUMP
AVU
Production All Reciprocating Pumps &

HAZARDS INVOLVED:
SL.
.
2 Ensure proper box up

Page 363 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA

Page 364 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
1 Check suction & discharge √
pressure.
2 Check gear box oil level &
plunger oil. Top up if required.
If lube oil gets
colored/contaminated, it is to be
3 √
notified to shift in-charge and it
is to be get replaced by M/M. If
required, change over the pump.
If lube oil leakage observed, it is
4 to be notified to shift in-charge
and it is to be get attended by
M/M

Page 365 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Check motor sound. If abnormal
5 √ √
inform SI to get it checked by
E/M.
Check pumps sound / vibration.
6 √ √
If abnormal inform SI to get it
checked by M/M.
7 Check for any leakage. Inform SI √ √
if any.
8 Check dozing rate (fall rate of √
pot). Adjust stroke if required.
9 Note down chemical level of √
storage vessel.

Page 366 of 732
PARADIP REFINERY
SOP No : AVU/081 SOP For: CHANGE OVER OF CENTRIFUGAL PUMP (Hot Pumps) Revision No : 06
AVU
Production All Centrifugal Pumps &

HAZARDS INVOLVED:
SL.
.
1 Flange Leak Ensure proper flange box up.
2 Low flow / high flow Monitor and take action.

Page 367 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2 Check suction valve line up.
area
PRE START CHECK:

Potential
. JEA JEA


Page 368 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Change over may be scheduled
or emergency (leak, vibration,
1 √
temperature) or overload
tripping Inform panel engineer
about changeover
Ask panel engineer, if power
2 √
clearance is there for change
over.
Check stand by pump is Ensure proper warm
3 up before start up. √
sufficiently hot or not. If not Cold Start
then warm up.
4 Vent if required to flare / √
Column
Ensure proper cooling water
5 supply/return to Bearing √ √
Housing , L.O. cooler, seal flush
cooler(if any)
6 Ensure seal plan system is in line √ √
& seal pot level is at proper level.

Page 369 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 Ensure proper lube oil Insufficient √ √
circulation (if any) is healthy. lubrication.
Open minimum circulation line
8 √
valve / check minimum
circulation valve opening.
9 Starting the pump √
10 Start the pump. √
After pump develops normal
operating discharge pressure &
11 start current is reduced, slowly
√
open discharge valve and
simultaneously close running
pump discharge valve
12 Check pump load & confirm
√
from panel.
Observe vibration, bearing
13 temperatures of motor,
√
abnormal sound in the pump
and motor

Page 370 of 732
PARADIP REFINERY

Potential
.
JEA JEA
14 Stopping the Pump √
15 Fully close discharge valve √
16 Check running pump load. Stop

√
the pump motor
Leave the suction open unless
17 the shut-down is for √
maintenance.
18 Open warm up valve & keep the
√
pump in worm up condition.

Page 371 of 732
PARADIP REFINERY
SOP No : AVU/082 SOP For: CHANGE OVER OF CENTRIFUGAL PUMP (Cold pump) Revision No : 06
AVU
Production All Cold Centrifugal Pumps &

HAZARDS INVOLVED:
SL.
.

Page 372 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA


Page 373 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 temperature) or overload √
tripping
Inform panel engineer about
changeover
Ask panel engineer, if power
2 √
clearance is there for change
over.
3 Vent if required to flare. √
Ensure proper cooling water

4 supply/return to Bearing √
Housing , L.O. cooler, seal flush
cooler(if any) .
5 Ensure seal plan system is in line √ √
& seal pot level is at proper.
6 Ensure proper lube oil √ √
circulation (if any)

Page 374 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Open minimum circulation line
7 √ √
valve / check minimum
circulation valve opening.
8 temperature) or overload √
tripping
Inform panel engineer about
changeover
9 Starting the pump √
10 Start the pump. √
After pump develops normal
operating discharge pressure,
11 slowly open discharge valve and √
simultaneously close running
pump discharge valve
12 Check pump load & confirm
√
from panel.

Page 375 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
and motor
14 Stopping the Pump √
15 Fully close discharge valve √
16 Stop the pump motor √
Leave the suction open unless
17 the shut-down is for √
maintenance.

Page 376 of 732
PARADIP REFINERY
SOP No : AVU/083 SOP For: CHANGE OVER OF RECIPROCATING PUMP Revision No : 06

AVU
Production All Cold Centrifugal Pumps &

HAZARDS INVOLVED:
SL.
.

Page 377 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA


Page 378 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Pump must not be started with
the discharge valve closed, as the
1 pump could be damaged or the √
discharge line ruptured
Inform panel officer about
changeover
2 Check lube oil level. √
3 Open the suction valve. √
4 Open the bleed valve to bleed √

gas from the pump.
5 Open the discharge valve. Start √ √
the pump motor.
6 temperatures of motor, √ √
and motor
7 Observe discharge pressure. √

Page 379 of 732
PARADIP REFINERY

Potential
.
JEA JEA
After ensure that standby pump
8 is developed pressure, stop duty √
pump motor
9 Adjust stroke to get desired flow. √

Page 380 of 732
PARADIP REFINERY
SOP No : AVU/084 SOP For: CHANGE OVER OF SUNDYNE PUMP Revision No : 06

AVU
Production All Cold Sundyne Pumps &

HAZARDS INVOLVED:
SL.
.

Page 381 of 732
PARADIP REFINERY
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
2
area
PRE START CHECK:

Potential
. JEA JEA


Page 382 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Inform panel officer about √
changeover
For high power load pump, prior
2 to start-up ensure that clearance √
has been taken from Power
Generation Plant
3 Start the auxiliary oil pump, if √
installed.
4 Pressurize the seal buffer system, √
if provided.
Open the pump suction valve
5 √ √
100% and gradually vent the
casing.
Open the pump discharge valve
6 √ √
to design conditions (15-20
%)
Start the main pump motor and
7 √
observe the flow rate and
discharge pressure.

Page 383 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Gradually adjust the discharge
valve for the pump operation
8 with the recommended flow
√
limits. Simultaneously close
running pump discharge valve
(leave 15-20% open)
Shut down the auxiliary oil
9 pump within two minutes of
√
main motor start-up and put it
in AUTO mode.
√
and motor
11 Stop the pump motor √
12 Fully close the discharge valve √
Start the auxiliary oil pump in
13 manual mode, if does not started √
automatically.

Page 384 of 732
PARADIP REFINERY

Page 385 of 732
PARADIP REFINERY
SOP No : AVU/085 SOP For: CORROSION INHIBITOR DOSING PUMP HANDOVER Revision No : 06
AVU
Production Corrosion Inhibitor Dosing Pump &

HAZARDS INVOLVED:
SL.
.
1 Corrosive Chemical Use PPEs
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 386 of 732
PARADIP REFINERY
1 Use PPEs Don’t bypass any process interlocks / approved procedure.

2 Check nearby Safety Shower working.
area
PRE START CHECK:

Potential
. JEA JEA
1 Ensure other pump is working. √

DETAILED STEPS:
Potential
.
JEA JEA
1 Inform panel officer. √ √

Page 387 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Start standby pump and stop the
2 √ √
pump which is to be handed
over.
Isolate the pump by tightly
3 √
closing suction and discharge
valves.
4 Lock the stop button of pump to √
be handed over.
Drain pump casing and line
5 Chemical √
material to OWS. Keep running Use PPEs
Spill
water on it.
6 Check de-pressurization through Chemical √
Use PPEs
PG & draining slowly in OWS. Spill
7 Slowly open casing vent & allow √
complete draining in OWS.
De-energise the motor and
8 confirm power cut off locally by √ √
pressing the start button of
pump to be handed over.
9 Ensure isolation valves are √
holding.

Page 388 of 732
PARADIP REFINERY

Potential
.
JEA JEA
10 Wash the pump & area with √
water.
11 Handover to maintenance after √ √
doing tool box talk.
12 Ensure use of proper PPEs. √ √

Page 389 of 732
PARADIP REFINERY
SOP No : AVU/086 SOP For: NEUTRALISING AMINE DOSING PUMP HANDOVER Revision No : 06
AVU
Production Neutralizing Amine Dosing Pump &

HAZARDS INVOLVED:
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 390 of 732
PARADIP REFINERY

area
PRE START CHECK:

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA

Page 391 of 732
PARADIP REFINERY

Potential
.
JEA JEA
2 √ √
over.
3 √
valves.
be handed over.
5 Chemical √
Spill
water on it.
Use PPEs
holding.

Page 392 of 732
PARADIP REFINERY

Potential
.
JEA JEA
water.

Page 393 of 732
PARADIP REFINERY
SOP No : AVU/087 SOP For: ANTIFOULANT DOSING PUMP HANDOVER Revision No : 06

AVU
Production Antifoulant Dosing Pump &

HAZARDS INVOLVED:
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 394 of 732
PARADIP REFINERY

area
PRE START CHECK:

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA
1 √ √
Inform panel officer.

Page 395 of 732
PARADIP REFINERY

Potential
.
JEA JEA
2 √ √
over.
3 √
valves.
be handed over.
5 Chemical √
Spill
water on it.
Use PPEs
holding.

Page 396 of 732
PARADIP REFINERY

Potential
.
JEA JEA
water.
12 √ √
Ensure use of proper PPEs.

Page 397 of 732
PARADIP REFINERY
SOP No : AVU/088 SOP For: CAUSTIC DOSING PUMP HANDOVER Revision No : 06

AVU
Production Caustic Dosing Pump &

HAZARDS INVOLVED:
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 398 of 732
PARADIP REFINERY

area
PRE START CHECK:

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA

Page 399 of 732
PARADIP REFINERY

Potential
.
JEA JEA
2 √ √
over.
3 √
valves.
be handed over.
5 Chemical √
material. Keep running water on Use PPEs
Spill
it.
Use PPEs
holding.

Page 400 of 732
PARADIP REFINERY

Potential
.
JEA JEA
water.
11 Inform ETP about caustic √ √
draining in CRWS.
doing JSA & tool box talk.
SOP No : AVU/089 SOP For: DEMULSIFIER DOSING PUMP HANDOVER Revision No : 06

AVU
Production Demulsifier Dosing Pump &


Page 401 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA

Page 402 of 732
PARADIP REFINERY

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA
1 √ √
Inform panel officer.
2 √ √
over.
3 √
valves.
be handed over.
5 Drain pump casing and line Chemical Use PPEs √
material to OWS. Keep running Spill

Page 403 of 732
PARADIP REFINERY

Potential
.
JEA JEA
water on it.
Use PPEs
holding.
water.
doing JSA & tool box talk.
12 √ √
Ensure use of proper PPEs.
SOP For: HANDOVER/TAKEOVER/STARTUP OF 010-P-001 A/B

(DESALTER MAKEUP WATER PUMP)

Page 404 of 732
PARADIP REFINERY

AVU
Production De-salter Makeup Water Dosing Pumps &

HAZARDS INVOLVED:
SL.
.
1 Stripped Sour Water Use PPEs
2 High Pressure Pump Use PPEs

Page 405 of 732
PARADIP REFINERY
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 406 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Changeover pump and Isolate √ √

suction, discharge.
2 De-blind the OWS drain of the √
pump.
3 Note pump suction & discharge √
pressure from local PG.
Drain entire pump content to High Ensure precaution
4 √
OWS. Ensure draining by Residual while draining.
observing PG reading. Pressure Use PPEs.
Again close pump drain valve to
5 check if pump is getting √
pressurized by the way of any
valve passing.
If it is ensured that none of the
valves are passing then, open the
6 √
pump drain to OWS and ensure
complete draining to OWS by
opening PG vent.

Page 407 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 De-energized motor from the √ √
substation if required.
Get suction / discharge blinded,
if required. Preference may be
8 given to blind at pump nozzle as √
drain facilities will help to check
possible passing of
suction/discharge valve.
Handover the pump & strainer
9 √
for maintenance job by issuing
work permit.
10 √ √
Decouple the pump if required.
Ensure maintenance job is done
11 √ √
in presence of production /
maintenance personal.
TAKE OVER PROCEDURE
Ensure pump maintenance job is
1 √ √
over & handed over by
maintenance

Page 408 of 732
PARADIP REFINERY

Potential
.
JEA JEA
2 Check pump suction / discharge √ √
are de-blinded.
Check all disturbed flanges are
3 √ √
properly tightened with proper
gasket.
4 Check coupling guard is √ √
properly fixed.
5 Close all drain (CBD/OWS) & √
vents.
6 Slowly fill pump with stripped √
water by opening suction valve.
7 Displace air through discharge √
PG drain.
After filling is over close the
drain, suction PG drain & allow
8 √
pressurizing the pump. Ensure
the pressure equals suction
pressure.
9 Check for any leakage. Attend if √
any.

Page 409 of 732
PARADIP REFINERY

Potential
.
JEA JEA
10 √
Slowly open suction valve fully.
11 Energize motor from the √

substation.
12 √
Blind pump drain to OWS.
PUMP START UP
PROCEDURE
Inform panel officer before carry
out the operation and ensure
1 √ √
healthiness of interlock
associated with pump (in case
applicable).
Ensure lube oil level in bearing
2 √
chamber (inboard/outboard) &
oil cups. Line up bearing CW
3 Take power clearance from √
substation.
4 Ensure discharge valve is closed √
& suction valve is fully opened.

Page 410 of 732
PARADIP REFINERY

Potential
.
JEA JEA
5 Start the pump from local √
switch board.
6 Line up minimum circulation & √ √
keep C/V 50% open.
7 Keep stripped sour water to √
desalted C/Vs closed.
Gradually open the discharge
8 √
valve as per requirement of with
information to panel officer.
Gradually route stripped sour
9 water to desalter. Accordingly √
High Flow Monitor and Control
close min. Circulation from
panel.
10 Check Discharge Pressure & √
Ammeter readings.
Check physically for any leak,
11 abnormal sound, vibration etc √
and if any abnormality observed,
inform to S/I.
12 Ensure remote monitoring √

Page 411 of 732
PARADIP REFINERY

Potential
.
JEA JEA
system healthiness
(vibration/bearing temp/running
status) from DCS.

Page 412 of 732
PARADIP REFINERY
SOP For: HANDOVER/TAKEOVER/STARTUP OF 010-P-002 A/B/C

(DE ETHANISER PRODUCT PUMPS)
AVU
Production De-Ethaniser Product Pumps &

HAZARDS INVOLVED:
SL.
.
1 Sour LPG Use PPEs

Page 413 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 414 of 732
PARADIP REFINERY

Page 415 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 √ √
Isolate suction, discharge.
2 Isolate individual pump √

minimum circulation C/Vs.
3 √
Isolate seal plan 52.
High Ensure precaution
4 De-blind the casing vent to flare √
Residual while draining.
& OWS drain to OWS. Pressure Use PPEs.
Vent entire pump content to
flare through casing vent. Ensure
6 √
complete draining by observing
pump discharge / suction
pressure.
7 Again close pump vent valve to √ √
check if pump is getting

Page 416 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pressurize is increasing by the
way of any valve passing.
If isolation valves are holding,
8 √
open drain to OWS to de-
pressurize completely.
possible passing of
10 √ √
work permit.
11 De-energize /Decouple the √ √
pump if required.
12 in presence of production /

Page 417 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE
1 √ √
maintenance
2 Check pump suction / discharge √ √
are de-blinded.
3 √ √
gasket.
4 Check coupling guard is √ √
properly fixed.
5 Close drain to OWS & casing √
vent.
6 √
Line up seal plan 52.
7 Crack open suction valve & vent √

to flare through casing vent.
8 Observe chilling effect in vent √
line.

Page 418 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Close casing vent & allow to
9 √
pressurize pump. Ensure the
pressure equals suction pressure.
any.
11 √
Slowly open suction valve fully.

substation.
Blind pump drain & vent.
PUMP START UP
PROCEDURE
1 √ √
applicable).
2 √

Page 419 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Ensure seal plan 52 is in line and
3 √
proper level is maintained &
CWS/CWR is lined up.
4 Take power clearance from √
substation.
6 Start the pump from local √ √
switch board.
7 √
Ammeter readings.
inform to S/I.
system healthiness

Page 420 of 732
PARADIP REFINERY

Potential
.
JEA JEA
status) from DCS.

Page 421 of 732
PARADIP REFINERY

(FLASHED CRUDE PUMPS)
AVU
Production Flashed Crude Pumps &

HAZARDS INVOLVED:
SL.
.
1 Hot Crude at 180 Deg C Use PPEs

Page 422 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 423 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Isolate suction B/V & its √

equalization
2 Isolate min. circulation FV √
(1121/1122/1123) by b/v.
3 Isolate pump discharge to Tr-1 / √
Tr-2 & its equalization
4 √
Isolate warm-up B/V
5 √
Isolate SP-32
6 Allow to cool till casing √
temperature is below 150 deg C.
Check the temperature by
temperature gun / thermo

Page 424 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
7 De-blind the CBD & OWS and √ √
suction strainer drain.
8 De-blind FLO header at pump
suction.
pressure at PG.
Drain entire pump content to
CBD. Ensure draining by
10 √
observing CBD line temperature
by temperature gun / thermo
hunter.
Ensure draining of the pump and
connected header by draining
through pump casing header,
11 discharge line drain and suction √
strainer drain one by one to
check that any of the drains is
not chocked with any foreign
material.

Page 425 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Ensure complete draining by
12 observing CBD level / CBD drain √
line temperature / pump
pressure.
Close pump drain valves to
13 √
pressurize / temperature is
increasing by the way of any
valve passing.
Observe the casing temperature
of the pump by temperature gun
/ thermo hunter. If temperature
14 √
is not increasing, then it is
ensured that suction / discharge /
warm-up valve or NRV is not
passing.
15 √
pump drain to CBD/OWS and
ensure complete draining to
OWS by opening PG vent.

Page 426 of 732
PARADIP REFINERY

Potential
.
JEA JEA
16 De-energized motor from the √
possible passing of
18 √
work permit.
19 √ √
20 √ √
TAKE OVER PROCEDURE
1 √
maintenance

Page 427 of 732
PARADIP REFINERY

Potential
.
JEA JEA
2 Check pump suction / discharge √
are de-blinded.
3 √
gasket.
4 Check coupling guard is √
properly fixed.
5 Close all drain (CBD/OWS) & √
vents.
6 Line up seal plan 32, 52, and 62. √
Open SP52 vent to flare
Slowly open equalization of
7 √
suction valve & fill with V3
content.
Displace air through suction
8 √
strainer drain to OWS or suction
PG drain.
9 After filling is over close suction √
strainer drain, suction PG drain
& allow pressurizing the pump
with V3 content. Ensure the

Page 428 of 732
PARADIP REFINERY

Potential
.
JEA JEA
any.
Allow settling for 1 hr & drain
11 √
out accumulated water from
casing.
Close equalization of suction
12 √
valve & slowly open suction
valve fully.
Open warm valve and allow
13 √
some time to achieve system
temperature
substation.
15 √ √
Keep pump as standby.
PUMP START UP
PROCEDURE
1 Inform panel officer before carry √ √

Page 429 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
2 √
Line up SP-52. Check/top up oil
3 √
level in seal pot. Open its vent to
flare. Line up seal pot CW.
4 Commission SP-32 & maintain √
required flow.
5 Ensure lube oil level for motor √
bearing.
6 Take power clearance from √ √
substation.
8 Start the pump from local √
switch board.
Inform Panel to open minimum
9 √
circulation C/V & run of full
circulation.

Page 430 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Ammeter readings.
inform to S/I.
12 √
valve as per requirement of
panel.
Ensure remote monitoring
13 system healthiness √ √ √
status) from DCS.

Page 431 of 732
PARADIP REFINERY

(TPA PUMPS)
AVU
Production Top Pump Around Pumps &

HAZARDS INVOLVED:
SL.
.
1 Hot Naphtha at 140 Deg C Use PPEs

Page 432 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 433 of 732
PARADIP REFINERY

Page 434 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Isolate suction, discharge &

√
warm up B/V.
2 Isolate seal plan 52. √
Allow to cool till casing
3 Check the temperature by √
hunter.
4 De-blind the CBD & OWS drain
√
of the pump.
5 Note pump suction & discharge
√
6 observing CBD line temperature √
hunter.

Page 435 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 discharge line drain and suction
√
material.
8 observing CBD level / CBD drain
√
pressure.
Close pump drain valves to
9 pressurize / temperature is √
valve passing.
10 Observe the casing temperature √

Page 436 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
11 pump drain to CBD/OWS and √
12 De-energized motor from the
√
13 given to blind at pump nozzle as
√ √
possible passing of
14 for maintenance job by issuing √
work permit.
15 Decouple the pump if required. √ √

Page 437 of 732
PARADIP REFINERY

Potential
.
JEA JEA
16 in presence of production / √ √
TAKE OVER PROCEDURE
1 over & handed over by √ √
maintenance
2 Check pump suction / discharge
√
are de-blinded.
3 properly tightened with proper √
gasket.
4 Check coupling guard is
√
properly fixed.
5 Close all drain (CBD/OWS) &
√
vents.
Line up seal fluid /seal pot
6 /cooling water. Line up seal pot √
vent to flare.

Page 438 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 Crack open suction valve & fill. √
8 strainer drain to OWS or suction √
PG drain.
After filling is over close suction
9 & allow pressurizing the pump. √
Ensure the pressure equals
suction pressure.
10 Check for any leakage. Attend if
√
any.
11 out accumulated water from √
casing.
12 Slowly open suction valve fully. √
13 Then gradually open pump

√
suction valve fully.
14 Energize motor from the
√
substation.

Page 439 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PUMP START UP
PROCEDURE
1 healthiness of interlock √
applicable).
2 chamber (inboard/outboard) & √
Line up SP-52. Check oil level in
3 seal pot. Open its vent to flare. √
Line up seal pot CW
4 Take power clearance from
√
substation.
5 Ensure discharge valve is closed
√
6 Start the pump from local
√
switch board.
7 Gradually open the discharge √

Page 440 of 732
PARADIP REFINERY

Potential
.
JEA JEA
8 Check Discharge Pressure &
√
Ammeter readings.
9 abnormal sound, vibration etc
√
inform to S/I.
10 system healthiness
√
status) from DCS.

Page 441 of 732
PARADIP REFINERY

(KEROSENE PUMP AROUND PUMPS)
AVU
Production KEROSENE Pump Around Pumps &

HAZARDS INVOLVED:
SL.
.
1 Hot Kerosene at 190-200 Deg C Use PPEs

Page 442 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 443 of 732
PARADIP REFINERY

Page 444 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
√
hunter.
6 Ensure draining of the pump and √

Page 445 of 732
PARADIP REFINERY

Potential
.
JEA JEA
discharge line drain and suction
material.
√
pressure.
valve passing.

Page 446 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
√
√
possible passing of
13 for maintenance job by issuing √ √
work permit.
14
Decouple the pump if required. √

Page 447 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal fluid /seal pot √
/cooling water. Line up seal pot

Page 448 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent to flare.
Slowly open pressure
7 equalization of suction valve & √
fill.
PG drain.
suction pressure.
√
any.
casing.
√
13 Open warm valve and allow √

Page 449 of 732
PARADIP REFINERY

Potential
.
JEA JEA
temperature
√
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
√
substation.
√

Page 450 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
switch board.
7 valve as per requirement of with √
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 451 of 732
PARADIP REFINERY

(LAGO PUMP AROUND PUMPS)
AVU
Production LAGO Pump Around Pumps &

HAZARDS INVOLVED:
SL.
.
1 Hot LAGO at 250 Deg C. Use PPEs

Page 452 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 453 of 732
PARADIP REFINERY

Page 454 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
√
hunter.

Page 455 of 732
PARADIP REFINERY

Potential
.
JEA JEA
material.
√
pressure.
valve passing.

Page 456 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
Isolate seal fluid /seal pot
11 /cooling water. Isolate seal pot √
vent to flare.
12 Isolate SP-32 √

√ √
√
possible passing of
15 Handover the pump & strainer √ √

Page 457 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.

Page 458 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent to flare.
7 Crack open suction valve &
√
slowly fill.
PG drain.
suction pressure.
√
any.
casing.
√

Page 459 of 732
PARADIP REFINERY

Potential
.
JEA JEA
13 some time to achieve system √
temperature
√
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
4 Line up SP-32 & maintain
√
required flow.

Page 460 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 461 of 732
PARADIP REFINERY

(RCO PUMPS)
AVU
Production RCO PUMPS &

HAZARDS INVOLVED:
SL.
.
1 RCO at 340 Deg C. Use PPEs
3 Fluid at auto ignition temperature.

Page 462 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 463 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 464 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
Isolate suction, discharge &
1 warm up B/V. Close casing vent √
to C1.
2 Isolate seal plan 32, 52 & 62. √
hunter.
√
of the pump.
√
suction.
√
7 Drain entire pump content to √

Page 465 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
Slowly flush pump with FLO to
CBD from pump casing drain,
10 pump discharge and suction
√
strainer drain sequentially to
ensure VR is flushed out from
the casing as well as drain lines.

Page 466 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Visually check flushed product
viscosity by opening drain to
11 OWS. If draining material is √
well diluted, isolate CBD & open
drain to OWS. Close FLO valve.
Again close pump drain valves &
FLO valve to check if pump is
12 getting pressurize / temperature √
is increasing by the way of any
valve passing.
13 is not increasing, then it is √ √
passing.
14 If it is ensured that none of the √

Page 467 of 732
PARADIP REFINERY

Potential
.
JEA JEA
15 /cooling water. Isolate seal pot √ √
vent to flare.
16 Isolate SP-32 √ √

√
√
possible passing of
work permit.
20 Decouple the pump if required. √
21 Ensure maintenance job is done √ √

Page 468 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
vent to flare.

Page 469 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 Slowly fill pump with FLO √
PG drain.
suction pressure.
√
any.
casing.
12 Slowly open suction valve
√
pressure equalization line.
√
14 Open warm valve and allow √

Page 470 of 732
PARADIP REFINERY

Potential
.
JEA JEA
temperature
Energize motor from the
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
4 Commission SP-32 & maintain
√
required flow.

Page 471 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.
system healthiness

Page 472 of 732
PARADIP REFINERY

Potential
.
JEA JEA
status) from DCS.

(KEROSENE PRODUCT PUMPS)
AVU
Production KEROSENE Product Pumps &

HAZARDS INVOLVED:

Page 473 of 732
PARADIP REFINERY
SL.
.
1 Hot Kerosene at 190-200 Deg C Use PPEs
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA

Page 474 of 732
PARADIP REFINERY

Potential
. JEA JEA


Page 475 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
√
hunter.

Page 476 of 732
PARADIP REFINERY

Potential
.
JEA JEA
material.
√
pressure.
valve passing.

Page 477 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
√
vent to flare.
√ √
possible passing of
work permit.

Page 478 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal fluid /seal pot √
/cooling water. Line up seal pot

Page 479 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent to flare.
7 Crack open suction valve &
√
slowly fill.
PG drain.
suction pressure.
√
any.
casing.
√
temperature

Page 480 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
√
substation.
√
√
switch board.

Page 481 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 482 of 732
PARADIP REFINERY

(LAGO PRODUCT PUMPS)
AVU
Production LAGO PRODUCT Pumps &

HAZARDS INVOLVED:
SL.
.
1 LAGO AT 250 DEG C Use PPEs

Page 483 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 484 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
√

Page 485 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
valve passing.

Page 486 of 732
PARADIP REFINERY

Potential
.
JEA JEA
9 is not increasing, then it is √
passing.
vent to flare.
12 Isolate SP-32 / SP 62 √

√ √
14 Get suction / discharge blinded, √

Page 487 of 732
PARADIP REFINERY

Potential
.
JEA JEA
given to blind at pump nozzle as
possible passing of
15 for maintenance job by issuing √ √
work permit.
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.

Page 488 of 732
PARADIP REFINERY

Potential
.
JEA JEA
gasket.
√
properly fixed.
√
vents.
vent to flare.
7 Line up SP-62 & ensure steam
√
flow.
8 Slowly open equalization of
√
suction valve & fill.
PG drain.
10 After filling is over close suction √
& allow pressurizing the pump.

Page 489 of 732
PARADIP REFINERY

Potential
.
JEA JEA
suction pressure.
√
any.
casing.
√
temperature
√ √
substation.
PUMP START UP
PROCEDURE
applicable).

Page 490 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Line up seal pot CW
4 Line up SP-32 / SP-62&
√
maintain required flow.
√
substation.
√
√
switch board.
√
Ammeter readings.
10 Check physically for any leak, √
abnormal sound, vibration etc

Page 491 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√ √
status) from DCS.

Page 492 of 732
PARADIP REFINERY

(NAPHTHA PUMPS)
AVU
Production NAPHTHA Pumps &

HAZARDS INVOLVED:
SL.
.
1 NAPHTHA PUMPS Use PPEs

Page 493 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 494 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Isolate suction, discharge B/V. √

√
of the pump.
√
4 CBD. Ensure draining by √
observing pump pressure.
5 observing CBD level / pump √
pressure.

Page 495 of 732
PARADIP REFINERY

Potential
.
JEA JEA
6 Depressurize pump to flare. √
Again close pump drain & vent
7 valves to check if pump is
√
getting pressurized by the way
of any valve passing.
√
√
possible passing of
11 Decouple the pump if required.

Page 496 of 732
PARADIP REFINERY

Potential
.
JEA JEA
12 for maintenance job by issuing
work permit.
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.

Page 497 of 732
PARADIP REFINERY

Potential
.
JEA JEA
6 Crack open suction valve. √
7 Displace air through discharge

√
PG drain.
After filling is over close PG
drain & allow pressurizing the
8 pump. √
suction pressure.
√
any.
Slowly open suction valve.
10 Ensure that running pump does
not get vapor lock during this
operation.
substation.
13 Blind pump drain to CBD/OWS.

Page 498 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PUMP START UP
PROCEDURE
applicable).
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 499 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
inform to S/I.
√
status) from DCS.

Page 500 of 732
PARADIP REFINERY

(SOUR WATER PUMPS)
AVU
Production SOUR WATER Pumps &

HAZARDS INVOLVED:
SL.
.
1 SOUR WATER PUMPS Use PPEs

Page 501 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 502 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 503 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
2 De-blind the OWS drain of the

√
pump.
√
4 Depressurize to flare. √
5 Drain entire pump content to

√
OWS.
Again close pump drain & vent
√
7 If it is ensured that none of the √
pump drain to OWS and ensure

Page 504 of 732
PARADIP REFINERY

Potential
.
JEA JEA
opening PG vent.
8 Provide water connection at
√
pump suction bleeder.
9 Flush pump with water & drain
√
to OWS.
√
possible passing of
work permit.

Page 505 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
7 Displace air through casing vent

√
to flare.
8 After filling is over close vent & √
allow pressurizing the pump.

Page 506 of 732
PARADIP REFINERY

Potential
.
JEA JEA
suction pressure.
√
any.
operation.
substation.
13 Blind pump drain to OWS.

substation.
PUMP START UP
PROCEDURE
1 Inform panel officer before carry √

Page 507 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 508 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

(UNSTABILISED NAPHTHA PUMPS)
AVU
Production Unstabilised Naphtha Pumps &


Page 509 of 732
PARADIP REFINERY
HAZARDS INVOLVED:
SL.
.
1 Unstabilised Naphtha Pumps Use PPEs
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Page 510 of 732
PARADIP REFINERY

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Isolate suction, discharge. √
3 De-blind the casing vent to flare

√
& OWS drain to OWS.

Page 511 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
5 complete draining by observing √
pressure.
Again close pump vent valve to
6 check if pump is getting
√
7 open drain to OWS to de-
√
pressurize completely. Open PG
drain.
possible passing of

Page 512 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
10 De-energize /Decouple the
√
pump if required.
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
4 Check coupling guard is √

Page 513 of 732
PARADIP REFINERY

Potential
.
JEA JEA
properly fixed.
5 Close drain to OWS & casing
√
vent.
6 Line up seal plan 52. √
7 Crack open suction valve & vent

√
8 pressurize pump. Ensure the √
√
any.
10 Slowly open suction valve fully.

substation.
12 Blind pump drain & vent.
PUMP START UP
PROCEDURE

Page 514 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
3 proper level is maintained & √
√
substation.
√
√
switch board.

Page 515 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 516 of 732
PARADIP REFINERY

(SIDE CUT NAPHTHA PUMPS)
AVU
Production Side Cut Naphtha Pumps &

HAZARDS INVOLVED:
SL.
.
1 Side Cut Naphtha Pumps Use PPEs

Page 517 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 518 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 519 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
& drain to CBD / OWS.
√
5 CBD. Ensure complete draining
√
by observing pump discharge /
suction pressure.
√
7 If isolation valves are holding, √
drain completely to CBD, open

Page 520 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent to flare.
8 Check complete draining by
√
opening drain to OWS.
9 Close drain to CBE & vent to
√
flare.
10 Open PG drain & casing drain to
√
OWS.
possible passing of
work permit.
pump if required.
14 Ensure maintenance job is done

Page 521 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

√
8 Close casing vent & allow to √
pressurize pump. Ensure the

Page 522 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
any.

substation.
PUMP START UP
PROCEDURE
applicable).
3 Ensure seal plan 52 is in line and √
proper level is maintained &

Page 523 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 524 of 732
PARADIP REFINERY

Page 525 of 732
PARADIP REFINERY

(NAPHTHA STABILISER REFLUX PUMPS)
AVU
Production Naphtha Stabilizer Reflux Pumps &

HAZARDS INVOLVED:
SL.
.
1 Naphtha Stabilizer Reflux Pumps Use PPEs

Page 526 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 527 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
& OWS drain to OWS.
√
pressure.

Page 528 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
7 open drain to OWS to de- √
√
possible passing of
work permit.
√
pump if required.

Page 529 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

Page 530 of 732
PARADIP REFINERY

Potential
.
JEA JEA

√
8 Observe chilling effect in vent
√
line.
any.

substation.
PUMP START UP
PROCEDURE

Page 531 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
√
substation.
√
√
switch board.

Page 532 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 533 of 732
PARADIP REFINERY

(SOUR LPG PUMPS)
AVU
Production Sour LPG Pumps &

HAZARDS INVOLVED:
SL.
.
1 Sour LPG Pumps Use PPEs

Page 534 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 535 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
2 Isolate individual pump

√

√
& OWS drain to OWS.
√
6 Vent entire pump content to √

Page 536 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pressure.
√
√
possible passing of
work permit.
pump if required.

Page 537 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

√

Page 538 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
line.
any.

substation.
PUMP START UP
PROCEDURE
applicable).

Page 539 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 540 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

Page 541 of 732
PARADIP REFINERY

(DEETHANISER REFLUX PUMPS)
AVU
Production Deethaniser Reflux LPG Pumps &

HAZARDS INVOLVED:
SL.
.
1 Deethaniser Reflux LPG Pumps Use PPEs

Page 542 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 543 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
& drain to OWS.
√
pressure.

Page 544 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
√
possible passing of
work permit.
√
pump if required.

Page 545 of 732
PARADIP REFINERY

Potential
.
JEA JEA
12
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

√

Page 546 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
line.
any.

substation.
PUMP START UP
PROCEDURE
applicable).

Page 547 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 548 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

Page 549 of 732
PARADIP REFINERY

(C3 PUMP)
AVU
Production C3 LPG Pumps &

HAZARDS INVOLVED:
SL.
.
1 C3 LPG Pumps Use PPEs

Page 550 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 551 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 552 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√

√
& OWS drain to OWS.
√
pressure.
7 Again close pump vent valve to √

Page 553 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
possible passing of
work permit.
pump if required.
12
TAKE OVER PROCEDURE

1 Ensure pump maintenance job is √ √

Page 554 of 732
PARADIP REFINERY

Potential
.
JEA JEA
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

√
√
line.

Page 555 of 732
PARADIP REFINERY

Potential
.
JEA JEA
any.

substation.
PUMP START UP
PROCEDURE
applicable).

Page 556 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 557 of 732
PARADIP REFINERY

Page 558 of 732
PARADIP REFINERY

(C4 PUMP)
AVU
Production C4 LPG Pumps &

HAZARDS INVOLVED:
SL.
.
1 C3 LPG Pumps Use PPEs

Page 559 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 560 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√

√
& OWS drain to OWS.
√

Page 561 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pressure.
√
√
possible passing of
work permit.
pump if required.

Page 562 of 732
PARADIP REFINERY

Potential
.
JEA JEA
12
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

√

Page 563 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
line.
any.

substation.
PUMP START UP
PROCEDURE
applicable).

Page 564 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 565 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

Page 566 of 732
PARADIP REFINERY

(VACUUM DIESEL PUMP)
AVU
Production VACUUM DIESEL PUMP &

HAZARDS INVOLVED:
SL.
.
1 VACUUM DIESEL PUMP Use PPEs

Page 567 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 568 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
to C7.
hunter.
√
of the pump.
5 De-blind FLO header at pump √

Page 569 of 732
PARADIP REFINERY

Potential
.
JEA JEA
suction.
√
hunter.
√
material.
√
pressure.

Page 570 of 732
PARADIP REFINERY

Potential
.
JEA JEA
pump discharge and suction
10 strainer drain sequentially to √
ensure Vac diesel is flushed out
from the casing as well as drain
lines.
11 OWS. If draining material is
12 getting pressurize / temperature
valve passing.
13 Observe the casing temperature

Page 571 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
14 pump drain to CBD/OWS and
possible passing of
work permit.

Page 572 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal plan 62 & maintain
√
steam flow

Page 573 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PG drain.
suction pressure.
any.
11 out accumulated water from
casing.
Open warm valve and displace
12 casing content to column
through casing vent.
13 Observe casing temperature. If it
achieves required temperature,
close casing vent & drain from

Page 574 of 732
PARADIP REFINERY

Potential
.
JEA JEA
suction strainer drain to CBD.
After achieving temperature in
14 suction strainer drain line close
draining.
operation.
17 Keep pump under warm
condition.
substation.
PUMP START UP
PROCEDURE

Page 575 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
3 Ensure line up of seal plan 62 &
√
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 576 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

Page 577 of 732
PARADIP REFINERY

(VGO PUMP)
AVU
Production VGO PUMP &

HAZARDS INVOLVED:
SL.
.
1 VGO PUMP Use PPEs

Page 578 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 579 of 732
PARADIP REFINERY

Page 580 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
to C7.
hunter.
√
of the pump.
√
suction.
√

Page 581 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
10 Slowly flush pump with FLO to √
ensure VGO is flushed out from

Page 582 of 732
PARADIP REFINERY

Potential
.
JEA JEA
valve passing.
13 is not increasing, then it is
passing.
14 If it is ensured that none of the

Page 583 of 732
PARADIP REFINERY

Potential
.
JEA JEA
possible passing of
work permit.

Page 584 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal plan 62 & maintain
√
steam flow
8 Displace air through suction √

Page 585 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PG drain.
suction pressure.
any.
casing.
Observe casing temperature. If it
13 achieves required temperature,
14 After achieving temperature in
suction strainer drain line close

Page 586 of 732
PARADIP REFINERY

Potential
.
JEA JEA
draining.
operation.
condition.
substation.
PUMP START UP
PROCEDURE
applicable).

Page 587 of 732
PARADIP REFINERY

Potential
.
JEA JEA
3 Ensure line up of seal plan 32 &
√
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.

Page 588 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
status) from DCS.

Page 589 of 732
PARADIP REFINERY

(HVGO PUMP)
AVU
Production HVGO PUMP &

HAZARDS INVOLVED:
SL.
.
1 HVGO PUMP Use PPEs

Page 590 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 591 of 732
PARADIP REFINERY

Page 592 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
to C7.
2 Isolate seal plan 32, 52, 62.
√
Isolate SP52 vent to flare.
hunter.
√
of the pump.
√
suction.
√

Page 593 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
10 Slowly flush pump with FLO to √

Page 594 of 732
PARADIP REFINERY

Potential
.
JEA JEA
ensure HVGO is flushed out
from the casing as well as drain
lines.
valve passing.
passing.

Page 595 of 732
PARADIP REFINERY

Potential
.
JEA JEA
possible passing of
work permit.

Page 596 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal plan 32, 52, 62 &
√
maintain steam flow
8 Displace air through suction √

Page 597 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PG drain.
suction pressure.
any.
casing.
14 After achieving temperature in
suction strainer drain line close

Page 598 of 732
PARADIP REFINERY

Potential
.
JEA JEA
draining.
operation.
condition.
substation.
PUMP START UP
PROCEDURE
applicable).

Page 599 of 732
PARADIP REFINERY

Potential
.
JEA JEA
3 Ensure seal plan 32, 52, and 62
√
are in line
√
substation.
√
√
switch board.
√
Ammeter readings.
√
inform to S/I.

Page 600 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
status) from DCS.

Page 601 of 732
PARADIP REFINERY

(RECYCLE OIL PUMP)
AVU
Production RECYCLE OIL PUMP &

HAZARDS INVOLVED:
SL.
.
1 RECYCLE OIL PUMP Use PPEs

Page 602 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA

Page 603 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
to C7.
2 Isolate seal plan 32, 62. √
hunter.

Page 604 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
of the pump.
√
suction.
√
hunter.
√
material.
9 Ensure complete draining by √

Page 605 of 732
PARADIP REFINERY

Potential
.
JEA JEA
observing CBD level / CBD drain
pressure.
√
ensure RO is flushed out from
valve passing.

Page 606 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
possible passing of
17 Handover the pump & strainer

Page 607 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
TAKE OVER PROCEDURE

1
over & handed over by √ √
maintenance
√
are de-blinded.
gasket.
√
properly fixed.

Page 608 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
vents.
6 Line up seal plan 32,62. √
PG drain.
suction pressure.
any.
casing.
12 Open warm valve and displace
casing content to column

Page 609 of 732
PARADIP REFINERY

Potential
.
JEA JEA
draining.
operation.
condition.
substation.
19
Blind pump drain to CBD/OWS.

Page 610 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PUMP START UP
PROCEDURE
applicable).
3 Ensure seal plan 32, and 62 are
√
in line
√
substation.
√
√
switch board.

Page 611 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 612 of 732
PARADIP REFINERY

(VR PUMP)
AVU
Production VR PUMP &

HAZARDS INVOLVED:
SL.
.
1 VR PUMP Use PPEs

Page 613 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 614 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
to C7.
2 Isolate seal plan 32, 52, 62. √
hunter.
√
of the pump.
5 De-blind FLO header at pump √

Page 615 of 732
PARADIP REFINERY

Potential
.
JEA JEA
suction.
√
hunter.
√
material.
√
pressure.

Page 616 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
ensure VR is flushed out from
valve passing.

Page 617 of 732
PARADIP REFINERY

Potential
.
JEA JEA
passing.
possible passing of
work permit.
18

Page 618 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
6 Line up seal plan 32,52,62. √

Page 619 of 732
PARADIP REFINERY

Potential
.
JEA JEA
8 strainer drain to OWS and √
suction PG drain.
suction pressure.
any.
casing.
13 Observe casing temperature. If it
achieves required temperature,

Page 620 of 732
PARADIP REFINERY

Potential
.
JEA JEA
draining.
operation.
condition.
substation.
PUMP START UP
PROCEDURE

Page 621 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
3 Ensure seal plan 32,52 and 62 are
√
in line
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 622 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
√
status) from DCS.

Page 623 of 732
PARADIP REFINERY

(HOT WELL OIL PUMP)
AVU
Production HOT WELL OIL PUMP &

HAZARDS INVOLVED:
SL.
.
1 H2S EXPOSURE Use PPEs
2 PUNGENT SMELL Use PPEs

Page 624 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 625 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
2 De-blind the OWS drain of the

√
pump.
√
4 Depressurize to flare. √
5 Drain entire pump content to

√
OWS.
6 Again close pump drain & vent √
valves to check if pump is

Page 626 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 pump drain to OWS and ensure √
opening PG vent.
8 Provide water connection at
√
pump suction bleeder.
9 Flush pump with water & drain
√
to OWS.
√
possible passing of
12

Page 627 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.

Page 628 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 Displace air through casing vent

√
to flare.
After filling is over close vent &
8 allow pressurizing the pump.
√
suction pressure.
√
any.
operation.
substation.

Page 629 of 732
PARADIP REFINERY

Potential
.
JEA JEA
substation.
PUMP START UP
PROCEDURE
applicable).
√
substation.
√
√
switch board.

Page 630 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

(SOUR WATER PUMP)
AVU
Production SOUR WATER PUMP &

Page 631 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
2 PUNGENT SMELL Use PPEs
Do’s & Don’ts:

SL
No Do’s Don’ts
.

Page 632 of 732
PARADIP REFINERY

area
PRE START CHECK:

Potential
. JEA JEA

DETAILED STEPS:

Page 633 of 732
PARADIP REFINERY

Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
√
hunter.

Page 634 of 732
PARADIP REFINERY

Potential
.
JEA JEA
material.
√
pressure.
valve passing.
9 is not increasing, then it is √
passing.

Page 635 of 732
PARADIP REFINERY

Potential
.
JEA JEA
11 /cooling water. Isolate seal pot
vent to flare.
12 Isolate SP-32 / SP 62

possible passing of
work permit.

Page 636 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.

Page 637 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent to flare.
√
flow.
8 Slowly open equalization of
√
suction valve & fill.
PG drain.
10 & allow pressurizing the pump.
suction pressure.
any.
casing.

Page 638 of 732
PARADIP REFINERY

Potential
.
JEA JEA
14 some time to achieve system
temperature
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW

Page 639 of 732
PARADIP REFINERY

Potential
.
JEA JEA
4 Line up SP-32 / SP-62&
√
√
substation.
√
√
switch board.
√
Ammeter readings.
inform to S/I.
11 Ensure remote monitoring
system healthiness

Page 640 of 732
PARADIP REFINERY

Potential
.
JEA JEA
status) from DCS.

Page 641 of 732
PARADIP REFINERY

(HAGO PRODUCT PUMP)
AVU
Production HAGO PRODUCT PUMP &

HAZARDS INVOLVED:
SL.
.
1
HOT HAGO AT AUTO IGNTITION Use PPEs
TEMPERATURE
2

Page 642 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 643 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
4 De-blind FLO √

√

Page 644 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
9 Slowly flush pump with FLO to
√
CBD
10 Isolate CBD & open drain to √

Page 645 of 732
PARADIP REFINERY

Potential
.
JEA JEA
OWS. Completely drain out
flushed material.
11 pressurize / temperature is
valve passing.
passing.
14 Isolate seal fluid /seal pot

Page 646 of 732
PARADIP REFINERY

Potential
.
JEA JEA
/cooling water. Isolate seal pot
vent to flare.
vent to flare (SP-32).Isolate SP-
SP 52
possible passing of
work permit.

Page 647 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
vent to flare.
√
flow.

Page 648 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PG drain.
suction pressure.
any.
casing.
temperature

Page 649 of 732
PARADIP REFINERY

Potential
.
JEA JEA
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
4 Line up SP-32, maintain
√
required flow.
√
substation.
√

Page 650 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
switch board.
√
Ammeter readings.
inform to S/I.
status) from DCS.

Page 651 of 732
PARADIP REFINERY

(HAGO PA PUMP)
AVU
Production HAGO PA PUMP &

HAZARDS INVOLVED:
SL.
.
1
HOT HAGO AT AUTO IGNTITION Use PPEs
TEMPERATURE
2

Page 652 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 653 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE

√
warm up B/V.
hunter.
√
of the pump.
4 De-blind FLO √

√

Page 654 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hunter.
√
material.
√
pressure.
9 Slowly flush pump with FLO to
√
CBD
10 Isolate CBD & open drain to √

Page 655 of 732
PARADIP REFINERY

Potential
.
JEA JEA
OWS. Completely drain out
flushed material.
11 pressurize / temperature is
valve passing.
passing.
14 Isolate seal fluid /seal pot

Page 656 of 732
PARADIP REFINERY

Potential
.
JEA JEA
/cooling water. Isolate seal pot
vent to flare.
vent to flare (SP-32).Isolate SP-
SP 52
possible passing of
work permit.

Page 657 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vents.
vent to flare.
√
flow.

Page 658 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PG drain.
suction pressure.
any.
casing.
temperature

Page 659 of 732
PARADIP REFINERY

Potential
.
JEA JEA
substation.
PUMP START UP
PROCEDURE
applicable).
Line up seal pot CW
4 Line up SP-32, maintain
√
required flow.
√
substation.
√

Page 660 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
switch board.
√
Ammeter readings.
inform to S/I.
status) from DCS.

Page 661 of 732
PARADIP REFINERY

(RICH AMINE PUMP)
AVU
Production RICH AMINE PUMP &

HAZARDS INVOLVED:
SL.
.
1 RICH AMINE Use PPEs
2 H2S SATURATED LIQUID Use PPEs

Page 662 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA


Page 663 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
2 Isolate pump minimum

√
circulation C/V.
De-blind the casing vent & drain
4 to ABD. remove suction / √
discharge open drain end flange.
√
ABD. Ensure complete draining

Page 664 of 732
PARADIP REFINERY

Potential
.
JEA JEA
by observing pump discharge /
suction pressure and from open
drain.
Again close pump drain valves to
√
flush the pump with water
8 initially to ABD & than to open.
√
Provide water hose connection
at pump suction line drain
accordingly.
√
possible passing of

Page 665 of 732
PARADIP REFINERY

Potential
.
JEA JEA
work permit.
pump if required.
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.

Page 666 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
properly fixed.
√
vent.
Crack open suction valve & vent
7 to atmosphere through casing √
vent.
8 pressurize the pump. Ensure the √
√
any.

substation.

Page 667 of 732
PARADIP REFINERY

Potential
.
JEA JEA
PUMP START UP
PROCEDURE
applicable).
√
substation.
√
√
switch board.

Page 668 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
Ammeter readings.
√
inform to S/I.
status) from DCS.

(RICH AMINE PUMP)
Production RICH AMINE PUMP AVU
&

Page 669 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
1 RICH AMINE Use PPEs
2 H2S SATURATED LIQUID Use PPEs
Do’s & Don’ts:

SL Do’s Don’ts
No

Page 670 of 732
PARADIP REFINERY
.
area
PRE START CHECK:

Potential
. JEA JEA

DETAILED STEPS:

Page 671 of 732
PARADIP REFINERY

Potential
.
JEA JEA
HANDOVER PROCEDURE
2 Isolate pump minimum

√
circulation C/V.
De-blind the casing vent & drain
4 to ABD. remove suction / √
discharge open drain end flange.
√
ABD. Ensure complete draining
6 by observing pump discharge / √
drain.
7 Again close pump drain valves to √

Page 672 of 732
PARADIP REFINERY

Potential
.
JEA JEA
flush the pump with water
8 initially to ABD & than to open.
√
Provide water hose connection
at pump suction line drain
accordingly.
√
possible passing of
work permit.
pump if required.

Page 673 of 732
PARADIP REFINERY

Potential
.
JEA JEA
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.

Page 674 of 732
PARADIP REFINERY

Potential
.
JEA JEA
vent.
√
any.

substation.
PUMP START UP
PROCEDURE

Page 675 of 732
PARADIP REFINERY

Potential
.
JEA JEA
applicable).
√
substation.
√
√
switch board.
√
Ammeter readings.

Page 676 of 732
PARADIP REFINERY

Potential
.
JEA JEA
inform to S/I.
status) from DCS.
SOP For: HANDOVER/TAKEOVER/STARTUP OF 010-P-035 A/B /

010-P-036 A/B (SEAL FLUID PUMP)
AVU
Production SEAL FLUID PUMP &


Page 677 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
1 HOT FLUID Use PPEs
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Page 678 of 732
PARADIP REFINERY

Potential
. JEA JEA

DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
1 Stop lube oil AOP & its inter

√
cooler CW.
3 Isolate seal plan 52 & its CW √

Page 679 of 732
PARADIP REFINERY

Potential
.
JEA JEA
4 De-blind pump casing vent &
√
drain to CBD/OWS.
√
CBD. Ensure complete draining
drain.
Again close pump drain / vent
√
getting pressurize is increasing
by the way of any valve passing.
8 drain completely to OWS & √
open PG drain.

Page 680 of 732
PARADIP REFINERY

Potential
.
JEA JEA
possible passing of
√
pump if required.
11 De-cable motor & give clearance
√
to remove motor.
work permit.
13 in presence of production / √
TAKE OVER PROCEDURE

maintenance
√
are de-blinded.

Page 681 of 732
PARADIP REFINERY

Potential
.
JEA JEA
gasket.
4 Ensure motor is place / cabled &
√
direction of rotation is checked.
5 Ensure motor is coupled &
√
coupling guard is properly fixed.
√
vent.
vent.
√
any.

Page 682 of 732
PARADIP REFINERY

Potential
.
JEA JEA
substation.
12 Blind pump drain & vent. √
PUMP START UP
PROCEDURE
applicable).
Line up seal plan 52 systems.
2 Ensure its lube oil level. Line up √
CW.
3 chamber. Line up bearing cooler √
CW
4 Line up CW to AOP lube oil
√
cooler.
5 Start lube oil AOP. Check if it √
has developed pressure. If
required remove air lock from

Page 683 of 732
PARADIP REFINERY

Potential
.
JEA JEA
LO cooler.
√
substation.
√
√
switch board.
Maintain pump minimum flow,
10 if required open min. √
Circulation C/V.
√
Ammeter readings.
√
inform to S/I.

Page 684 of 732
PARADIP REFINERY

Potential
.
JEA JEA
system healthiness
status) from DCS.

Page 685 of 732
PARADIP REFINERY
SOP For: HANDOVER/TAKEOVER/STARTUP OF 010-P-

102/202/103/203 (DESALTER WATER PUMP)
AVU
Production DESALTER WATER PUMP &

HAZARDS INVOLVED:
SL.
.
1 HOT FLUID Use PPEs

Page 686 of 732
PARADIP REFINERY
SL.
.
3
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA

Page 687 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 688 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
HANDOVER PROCEDURE
2 Isolate sealing water (Ex P01) √
3 De-blind pump casing vent &

√
drain to OWS.
√
OWS. Ensure complete draining
drain.
Again close pump drain valves to
√
7 If isolation valves are holding, √

Page 689 of 732
PARADIP REFINERY

Potential
.
JEA JEA
drain completely to OWS &
open PG drain.
√
possible passing of
work permit.
√
pump if required.
11 in presence of production / √
TAKE OVER PROCEDURE
1 Ensure pump maintenance job is √ √


Page 690 of 732
PARADIP REFINERY

Potential
.
JEA JEA
maintenance
√
are de-blinded.
gasket.
√
properly fixed.
√
vent.
vent.
√
any.

Page 691 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
substation.
11 Blind pump drain & vent. √
PUMP START UP
PROCEDURE
applicable).
3 Line up sealing water. √

√
substation.
√

Page 692 of 732
PARADIP REFINERY

Potential
.
JEA JEA
√
switch board.
√
Ammeter readings.
√
inform to S/I.
√
status) from DCS.

Page 693 of 732
PARADIP REFINERY
SOP For: HOT / COLD WATER WASH OF AMINE COLUMN (010-C-

010)
AVU
Production OFF GAS AMINE SCRUBBER WATER WASH &

HAZARDS INVOLVED:
SL.
.
2 RICH AMINE EXPOSURE

Page 694 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Ensure area is barricaded. √
Ensure fire water adaptor is

3 √
correctly installed.

Page 695 of 732
PARADIP REFINERY

Potential
. JEA JEA

Page 696 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Bypass 010-C-010 off gas amine FG header Monitor
1 column by opening bypass valve pressure Inform RSM, UCR,
√ √
and closing inlet / outlet valves fluctuation Indmax
near V-16/17.
2 Stop Lean Amine inlet and
√ √
isolate the CV.
Pump out rich amine to ARU
3 while the column is in √ √
pressurized condition.
4 Drain balance Amine to ABD till
√ √
gas blows off.
Depressurize the column by
5 opening PSV bypass till pressure √ √
floats with flare header.
Pressurize / depressurize the
6 column with nitrogen for
√
removal of residual
hydrocarbons.

Page 697 of 732
PARADIP REFINERY

Potential
.
JEA JEA
7 After PDP is complete,
√
depressurize the column.
8 Isolate the rich amine export
√
control valve.
Connect FW adaptor to make up
9 water in 010-C-010 and take √
water.
On build up of level, start rich
10 amine pump and circulate water
√
with jump over from rich amine
to lean amine.
Drain water intermittently and
11 makeup water to remove dirty √
water.
Ensure area is barricaded
12 properly for safe disposal of
√
drained water since it may
contain H2S.
13 For hot water wash, open steam √
and steam out through PSV

Page 698 of 732
PARADIP REFINERY

Potential
.
JEA JEA
bypass. After few minutes,
venting to be done from column
vent.
For hot water wash continue
14 column water wash as well as √
steaming.
15 Continue water wash till water
√
becomes clear.
SOP No : AVU/121 SOP For: HIGH DP IN COLUMN (CDU COLUMN 010-C-001) Revision No : 06
AVU
Production HIGH DP IN CDU COLUMN 010-C-001 &


Page 699 of 732
PARADIP REFINERY

HAZARDS INVOLVED:
SL.
.
1
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Page 700 of 732
PARADIP REFINERY

Potential
. JEA JEA
1 Inform RSM and UiC /CPNM √
2 Inform Downstream Units. √

Page 701 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Keep on observing the
following parameters and take
necessary action stated below to
keep the column steady.
Parameters to be observed are:
 All the 4 draw temperatures
1 (TPA, Kerosene, LAGO √ √
and HAGO)
 Top temperature
 Top pressure
 Combined heavy naphtha
and light naphtha flows
(FIC1092 + FIC1030)
The above mentioned parameters
to be maintained steady to the
extent possible, by varying
2 column heat duties, COT, CDU
√ √
Overhead AFC fan loads,
compressor load and rundown
flows (LAGO, HAGO and Heavy
naphtha), as required.

Page 702 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Reduce the crude flow to the
Column by 50 MT/hr by reducing
3 flow through furnace. Adjust
√ √
firing in the furnace accordingly
to maintain the same Coil outlet
temperatures.
For being able to reduce the
furnace outlet flows, pre flash
4 vessel V-003 is needed to be √ √
operated at healthy level of range
55-60%.
After reducing crude flows into
the column, if the disturbance gets
controlled within the operating
limits of level of pre flash vessel,
5 throughput reduction is not √ √
required. Else, crude throughput
at the battery limit needs to be
reduced to keep healthy level in
V-003.
6 Since heavier fractions being up- √ √
lifted to V005, in uncontrolled
manner, which causes the increase
of light and heavy naphtha flow

Page 703 of 732
PARADIP REFINERY

Potential
.
JEA JEA
combined, two actions are
considered to keep top conditions
under control.
1. Cut the heavy naphtha flow, to
preserve the quality of naphtha
going downstream.
2. Increase column top pressure
to prevent the vaporization of
heavier and promote
condensation. This will also
help is lower vapor velocity
due to increase in vapor
density.
Reduce TPA Internal Reflux, to
7 less than 400 T/hr to control Delta
√ √
P across the zone, also, to
maintain level in TPA draw tray.
TPA pump around flow to be
maximized through E-104/204 to
maintain top temperature. This
8 will increase liquid flow in Tray-1 √ √
to 4 but since we are not facing
any DP increase in the section, it
should be fine.

Page 704 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Maximize the LAGO and HAGO
9 pump around duties to reduce
√ √
vapor flow along the column up to
kerosene zone.
Try to not to reduce kerosene
internal reflux flow beyond 200
10 T/hr, unless the level falls to 3 % √ √
and continues to stay at that value
for more than 5 minutes.
Adjust LAGO and HAGO product
rates to maintain the liquid level
11 in the trays. Inform DHDT panel √ √
accordingly to adjust hot feed
rate.
Once the level in kerosene tray is
12 observed, slowly start restoring
√ √
the kerosene IR, LAGO and
HAGO rundown flows.
13 If not successful, reduce crude
√ √
throughput further.
Reduce Stripping steam to C-001
14 and reduce COT by 4-5 Deg C to
√ √
reduce vapor flow in the column
and try to stabilize the column.

Page 705 of 732
PARADIP REFINERY

Page 706 of 732
PARADIP REFINERY
SOP No : AVU/122 SOP For: SIMULTANEOUS FAILURE OF 3 VR PUMPS Revision No : 06

AVU
Production 010-P-025 A/B/C &

HAZARDS INVOLVED:
SL.
.
1 HIGH VR FLOW/LEVEL

Page 707 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 Inform RSM and UiC /CPNM √
2 Inform Downstream Units. √

Page 708 of 732
PARADIP REFINERY

Potential
. JEA JEA
DETAILED STEPS:
Potential
.
JEA JEA
Inform units, RSM, Unit In-
1 Charge, CPNM, HOD and CGM √ √
(T)
2 Reduce crude throughput
√ √
gradually as per SOP
3 Crude mix to be altered to
√ √
lighter grade if feasible
During feed reduction, maintain
4 CDU furnace COT and CDU
√ √
operating parameters and
reduce VDU furnace COT.
5 When VDU column bottom level √ √
reaches up to trip value of 010-
LZT-3023, ensure Stripping
Steam 010-XZV-3002 to VDU
Column is closed and Vent 010-

Page 709 of 732
PARADIP REFINERY

Potential
.
JEA JEA
XZV-3003 is opened as per
Interlock (IZ-0310).
Close stripping steam C/V (010-
6 FV-3007) and isolate the
√ √ √
individual isolation valves (2
nos.) near column body.
Initially route RCO to E-127-F-K
and E-227-F-K to VR rundown
circuit and finally route to DCU
tank/DCU hot feed in
7 consultation with DCU panel.
√ √ √
During routing of RCO to DCU
hot/cold feed, inform DCU panel
about changes in feed quality.
Ensure RCO temperature at B/L
is < 200 deg. C.
CDU standalone operation to be
restricted and maintained by
8 adjusting crude t’put, COT, RCO √ √ √
R/D flow and downstream unit
t’put.
9 During routing of RCO to DCU √ √ √
feed tank/hot feed, if CDU level

Page 710 of 732
PARADIP REFINERY

Potential
.
JEA JEA
gets distributed (gets high),
ensure tripping of stripping
steam XZV (010-XZV-1027).
Manually open XZV-9301/1528
in CDU furnace LP steam
header. In case
a) CDU bottom level is
manageable, within short
period of time, start
stripping steam as per
SOP.
b) If level is not healthy, go
for CDU hot circulation
as per SOP.
When RCO flow is established
fully towards E-127 F-K and E-
227 F-K, close the individual
pass flow control valves in VDU
10 furnace and start coil purging √ √ √
steam (3-5 MT/hr. per pass).
Ensure that the coil purging
steam is free of condensate,
before charging in furnace.

Page 711 of 732
PARADIP REFINERY

Potential
.
JEA JEA
When coil purging is started
11 gradually cut ejectors one by
√ √ √
one and break vacuum with
Nitrogen.
When Coil outlet temperatures
12 of F-002 are about 200 Deg C
√ √ √
stop coil purging steam in all
the coils.
Stop product routing from VDU
13 section and inform to all √ √
affected units.
After breaking column vacuum,
try to restart bottom pump. If
VR flow is established, Vacuum
Column bottom to be gradually
14 emptied out to DCU tank/Heavy
√ √ √
Slop tank in VR rundown circuit.
Simultaneously, establish VDU
cold and hot circulation
followed by CDU/VDU startup
as per SOP.
15 If VR bottom pump is not √ √
available for a long duration of

Page 712 of 732
PARADIP REFINERY

Potential
.
JEA JEA
time (mechanical failure), then
go for FLO dilution in pump
around and internal reflux lines.

Page 713 of 732
PARADIP REFINERY
SOP No : AVU/123 SOP For: TAKE OVER OF E-127 / 227 A-E & F-K Revision No : 06
AVU
Production 010-E-127 / 227 A-E & F-K &

HAZARDS INVOLVED:
SL.
.
Leakages from flanges where gaskets were Check for leakages & arrest the same. Carry gas detectors
1
replaced.
Contact with hot fluids due to leakage during check complete box-up and do leak check before taking in line.
2
exchanger line-up
Contact with hot surfaces during line-up Use heat resistant hand gloves
3

Page 714 of 732
PARADIP REFINERY
Do’s & Don’ts:

SL
No Do’s Don’ts
.
1 Inform to panel before going to line-up Don’t bypass any line-up procedure
2 Do tool box talk before start the job
area
3 Use proper PPE’s/IFR suit Don’t keep open any drains to atmosphere in open condition
PRE START CHECK:

Potential
. JEA JEA
Passing of
Ensure complete box-up and close √ √
1 block
all drain points/vents. valves
Depressu
rize
through
Connect air hose connection and LPD’s to
2 do leak check (with 5.0Kg/cm2 remove √ √
pressure) for all disturbed flanges. water(avo
id water
entrainm
ent)

Page 715 of 732
PARADIP REFINERY

Page 716 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 De-blind FLO for both shell and FLO valve √
Check in LPD
tube side for filling. Passing
Provide hose connection at both
2 side vents (Ensure separate hose
Trip / Fall Use proper PPEs √ √
for E-227 A / C /E shell side and
Tube side HPVs).
Fill both side with FLO &
3 displace air through vents. Ensure FLO fill up
FLO Spill
(ensure air removal in all HPVs slowly
separately)
Drain both side material to CBD
to ensure that it is free from
4 water. If water exists, drain √
more & subsequently fill with
FLO.
Close vents & Pressurize both
5 sides with FLO, 7 kg / cm2
Trip / Fall Use proper PPEs √
pressure. Do leak test of both
side de-blinded flanges.

Page 717 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Close & end
6 blind/plugged for Trip / Fall Use proper PPEs √
both side vents.
Inform to panel (as well as DCU)
and Slowly line up cold side
fluid outlet isolation valve and Lighter
material may
7 then inlet. Do not close its FLO replacement to √
cavitate √
bypass. Observe DCU feed
be done slowly.
flow/temperature changes and pump
Monitor furnace inlet
temperature / vibration.
Then Slowly line up hot side
fluid outlet isolation valve and
8 then inlet. Do not close its √ √
bypass. Observe
flow/temperature changes.
When reaches 80% opening of Flange Leak
9 cold side and 50% hot side, then due to Activity to be
√
slowly close cold side bypass. thermal carried out slowly.
expansion
10 After above step, slowly increase Flange Leak Activity to be √ √

Page 718 of 732
PARADIP REFINERY

Potential
.
JEA JEA
hot side flow. Take sufficient
due to
time for opening hot side.
thermal carried out slowly.
Observe flow/temperature expansion
changes.
When coil purging is started
11 gradually cut ejectors one by
√ √
one and break vacuum with
Nitrogen.
When Coil outlet temperatures
12 of F-002 are about 200 Deg C
√
stop coil purging steam in all
the coils.
13 If found ok, then close hot side
bypass slowly till 80%. √ √
14 Finally open cold side flow 100%

√
and close bypass completely.
15 Hot bolting to be done as per
requirement. Hot Surface Use PPEs √
16 After hot bolting open hot side √

flow 100% and close bypass
completely. Blind

Page 719 of 732
PARADIP REFINERY

Potential
.
JEA JEA
FLO/CBD/OWS lines.

Page 720 of 732
PARADIP REFINERY
SOP No : SR-LPG/124 SOP For: PRE WASH CAUSTIC CHANGE Revision No : 06

AVU
Production 011-C-002 &

HAZARDS INVOLVED:
SL.
.
1 Caustic Exposure Use PPEs
2 LPG Exposure Use PPEs
3 H2S Exposure Use PPEs

Page 721 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
Ensure Battery limit caustic valve √ √
1
is lined up.
Ensure caustic pump 011-P-004
2 √ √
A/B is energized.
Ensure CCBD Vessel is lined up to
3 flare and CCBD Vessel inlet valve √
is lined up.

Page 722 of 732
PARADIP REFINERY

Potential
. JEA JEA
4 Ensure CCBD Pump is energized. √

Page 723 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
Open XZV-003 and Open LV-
1 0011 to drain caustic from Pre √
wash Section to CCBD.
2 Monitor CCBD Pressure for any
√
high rate of caustic draining.
3 Drain caustic till 20% level in LT
√
and cross check with LG.
After sufficient draining stop
4 draining and make the system √
ready for caustic makeup.
Start 11-P-004 and take caustic
5 in prewash section till sufficient √
level.
6 Add water as per requirement. √
7 Stop pump. √

Page 724 of 732
PARADIP REFINERY
SOP No : SR-LPG/125 SOP For: CAUSTIC DRAINING Revision No : 06

AVU
Production 011-C-001/2 &

HAZARDS INVOLVED:
SL.
.

Page 725 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 flare and CCBD Vessel inlet valve √ √
is lined up.
2 Ensure CCBD Pump is energized. √ √

Page 726 of 732
PARADIP REFINERY
DETAILED STEPS:
Potential
.
JEA JEA
1 Inform panel engineer before √ √
starting the job.
2 Carry gas meter and walkie- √
talkie along with you.
3 Get confirmation of level from √ √
local level gauge & from panel.
4 Panel engineer will constantly √
observe the boot water level.
Stand up-stream of the wind
5 √ √
direction. Second person should
present at nearby.
6 Full open 1st isolation valve √
7 Crack open 2nd valve. Observe √

draining.
In-case 2nd isolation valve does
8 √
not close due to formation ice,
close 1st isolation valve fully.
9 Do not leave the place when HC √ √
is being drained. If any

Page 727 of 732
PARADIP REFINERY

Potential
.
JEA JEA
abnormality is observed,
draining is to be stopped and it is
to be informed to shift in-
charge.
After draining is over, isolate the
10 drain valves. Ensure that the √ √
valves are holding, leave the
place. Inform panel engineer

Page 728 of 732
PARADIP REFINERY
SOP No : SR-LPG/126 SOP For: CAUSTIC HANDLING Revision No : 06

AVU
Production 011-C-001/2 &

HAZARDS INVOLVED:
SL.
.

Page 729 of 732
PARADIP REFINERY
SL.
.
4
Do’s & Don’ts:

SL
No Do’s Don’ts
.
area
PRE START CHECK:

Potential
. JEA JEA
1 flare and CCBD Vessel inlet valve √ √
is lined up.
2 Ensure CCBD Pump is energized. √ √
DETAILED STEPS:

Page 730 of 732
PARADIP REFINERY

Potential
.
JEA JEA
1 Inform ETP SI & Pump out √ √
CCBD content to ETP.
2 Use face shield & full body √ √
apron. Use rubber hand gloves.
Drain spent caustic from
vessel/column slowly. Observe
CCBD level. Run CCBD pump
continuously. Ensure that
3 caustic level does not fall below √
20%. Draining to be done
slowly. Drain line to be touched
and temperature to be
monitored. If LPG passes then it
will turn cold.
After draining is over, line up
4 √
pump P4 suction. Ask utility to
run their pump.
Ensuring battery limit pressure,
5 √ √
start booster pump & replenish
as required.

Page 731 of 732
PARADIP REFINERY

Potential
.
JEA JEA
Ask utility to stop their pump
6 after replenishment is over. √
Confirm it from our battery limit
pressure.
7 Check for any leakage. Fix, if √ √
any.

Page 732 of 732

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INDIAN OIL CORPORATION LIMITED

SOP No : AVU/001 SOP For: PREPARATION FOR LIGHTING UP OF BURNERS Revision No : 06

PPE’s Required Tools required Think & discuss JSA Requirement

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

PRE START CHECK:

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

SOP No : AVU/002 SOP For: PILOT BURNERS LIGHT UP Revision No : 06

PPE’s Required Tools required Think & discuss JSA Requirement

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

PRE START CHECK:

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

SL Action to be taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

SOP No : AVU/003 SOP For: FUEL GAS BURNERS LIGHT UP Revision No : 06

PPE’s Required Tools required Think & discuss JSA Requirement

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

 Hand Gloves  Fire Extinguisher  Nearby MCP

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Use face shield, heat resistance hand gloves, heat resistant

PRE START CHECK:

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

SOP No : AVU/004 SOP For: FUEL OIL BURNERS LIGHT UP Revision No : 06

PPE’s Required Tools required Think & discuss JSA Requirement

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Do’s & Don’ts:

PRE START CHECK:

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

SL Action to be taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

PPE’s Required Tools required Think & discuss JSA Requirement

Do’s & Don’ts:

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

PRE START CHECK:

1 Ensure other burners are available. Low COT Consult Panel √

Ensure work permits are available √ √

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Sl. Action taken by Signature

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

PPE’s Required Tools required Think & discuss JSA Requirement

Prepared By (PNM) Reviewed By (SPNM/CPNM) Approved By DGM (PN)

Do’s & Don’ts:

PRE START CHECK: