Mechanical Maintenance Manual

ISO FORMAT
FOR
JLPL/JMM
6.3 ANNEXURE
Doc. No. : JLPL/JMM

Issue No. : 07
Issue Date : June 01, 2009
Note: This doc. is the exclusive property of JLPL, GAIL. Any form of its reproduction/ copy in part or
in full without the written permission of the Management (JLPL,GAIL) is prohibited .
JAMNAGAR-LONI LPG PIPELINE

GAIL (INDIA) LTD.
A-3, 3RD FLOOR, CRYSTAL MALL, SAWAI JAISINGH HIGHWAY
BANIPARK, JAIPUR-302016
TEL. NO. 0141-5118530, 5118531 FAX NO. 0141-2205636
Issue No. : 07 Rev. No. : 00
Jamnagar - Loni LPG Pipeline System
Issue Dt. : June’01 , 2009 Rev. Dt. : 00
Maintenance Manual (Doc. No.: JLPL/JMM)
Jamnagar-Loni LPG Pipeline System

SWITCHYARD MAINTENANCE (FOR 862)
iz- ,oa vuq- csl O&M Base: Format No. : EM-02
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad / Date :---------------
SUPPLY VOLTAGE LEVEL : FUNCTION LOCATION:
ACTIVITES OBSERVATION READING
I PHYSICAL CHECK OF :
1 LIGTHNING ARRESTOR- L1 Counter reading
2. LIGTHNING ARRESTOR- L2: Counter reading
3. LIGTHNING ARRESTOR- TR1: Counter reading
4. LIGTHNING ARRESTOR- TR2: Counter reading
5. CURRENT TRANSFORMER L1: IR value
6. CURRENT TRANSFORMER L1-GEB: IR value
7. CURRENT TRANSFORMER L2: IR value
8. CURRENT TRANSFORMER L2-GEB: IR value
9. CURRENT TRANSFORMER TR1: IR value
10.CURRENT TRANSFORMER TR2: IR value
11.CURRENT TRANSFORMER B/C: IR value
12.VOLTAGE TRANSFORMER L1: IR value
13.VOLTAGE TRANSFORMER L2: IR value
14. ISOLATOR -101 Arching Horn and rod gap
A. Operation check
B. Tightness check Contact Resistance
A. Operation check
A. Operation check
A. Operation check
A. Operation check
A. Operation check
A. Operation check
A. Operation check
A. Operation check
A. Operation check
Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 2 of 94

24. NGR –TR-01 Resistance

A. Tightness check IR Value
25. NGR –TR-02 Resistance
A. Tightness check IR Value
JUNCTION / MARSHLING BOXES:
A. Vermin Proof
B. Bolt Missing
EARTHING CONTINUITY CHECK:
A. STRUCTURE
B. BODY
Sr. No. ekunaM / Parameters(EMS) Measurable Observation
1
2
Sr. No. ekunaM / Parameters(OHSAS) Safety Adopted Observation
1
2
fVIi.kh / Remarks
iqujh{kk fVIi.kh / Review Remarks
iqujh{kk drkZ / Reviewed By Fujh{k.k drkZ / Inspected By
uke / Name uke / Name
Inuke / Designation inuke / Designation
NOTE: N.A : NOT AVAILABLE N/A : NOT APPLICABLE


HALF YEARLY TRANSFORMER MAINTENANCE
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad / Date :
Transformer No :
RATED KVA VOLTAGE(P/S) CONNECTION/GROUP COOLING
TAP POSITION (OLTC)

OLTC FUNCTION CHECK
1. WINDING CHECKS
A. MEASUREMENT OF LV-HV LV-E HV-E
IR VALUE
B. MEASUREMENT OF R-Y Y-B B-R
RESISTANCE (HV)
RESISTANCE (LV)
2. EARTHING CONTINUITY
NEUTRAL Earth NGR RESISTANCE
BODY-Earth
(NGR) RATED/ACTUAL
3. OIL LEVEL
LOCATION OBSERVATION ACTION
TANK LEVEL INDICATOR
CONSERVATOR INDICATOR
LEVEL GAUGE
4. OIL TEST (BDV Test)
AVERAGE = KV
5. FUNCTIONAL TESTS (TICK APPROPRIATE ONE)
ACTIVITIES OBSERVATION ACTION
A. BUCHHOLZ RELAY
B. OIL LEVEL INDICATOR
3. OIL TEMPERATURE INDICATOR
4. WINDING TEMPERATURE INDICATOR
6. TIGHTENING
A. Terminal
B. Insulator Base
C. Bus Duct
A. Sealing of Bus Duct entry on both Side of wall
B. CORROSION CHECK (EXT.)
INSULATION LEVEL TEST / POLARISATION INDEX
TIME (Min) RY YB BR RN YN BN RE YE BE
(For PI value)
fVIi.kh / Remarks
inuke / Designation inuke / Designation


,p Vh eksVj dk frekgh vuqj{k.k
QUARTERLY MAINTENANCE HT MOTOR
esaVsusal csl /O&M Base: Format No. : EM-04
MAINTENANCE ORDER No. : fnukad / Date :---------------
HT Motor Tag No. : HT MOTOR Name & SL No. :
SL. NO. DESCRIPTION of JOB OBSERVATION ACTION
1 General cleaning of motor
External corrosion effect on

2 Motor
Checking of Ventilation / Cooling

3
Lubrication
4
Condition of Guards for moving

5
parts
Sr. No. Parameters (EMS) Measurable Measurable Measurable Measurable
2
Safety Safety Safety Safety
Sr. No. Parameters (OHSAS)
Adopted Adopted Adopted Adopted
1 Electrical shock
fVIi.kh /Remarks
Inspected By
Reviewed By


ANNUAL HT MOTOR MAINTENANCE

Maintenance Order No.: fnukad / Date :
MOTOR IR WITH CABLE: HT Motor Name & SL No.:
Phase to Earth R-E Y-E B-E Remarks
CABLE IR VALUE (OPT)
MOTOR IR VALUE (OPT )
MOTOR RESIT. (OPT) R-Y Y-B B-R
Maintenance Order No. HT Motor name & SL No.:
Maintenance Order No. HT Motor name & SL No.:
PARAMETERS (OHSAS) Safety Adopted Observations

1. Electric shock
fVIi.kh / Remarks
NOTE: AS PER REQUIREMENT FORMAT CAN BE EXPAND TO INCLUDE MORE MOTOR.


QUARTERLY L.T. MOTOR MAINTENANCE
LT MOTOR Name & SL No. :
SL.
DESCRIPTION of JOB
NO. Observation Action
1 General cleaning of motor, panel
External corrosion effect on

2
motor, panel
Checking of Ventilation /
3
Cooling
4 Lubrication (Greasing)
Condition of Guards for moving

5
parts
PARAMETERS (OHSAS) Safety Adopted OBSERVATION
1. Electric shock
fVIi.kh / Remarks:
Fujh{k.k drkZ / Inspected By
iqujh{kk drkZ / Reviewed By

ANNUAL L.T. MOTOR MAINTENANCE

LT Motor Name & SL No:
GEN CLEANING
FAN CLEANING
MOTOR IR WITH CABLE
Phase to Earth
R-E Y-E B-E REMARKS
CABLE IR VALUE (OPTIONAL)
MOTOR RESISTANCE (OPT) U1-U2 V1-V2 W1-W2
ACTIVITIES Observation Action

MOTOR TERMINAL CLEANING, DRYING &
TIGHTNESS
EARTHING
GLANDING
CONTACTOR
a) CONTACT CLANING
b) CONNEC. TIGHTNESS
PUSH BUTTON OPERATION
PANEL TERMINAL TIGHTNESS
FUSE TIGHTNESS/CONTINUITY
BREAKER MAINT.
MOTOR FOUNDATION BOLT TIGHTNESS
CABLE CONN. TIGHTNESS
LUBRICATION
PARAMETERS (OHSAS) Safety Adopted Observation
1. Electric Shock
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By………………………. Fujh{k.k drkZ / Inspected By ………
uke / Name ………………………….……………. uke / Name ………………….
Inuke / Designation …………………………….. inuke / Designation ……………

DG SET- ALTERNATOR MAINTENANCE

DG No.: RH:
SL.
ACTIVITES OBSERVATION ACTION
NO.
1 GENERAL CLEANING
HEALTHINESS OF
2
ROTATING DIODES / FUSES
CHECKING OF INTERNAL
3
CONNECTIONS
CHECKING OF TIGHTNESS
4 OF OUTGOING POWER
CABLE
CONDITION OF GUARDS ON
5
THE MOVING PARTS
CHECKING OF
6
VENTILATION
CHECKING OF EARTH
7
CONNECTIONS
8 PI VALUE
10 IR Value Phase To Phase R-Y Y-B B-R
11 IR Value Phase to Earth R-N Y-N B-N
INSULATION LEVEL TEST / POLARISATION INDEX
TIME RY YB BR RN YN BN RE YE BE
(Min)
(For PI
value)
1
10
10/ 1
Min
NOTE: Observe PI value of each phase with respect to Earth with all other phases earthed
MEASUREMENT OF NGR RESISTANCE

RATED VALUE: ACTUAL VALUE
1. Electric shock
2.

Uke / Name uke / Name


QUARTERLY HT & LT PANEL MAINTENANCE
PANEL No. :
SL. QUARTER-
DESCRIPTION OF JOB
NO. Observation Action
1 General Cleaning
2 Weather Protection
3 Dust & Vermin proofness
4 External Damage
5 Control supply availability

6 Corrosion effect (External)
7 Functioning of meters
Functioning of indication
8
lamps
9 Correctness of Relay Setting

PARAMETERS (OHSAS)
Safety Adopted Observations
1. Electric Shock
2.
fVIi.kh / Remarks

ANNUAL HT & LT PANEL MAINTENANCE


MAINTENANCE ORDER No.: fnukad / Date :---------------
PANEL No.
SL.
DESCRIPTION of JOB Observation Action
NO.
1 Interlock Checking
Tightness of cable Connection

2
(Optional)
3 Checking of panel sealing
4 Relay Testing
Meter Calibration and Checking

5
for incomers
Maintenance of Bus coupler and
6
Incomer Breaker
7 Bus and Line PT Maintenance
PARAMETERS (OHSAS) Safety Adopted Observations
1. Electric Shock
fVIi.kh / Remarks

iqujh{kk drkZ / Reviewed By………………………. Fujh{k.k drkZ / Inspected By ………
Uke / Name ………………………….……………. uke / Name ………………….
Inuke / Designation …………………………….. inuke / Designation ……………

ANNUAL HT/LT CIRCUIT BREAKER MAINTENANCE
PANEL NO. :
BREAKER NO.: CUBICLE : TAG NO:
MAKE : MODEL : SL. NO.

NOMINAL CURRENT (IN) NO. OF OPERATIONS:

ACTIVITIES OBSERVATION ACTION TAKEN
I : PHYSICAL CHECK OF
CUBICLE CONDITION
CRADLE
SAFETY SHUTTER
POWER CONTACT (JAW)
SLIDING CONTACT
OPERATING MECHANISM
II MAIN CONTACT RESISTANCE
POLE R Y B
III INSULATION LEVEL : (MAIN POLES)
PH – E
RY YB BR
PH – PH
R Y B
POLE TO POLE (WITH BREAKER OPEN)
IV . AUXILIARY & POSITION CONTACTS OPERATION CHECK:

V. LUBRICATION : (EXCEPT CURRENT CARRYING CONTACT):
ALL METAL TO METAL RUBBING SURFACE PINS ROLLERS NOT REQUIRED
VI . INDICATION LAMP CHECK(TEST POSITION)
VII. FUNCTIONAL CHECK ( TEST POSITION)
VIII. SPARES USED :
PARAMETERS (OHSAS) SAFETY ADOPTED OBSERVATIONS
1.
fVIi.kh / Remarks


UPS MAINTENANCE
PANEL No.
MODULE - I MODULE- II
ACTIVITIES
Observation Action Observation Action
INTERNAL DAMAGES
PITTING OF CONTACTS
(SPECIFIED THE NO.)
VOLTAGE AND WAVE FORMS
TIGHTNESS OF WIRING
CONNECTIONS
OPERATION OF PROTECTIVE
DEVICES AND CHANGEOVER
CIRCUITS
FUNCTIONAL CHECKS
PHYSICAL INSPECTION OF UPS
UPS CLEANING
TIGHTNESS OF ALL FRC

CONNECTIONS
TIGHTNESS OF POWER
CONNECTIONS:
RECTIFIER CONNECTIONS
INVERTER CONNECTIONS
DC FILTER CONNECTIONS
S O A CONNECTIONS
O/P FILTER CONNECTIONS
FUNCTIONING AND DIRECTION

OF ROTATION OF COOLING
FANS
PARAMETERS (OHSAS) SAFETY ADOPTED OBSERVATIONS
1.
fVIi.kh / Remarks



BATTERY MONITORING AND MAINTENANCE
FUNCTIONAL LOCATION No. :
BATTERY TAG NO. : MAKE: TOTAL CELLS:
Bank Terminal Voltage Ambient Temp.
SP. ACID
CELL NO. SP. GRAVITY VOLT ACID LEVEL CELL NO. VOLT
GRAVITY LEVEL
NOTE: TAKE CELL VOLT READING UPTO TWO DECIMAL e.g. 2.24V
Acceptable Range S. Gravity: Cell Voltage:

CABLE TERMINATION COATING APPLICATION
CONDITION OF ACID PROOF FLOORING EXHAUST FAN STATUS

REMOVAL OF BLOCKAGE AT VENT
CELL LEAKAGE
PLUGS
PARAMETERS (EMS) MEASURABLES OBSERVATIONS
1. Electrolyte spillage
Parameters (OHSAS) Safety Adopted Observations
1. Handling of electrolyte
fVIi.kh / Remarks


HALF YEARLY MAINTENANCE OF BATTERY CHARGER
BATTERY CHARGER No.:
SR.
DESCRIPTION Observation Action
No.
PHYSICAL INSPECTION OF
1
CHARGER
2 CHARGER CLEANING
TIGHTNESS OF ALL CONTROL
3
CONNECTIONS
TIGHTNESS OF POWER
4
CONNECTIONS:
5 EXTERNAL DAMAGES
CONDITION OF CONTACTORS &

6
SWITCHES
7 Operation Check of charger Ckt.
Change Over Ckt check.

8
( Emergency Backup)
1. Electric shock
fVIi.kh / Remarks
Fujh{k.k drkZ / Inspected By …
iqujh{kk drkZ / Reviewed By…

HALF YEARLY MOV MAINTENANCE

MOV No.:
SL.
NO. DESCRIPTION OF JOB
Observation Action
1 General Cleaning
Cable Termination Tightness (At

2
MOV & Panel)
3 Earthing Check & Tightness
Push button Operation from Local

4
(Open / Close / Stop)
5 Fuse tightness
6 Position Checking of limit switch
Position checking of torque limit

7 switch
8 Remote operation check
9 Condition of foundation bolt
10 Cable IR value
PARAMETERS (OHSAS) Safety adopted Observation
1. Electric Shock
fVIi.kh / Remarks:
Fujh{k.k drkZ / Inspected By:
iqujh{kk fVIi.kh / Review Remarks :
iqujh{kk drkZ / Reviewed By:


MONTHLY LIGHTING MAINTENANCE
Location:
Month………
Sl. No.
Description Of Job
Observation Action
General Cleaning
1
Illumination in Critical areas

2
Condition of Conduits, Junction

3
boxes
Connections tightness
4
Grounding connections
5
Changeover Circuits
6
(Emergency Lights)
Corrosion Effects
7
Checking of conformity of flame
8
proofness
1. Electric shock
fVIi.kh / Remarks

vFkZfiV dh ekWuhVfajax ,oa vuqj{k.k
MONITORING & MAINTEANCE OF EARTH PIT


Earth Pit Grid
Electrode
Maint No Resistance Conn.
DATE Resistance Remarks Inspected By
Order No. & Type (Should be tightness
(Ohms)
< 1 Ohms)
Electrical (Earth resistance to be measured by 3-pin wenner method)
Make Model Sr. No

Earth resistance meter details
fVIi.kh Remarks:
iqujh{kk fVIi.kh Review Remarks:
iqujh{kk drkZ Reviewed By: fujh{k.k drkZ Inspected By

uke Name : uke Name :
Inuke Designation : inuke Designation :


ANNUAL RELAY TEST REPORT
Functional Location:
UNIT STATION
DEVICE No. FUNCTION
RELAY: CELL
PANEL MODEL
MAKE FIELD SETTING
Sl. No. P.T.RATIO
AUX.VOLTAGE C.T.RATIO/SHUNT
1 Physical Observatio Action 1 Physical Check Observation Action

Check n
a. Device c. Contacts
b. Resetting d. Flag
Lever
2. INSULATION LEVEL CHECK (TOR) 500V Megger
3. DEVICE TEST Value of device test TEST EQUIPMENT
A. Pick Up/ Drop Off Ratio
B. Minimum Operating Value:
SETTING TEST SIGNAL ( )

TEST
TMS/ ACTUAL TIME( )
No. PLUG x PLUG SET MAGNITUDE
SEC
4 CONTACTS OPERATING & CONTINUITY CHECK:

5 TIGHTENING CHECK Observation Action
A. Fixing Screws
B. Terminations
6. RELAY SETTING
A. CHECK SETTING
fVIi.kh / Remarks
iqujh{kk fVIi.kh / Review Remarks Fujh{k.k drkZ / Inspected By
NOTE:. In case of third party testing, Engineer In Charge shall review the report.


HALF YEARLY MAINTENANCE OF RECTIFIERS
Location:
Sl. RECTIFIER 110V/48V/24V
No. Description of Job RECTIFIER 1 RECTIFIER-2
OBSERVATION ACTION OBSERVATION ACTION
1 INPUT VOLTAGE
2 INPUT CURRENT
3 ALARM IF ANY
4 RECTIFIER CLEANING
PHYSICAL
5
INSPECTION
TIGHTNESS OF
6
CONNECTION
1. Electric shock
2.
fVIi.kh / Remarks
iqujh{kk fVIi.kh / Review

Remarks

midj.k ds vuqj{k.k dh foofj.kdk

EQUIPMENT HISTORY SHEET
EQUIPMENT NO: NAME OF STATION:
Job Job Nature Of Job Spare Part

Running Signature of
MO No. Starting Completion Nature Of Fault / Used(With Part
Hours HOD(Elect)
Date Date Inspection Carried Out No. / Part Name)
NOTE:
1. The information needed is as above, however the arrangement of information may vary
depending up on the requirement of equipment / station.
2. Consumption and requirement of spares and consumable shall be reviewed quarterly by

HOD (Elect) and monthly spare consumption shall be prepared for ORM.


CALIBRATION OF PRESSURE SWITCHES (PR/TEMP/ LEVEL)
esaVsusal csl /O&M Base: Format No. : IM-03
Name of Station : fnukad / Date
Tag No. MAINTENANCE ORDER No:

Service : Duration
Increasing / Decreasing :
SET POINT: Range:
Activity Desired Before After
Set
Reset
fVIi.kh / Remarks (Desired Acc= +/- 1% of F.S %)-
iqujh{kk drkZ / Reviewed By: drkZ / Done By:
uke / Name : uke / Name :
inuke / Designation : inuke / Designation :

CALIBRATION OF PSV/TSV
Tag No. : Duration MO No:
Service : Testing Gas :

Increasing / Decreasing :
SET POINT: Range:
Set point Desired Before After
Set
Reset
fVIi.kh / Remarks: (Allowable Blow down <20%)
Iqujh{kk fVIi.kh / Review Remarks
Iqujh{kk drkZ / Reviewed By: drkZ / Done By:


CALIBRATION OF PG/DPG/TG
Tag No. : Duration MO No:

Service : Range:
INPUT OUTPUT / READING
% VALUE BEFORE Adjustment AFTER Adjustment
00
25
50
75
100
fVIi.kh / Remarks: Acceptance limit= +/- 1.5% of FSR


TESTING OF RTD

Tag No: Duration MO No:
Service : Equipment :
Input Receiver Instrument (EU)
Ohms %
Desired Acc:
fVIi.kh / Remarks: Acceptance limit= +/- 1.5% of FSR



CALIBRATION OF PT/DPT /TT/PANEL INSTRUMENTS/INDICATOR
Tag No.: Duration

Service : MO No:
Range: Set Point : (If any used in logic or PLC)-
Input Output (mA) Before (EU) After (EU) Receiver Instr *
EU % (EU) tag-
Desired Acc: 0.5% of FS Actual Error

* Receiver can be - PLC, PIC, FIC, FQY., Recorder, Indicators
fVIi.kh / Remarks:
Strike out which ever is not applicable.


TESTING AND CALIBRATION OF CONTROL VALVE
Tag No.: Duration MO No:

Service : Equipment :
Range: (Travel in mm)
Input * Output Travel in Receiver Instruments (ZT)
mA % mm mA %
Actual Error :
Desired Acc: +/- 2 %
* Receiver can be - PLC, ZT.

fVIi.kh / Remarks
*Input to valve can be output of controller or thru mA source.


TESTING AND CALIBRATION OF LEL DETECTOR
Tag No.: MO no. Duration :

SERVICE : Equipment :
SET POINT: Range:
INPUT OUTPUT / READING
% Methane By
% LEL BEFORE AFTER
volume
Detector Health Check*
Sl No. Activities Ideal (Ohms) Actual (Ohms)
Resistance recorded between

a) 1.5
terminal 1 & 2
b) 1.5
terminal 1 & 3
c) 3.0
terminal 2 & 3
fVIi.kh / Remarks- Erratic or open Ohms is not acceptable -min 1.2 &2.6 Ohms.
• If resistance of detector is not OK, It is to be rejected and replaced with good detector.


TESTING OF PLC AND PLANTSCAPE SCADA SYSTEM
iz- ,oa vuq- csl O&M Base: Format No. : IM-10
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad / Date

Location : MAKE :
ACTIVITY Observation Action Remarks
1) AUTO TESTING
2) TERMINAL TIGHTENED
3) PANEL CLEANED
4) LED INDICATION OF CARDS
5) BATTERY BACKUP
6) REDUNDANCY CHECK:
A) FOR PROCESSOR RACK
B) FOR PROCESSOR RACK POWER
SUPPLY MODULE
C) FOR I/O RACK
6) PLC RELAY PANEL CHECKED

PLANTSCAPE SCADA
MIMIC DIAGNISTICS
TREND COMMUNICATION
CRT Software
HARDWARE
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: fujh{k.k drkZ / Done By:
uke / Name: uke / Name:
inuke / Designation: inuke / Designation :


CALIBRATION OF VIBRATION MONITOR

Tag No. :
MONITOR SCALE: PROBE No.:

PROXIMITOR No.: EXTENSION CABLE No.:
MONITOR TYPE: TEST EQUIPMENT USED:
INPUT (micron) MONITOR READING
DESIRED BEFORE AFTER
GAP VOLTAGE
Voltage
(mm)
ALARM CHECKING:
SET POINT BEFORE ADJ. AFTER ADJ.

(ACTUAL)
ALERT
DANGER
FLOAT DETAILS: (APPLICABLE FOR AXIAL VIBRATION PROBES ONLY)
INSTRUMENTATION FLOAT MECHANICAL FLOAT
fVIi.kh / Remarks: Acceptance limit= +/- 0.5 of FSR

Float check only if Mechanical is checking.


METER PROVING REPORT
easuVsaUl vkns’k la[;k
fnukad / Date
Maintenance Order No. :
Company Location GAIL,
Meter details:
Tag No.: Serial Number: Meter Size: Meter Model: CMF
Average Meter Flow Rate : Kg/Hr
Accuracy Limit = +/- 0.2%
+/- 0.05% +/- [ ½ (Zero Stability /
Repeatability Limit= Flow Rate) * 100 ] = +/ - %
Zero Stability for CMF =
Data From Consecutive Prover Runs:
Meter Factor =
Prover Run Number 1 2 3 4 5 Average
Prover Mass in Kg
Meter Mass in Kg
Meter Factor (Prover Mass/Meter Mass)
% Accuracy = ( (Average Prover Mass - Average Meter Mass) / Average Prover Mass ) * 100
% Repeatability = ( ( Maximum Meter Mass - Minimum Meter Mass) / (Minimum Meter Mass) * 100
Implementation of New Meter Factor required YES/NO
Data From Consecutive Prover Runs after Implementation of New Meter Factor:
Meter Factor =
Prover Run Number 1 2 3 4 5 Average
Prover Mass in Kg
Meter Mass in Kg
Meter Factor (Prover Mass/Meter Mass)
% Accuracy = ( (Average Prover Mass - Average Meter Mass) / Average Prover Mass ) * 100
% Repeatability = ( ( Maximum Meter Mass - Minimum Meter Mass) / (Minimum Meter Mass) * 100
Note: System Printout report considering above meter factors are enclosed as Annexure 1 & 2.
Tested By : M/s
Witnessed By :


LIST OF FIELD INSTRUMENTS
esaVsusal csl /O&M Base Format No. : IM-15
Sl TAG RANGE/Set FREQ

Make Model Ref Doc
No. NUMBER Point Location of cal
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: drkZ / Prepared By:

LIST OF INSTRUMENTS NOT COVERED UNDER CALIBRATION
Sl TAG NO. IF MAKE LOCATIO

INSTRUMENT MODEL
No. ANY N
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: fujh{k.k drkZ / Prepared By:
uke / Name:. uke / Name:
inuke / Designation: inuke / Designation:

LIST OF MASTERS


NEXT CAL CALIBRAT
SL INSTRUM TAG MODEL CAL DONE
FREQ. SR NO DUE ION
NO. ENT NAME NUMBER NO ON
ON HISTORY
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: fujh{k.k drkZ / Prepared By:
uke / Name: uke / Name :


CALIBRATION CERTIFICATE
fnukad / Date
DETAILS OF INSTRUMENT MASTER USED :
TAG NO. & NAME TAG NO. & NAME
MAKE MAKE
LOCATION SERIAL NO.
RANGE MASTER CERTIFICATE
NO.
LEAST COUNT DATE OF CALIBRATION
NEXT DUE NEXT DUE
CALIBRATION OBSERVATION
S/N Standard Value Observed Value Mean Deviation
Input Desired Before After calibration Value
calibration 1 2 3 4
Observed Error :
Permissible Error :
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: fujh{k.k drkZ / Inspected By:


CHECKING OF FIRE PANEL & ASSOCIATED EQPTS
Argonite / CO2 Flooding system
Instrument Total No. Checked
Solenoid valve
Pressure Gauge
Alarm on Panel
Gas release indication
Interlocks
Heat/Smoke Detector
ZONE Total Nos Checked
Zone-1
Zone-2
Zone-3
Zone-4
Zone-5
Zone-6
fVIi.kh / Remarks : Heat/Smoke detector to be replaced if not operated during
checking
iqujh{kk drkZ / Reviewed: drkZ / Prepared By:.


PROCESS INTERLOCKS CHECK
fnukad / Date
Interlock
Failure
Sl Interloc status at Functional Successful, Wiring
remarks, if
No. k No. the time check yes/no checked
any
testing
fVIi.kh / Remarks


HISTORY SHEET FOR MASTER
INSTRUMENT NAME:
TAGNO:
SR NO :
RANGE:
MODEL:
FREQUENCY:
DONE AT: EXTERNAL / INTERNAL
TRACEABILITY: INTERNATIONL/NATIONAL
Sr No Done On Next Due Remarks Sign
fVIi.kh / Remarks
iqujh{kk drkZ / Reviewed By: drkZ / Prepared By:.
inuke / Designation : inuke / Designation:


ckLdsV fQYVj dk vuqj{k.k
BASKET FILTER MAINTENANCE
esaVsusal csl O&M Base: Format No. : MM-02
Equipment No.: fnukad Date :
Man Days: MO No. :
Sr. No. Activities(QMS) Observation Action REMARKS

Check Differential pressure of filter if high
1
clean/ Back flush of filter elements.
2 Check the tightness of the bolts
3 Check the DPT & isolation valves etc.
4 Check drain and vent valves.
Sr. No. ekunaM / Parameters(EMS) Measurable Observation
1 LPG Vent for isolation of equipment.
2 Water consumed for cleaning of Basket.
3 Waste material.
4 Grease, kerosene, etc
Sr. No. ekunaM / Parameters(OHSAS) Safety Adopted Observation
1 LPG Vapor in the basket
2 Work at height
3 LPG Liquid handling
LIST HERE-UNDER ANY EXTRA WORK PERFORMED OR WHICH MAY WARRANT ATTENTION IN FUTURE :
1
SPARES / CONSUMABLES USED
Sr. No. ITEM NAME PART NO. CODE NO. QUANTITY REMARKS
fVIi.kh Remarks
iqujh{kk fVIi.kh Review Remarks
iqujh{kk drkZ Reviewed By: fujh{k.k drkZ Inspected By:
inuke Designation : inuke Designation :

vesajftalh Mh th ,oa Qk;j okVj batu dh foekgh vuqj{k.k

QUARTERLY MAINTENANCE OF EMERGENCY DIESEL ENGINE AND FIRE WATER ENGINE

esaVsusal csl O&M Base Format No. : MM-03
NAME OF EQUIPMENT : fnukad Date
Man Days: RH : MO No. :
Sr.
Activities(QMS) Observation Action Remarks
No.
1 Lubricating Check
For Any Leaks
Engine Oil Level. Top Up If Required.
2 Cooling Check
For Any Leaks
Hose And Connections.
Coolant Level. Top Up If Required.
Concentration Of Coolant
Belt Condition And Tension.
3 Air Intake Check
For Any Leaks
Air Cleaner Restriction Clean / Change
Air Cleaner Element
4 Fuel Check
For Any Leaks
Fuel Level

Sr.
ITEM NAME PART NO. CODE NO. QUANTITY REMARKS
No.
1
Dz0 la0
Sr. No.
EkunaM Parameters(EMS) Measurable Observation
1 Diesel leak.
2 Coolant Leak
3 Quality of Exhaust
4 Heat Emission
5 Sound emission
6 Lubricate leak
Dz0 la0 ekunaM
Sr. No. Parameters(OHSAS)
Safety adopted Observation
1 Lubricate Handling
2 Sound during test operation
3 Hot surface of engine
fVIi.kh Remarks:

vesajftalh Mh th ,oa Qk;j okVj batu dh v/kZ okfZ”kd vuqj{k.k

HALF YEARLY PREVENTIVE MAINTENANCE OF EMERGENCY DIESEL ENGINE AND FIRE WATER ENGINE
NAME OF EQUIPMENT: fnukad Date
Man Days: RH : MO No. :
Sr.
Activities (QMS) Observation Action Remarks
No.
1 LUBRICATING Check (Change If Required) Engine Oil
Check Engine Lube Filter (If Required).
Record Oil Pressure
2 FUEL SYSTEM Check Fuel Supply
Check Throttle Linkage.
Clean Fuel Tank Breather
3 COOLING Check /Change Coolant
Check Coolant Inhibitor (Add. Coolant
Concentrate, If Reqd).
Record Coolant Temperature.
Hose And Connections.
4 AIR SYSTEM Clean / Change Air Filter System.
Check Air Piping.
OTHER Check Any Leaks And Connections.
5 MAINTENANCE
Check Belts, Adjust If Required.

Dz0 la0
Sr. No.
ekunaM Parameters (EMS) Measurable Observation
1 Diesel leak.
2 Coolant Leak
4 Heat Emission
5 Sound emission
6 Lubricants
Dz0 la0
Sr. No.
ekunaM Parameters(OHSAS) Safety adopted Observation
fVIi.kh Remarks:

vesajftalh Mh th ,oa Qk;j okVj batu dh okfZ”kd vuqj{k.k
ANNUAL PREVENTIVE MAINTENANCE OF EMERGENCY DIESEL ENGINE AND FIRE WATER ENGINE


Man Days : RH: MO No. :
Sr. No. Activities (QMS) Observation Action Remarks
1 LUBRICATING Change Engine Oil
Change Engine Lube Filter.
Record Oil Pressure
2 FUEL SYSTEM Clean Fuel Tank From Inside
Check Fuel Supply
Check Throttle Linkage.
Change Fuel Filters.
3 COOLING Check Radiator.
Check Coolant Water Pump.
Check Coolant Inhibitor Add. Coolant
Concentrate, If Required.
Record coolant Temperature.
4 AIR SYSTEM Clean / Change Crank Case Breather.
Check Air Cleaner Restriction.
Clean / Change If Required.
Check Air Piping.
OTHER
5 Check Any Leaks And Connections.
MAINTENANCE
LIST HERE-UNDER ANY EXTRA WORK PERFORMED OR WHICH MAY WARRANT ATTENTION IN
FUTURE :

1
Dz0 la0
Sr. No.
ekunaM / Parameters (EMS) Measurable Observation
1 Diesel leak.
2 Coolant Leak
4 Heat Emission
5 Sound emission
Dz0 la0
Sr. No.
ekunaM / Parameters(OHSAS) Safety adopted Observation
fVIi.kh Remarks:

,p oh , lh dh ekfld vuqj{k.k
MONTHLY MAINTENANCE OF HVAC SYSTEM
esaVsusal csl O&M Base : Format No. : MM-06

Man Days : RH : MO No. :

Sr.
No.
1 Check Oil Level and Top up if required.
Check Oil Pressure (4 Kg / cm2 / 57 PSI above suction
2
pressure).
3 Check Thermostat setting and test loading.
4 Check Gas Pressure & fill if required.
5 Check for any abnormal noise (in running condition).
6 Check for any leakage in oil circuit.
7 Check the refrigerant circuit for leaks.
Check General Condition of Air Cooled Condenser, if
8
required cleaned it.
A.H.U. : UNIT NOS. :
1 Lubricate Bearings / Check For Any Abnormal Noise.
2 Check Drive Belts & Belt Tension, Adjust If Required.
3 Clean both set of filters.(macro and micro).

Sr. No. ITEM NAME PART No. CODE No. QUANTITY REMARKS
1
Dz0 la0
Sr. No.
ekunaM Parameters(EMS) Measurable Observation
1 R-22 leakage.
2 Oil leakage
3 Heat emission
4 Sound emission
Dz0 la0
Sr. No.
ekunaM Parameters(OHSAS) Safety adopted Observation
2 Sound during operation
3 Hot surface of compressor
fVIi.kh Remarks:

,p oh , lh dh okfZ”kd vuqj{k.k
ANNUAL MAINTENANCE OF HVAC SYSTEM
RH : MO No. :
Sr. No. Activities Observation Action Remarks
1 Check The Operating Controls(HP /LP /OP).

2 Replace Compressor Oil With New Oil.

3 Check the suction & discharge valve condition, If
required.
4 Calibration of all gauges
5 Piping System.
A) Check For Any Unusual Piping Vibration.
B) Check For Any Leakage At Joints.
C) Check For Any Corrosion / Rusting.
D) Perform Greasing Of All Valves.
E) Check & Repair The Insulation.
5 Check Thermostat setting and test loading.
6 Check For Any Abnormal Noise.
7 Check Gas Pressure & Fill If Required.
8 Check General Condition Of Air Cooled Condenser .
9 Check Bearing Condition Of Compressors. If required.
Check Piston, Piston Rings, And Cylinders & Clearance
Etc.
10 (If Required) And Record It.
A.H.U. : UNIT NOS. :
a Check Bearings And Change As per vibration analysis.
b Check Drive Belts & Belt Tension And Change If Required.
c Clean The Filters.
d Check The End Play.
Check Housing And Wheel For Rust, Accumulation Of Dirt,
Crack Etc. Which May Cause Unbalance And Excessive
e Vibrations, based on vibration analysis.
f Check And Tighten The Mounting Bolts.
g Check The Pulley Condition And Align.
1
Dz0 la0
Sr. No.
1 R-22 leakage.
2 Oil leakage
3 Heat Emission
4 Sound emission
Dz0 la0
Sr. No.
2 Sound during operation
3 Hot surface of compressor
fVIi.kh Remarks:

okYo dk vuqj{k.k
ANNUAL PREVENTIVE MAINTENANCE OF ALL VALVES
esaVsusal csl O&M Base: Format No.: MM- 08
Valve No. : MO No. : fnukad Date:
{A} MOV OPERATION : Normal / Hard Seat Test :

1. Gear Box : OK / Not OK 3. LPG Leakage : Yes / No 1. Bleed in close : Secs.

2. Lub. Leakage: Yes / No 4. Valve Status in CR: OK / Not OK 2. Bleed in open : Secs.
MOV 3. Valve seat holding
Operation of Valves MOV Manual
Local Remote in close condition : OK/ NOT OK
Close Sec Sec. Sec. 4. Valve seat holding
Open Sec Sec. Sec. in open condition : OK/ NOT OK
{B} MANUAL VALVES
Sr. Bleed in Bleed in Operation Sealant Injection
TYPE OF VALVE Size Remarks
No. close(Sec.) open(Sec.) Smooth / Hard Yes / No
1
2
3
{C} SEAT TEST OF VALVES:
SR. Sealant
TYPE OF VALVE Size Seat Test LPG Escape Final Seat Test Remarks
No. Injection
1 OK / Not OK Normal/ Continuous Yes/No OK / Not OK
{D} OTHER CHECK:
SR.
ACTIVITES OBSERVATION ACTION REMARKS
No.
1 Any LPG Leak from flange : OK / Not OK
2 P/L Support condition No / Yes
Sr.
ekunaM / Parameters(EMS) Measurable Observation
No.
1 Oil leakage through Gear Box
2 LPG Leakage through various points
3 Sealant waste
Sr.
No.
2 LPG Liquid Handling
3 LPG Vapor Handing
fVIi.kh Remarks :
iqujh{kk drkZ Reviewed By: fujh{k.k drkZ Inspected By :

esu Mh th dk foekgh vuqj{k.k
QUARTERLY MAINTENANCE OF MAIN DIESEL ENGINE (TIL MAKE)
NAME OF EQUIPMENT: fnukad Date:
RH: MO No. :
Sr.
No.
1 Check Engine Oil
2 Check Cooling system

3 Check PH of Cooling System and add coolant accordingly.

4 Check Leakage in Fuel system
5 Check /Clean air Filters
6 Check Belts & adjust if Required
7 Check crank Case Breather
8 Check the engine protective devices
9 Record any alarms from the panel.
NOTE: OBSERVATION ON ABOVE POINTS COMMUNICATE TO CONCERN DEPT.

Sr.
ITEM NAME PART NO. CODE NO. QUANTITY REMARKS
No.
Sr.
ekunaM / Parameters (EMS ) Measurable Observation
No.
1 Diesel leak.
2 Coolant Leak
4 Heat Emission
5 Sound emission
Sr.
No.
fVIi.kh Remarks:

esu Mh th dk v/kZ okf”kZd vuqj{k.k
HALF YEARLY MAINTENANCE OF MAIN DG (TIL MAKE)
NAME OF EQUIPMENT: fnukad Date :
RH: MO No. :
Sr. No. Activities Observation Action Remarks
1 Clean Crank case breather
2 Fuel system- drain water, sediments from tank
Linkages- Check and adjust all linkages,
3
if necessary lubricate them.

Engine protection devices -

4
Check/ Test for proper operation.
5 Engine- Wipe down and clean as needed.
6 Clean/ inspect & wash the radiator by water.
Note: Observation on above points communicate to concern dept.
Sr. No. ekunaM / Parameters (EMS) Measurable Observation

1 Diesel leak.
2 Coolant Leak
4 Heat Emission
5 Sound emission
Sr. No. ekunaM / Parameters(OHSAS) Safety adopted Observation
fVIi.kh Remarks:

esu Mh th dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF MAIN DG (TIL MAKE)
EQUIPMENT No. : fnukad / Date :
RH : MO No. :
1 Cooling System
Check Coolant Pump.
Check Coolant PH.
Record Coolant Temperature.
2 Fuel System
Clean Fuel Tank From Inside
Check Fuel Supply

Check /Change Fuel Filters.

Clean return fuel condenser.
3 Lubricating :
Change Engine Oil
Change Lube Oil Filter.
Record Oil Pressure
4 Air System
Clean / Change Crank Case Breather.
Clean Air Inlet filters.
Check Air Piping.
5 Other Maintenance
Check Any Leaks And Connections.
Check end play of crank shaft.
Check Turbo Charger Clearances.


1 Diesel leak.
2 Coolant Leak
4 Heat Emission
5 Sound emission
fVIi.kh Remarks:

,y ih th iEi dk ekfld vuqj{k.k
MONTHLY MAINTENANCE OF BOOSTER PUMP - MOTOR (DT-861)
EQUIPMENT No .: fnukad Date:
RH: MO No. :
1 Check Foundation Bolts & Tighten If Required.
Check Oil Level Of Lube Oil Bearing Housing And Seal
2
Pots, Top up If Required.
3 Check For Any Oil Leakage, Rectify It.
5 Check For Any Major Leakage / Mech. - Seal Leakage

/If Required Repair Or Replace It.

Check Differential Pressure Of Suction Strainer, Clean If
6
Required.

Sr. No. ITE M NAME PART NO. CODE NO QUANTITY REMARKS

1 Lube oil.
2 Seal Oil
fVIi.kh Remarks:
iqujh{kk drkZ Reviewed By: fujh{k.k drkZ Inspected By .
uke Name : uke Name
inuke Designation: inuke Designation

,y ih th iEi dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF BOOSTER PUMP - MOTOR (DT-861)
EQUIPMENT No. : fnukad Date :
RH: MO No. :
1 Replace Oil Of Constant Oiler And Seal Pots.
2 Check The Bearing Housing For Leakage.
3 Clean The Suction Strainer ( LPG)
4 Check Foundation Bolts For Tightness.
5 Check The Mech.-Seal, If Required Replaces It.
6 Clean All Orifices & Drains

7 Clean Balancing Line.

8 Clean All Drains &Lines
Check Alignment Between Pump & Motor And Fill
9
Data – Sheet MM-21.

1 Lube Oil.
2 Seal Oil.
fVIi.kh Remarks :
iqujh{kk fVIi.kh Review Remarks :

,y ih th iEi dk estj vuqj{k.k
MAJOR MAINTENANCE OF BOOSTER PUMP (DT-861)
EQUIPMENT No. : fnukad Date
RH: MO No. :
SR. No. ACTIVITIES (QMS) Observation Action Remarks
1 Replace Oil of Bearing Housing and Seal Pots.
2 Check the Bearing Housing for Leakage.
3 Clean the Suction Strainer ( LPG)
4 Check Foundation Bolts for Tightness.
Carry Out The Complete Overhaul of Pumps
5
and Check The Followings.
a) Check Impeller Ring. Replace If Required.
Check Impeller for Any Corrosion / Pitting /
b)
Dents / Cranks. Replace If Required.
Check Impeller Distance Sleeve for Any
c)
Damage.
Check All Bearings. Must be Free from
d)
Chipping, Cracks, Abrasion, Etc.

e) Check Shaft for Any Cracks / Dents Etc.

Clean All the Components With Diesel /
f)
Kerosene.
7 Check the Mech.-Seal, If Required Replaces It.
8 Clean All Orifices & Drains
9 Clean Balancing Line.
10 Clean All Drains & Lines.
Check Alignment Between Pump & Motor And
11
Fill Data - Sheet MM-21

1 Lube Oil.
2 Seal Oil.
3 LPG (Liquid)
2 LPG Handling.
fVIi.kh Remarks :
iqujh{kk drkZ Reviewed By : fujh{k.k drkZ Inspected By :


,y ih th esu iEi dk ekfld vuqj{k.k
MONTHLY MAINTENANCE OF MAINLINE PUMP (DR-861)
RH : MO No. :
Sr. No. ACTIVITIES (QMS) Observation Action Remarks
CHECK FOUNDATION BOLTS & TIGHTEN IF
1
REQUIRED.
CHECK OIL LEVEL OF LUBE OIL CONSTANT
2 OILER AND SEAL POTS REPLACE IF
REQUIRED.
3 CHECK FOR ANY OIL LEAKAGE, RECTIFY IT.
4 CHECK FOR ANY ABNORMAL NOISE.

CHECK FOR ANY MAJOR LEAKAGE / MECH. -
5 SEAL LEAKAGE /IF REQUIRED REPAIR OR
REPLACE IT.
SPARES / CONSUMABLES USED :

Sr. No. ITE M NAME PART NO. CODE NO. QUANTITY REMARKS

1 Lube Oil.
2 Seal Oil.
3 LPG ( Leakage)
2 LPG handling
fVIi.kh Remarks :
iqujh{kk drkZ Reviewed By : fujh{k.k drkZ Inspected By:


,y ih th esu iEi dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF MAINLINE PUMP - MOTOR (DT-861)
esaVsusal csl /O&M Base Format No. : MM-16
EQUIPMENT No.: fnukad Date :
RH: MO No. :
1 REPLACE OIL OF CONSTANT OILER AND SEAL POTS.

2 CHECK THE BEARING HOUSING FOR LEAKAGE.
3 CLEAN THE SUCTION STRAINER ( LPG)
4 CHECK FOUNDATION BOLTS FOR TIGHTNESS.
CHECK THE MECH.-SEAL, IF REQUIRED REPLACES
5 IT.
6 CLEAN ALL ORIFICES & DRAINS
7 CLEAN BALANCING LINE.
8 CLEAN ALL DRAINS & LINES
CHECK ALIGNMENT BETWEEN PUMP & MOTOR AND
9 FILL DATA – SHEET.MM-21

1 Lube Oil.
2 Seal Oil.
3 LPG (Leakage)
2 LPG handling.
fVIi.kh Remarks :
uke Name: uke Name :
inuke Designation: inuke Designation :

,y ih th esu iEi dk estj vuqj{k.k
MAJOR MAINTENANCE OF MAINLINE PUMP-MOTOR (DT-861)


RH: MO No. :
SR. NO. ACTIVITIES (QMS) OBSERVATION ACTION REMARKS
1 REPLACE OIL OF CONSTANT OILER AND SEAL POTS.
2 CHECK THE BEARING HOUSING FOR LEAKAGE.
3 CLEAN THE SUCTION STRAINER ( LPG)
CARRY OUT THE COMPLETE OVERHAUL OF PUMPS AND
5
CHECK THE FOLLOWINGS.
a) CHECK IMPELLER RING. REPLACE IF REQUIRED.
CHECK IMPELLER FOR ANY CORROSION / PITTING /
b)
DENTS / CRANKS. REPLACE IF REQUIRED.
c) CHECK IMPELLER DISTANCE SLEEVE FOR ANY DAMAGE.
CHECK ALL BEARINGS. MUST BE FREE FROM CHIPPING,
d)
CRACKS, ABRASION, ETC.
e) CHECK SHAFT FOR ANY CRACKS / DENTS ETC.
f) CLEAN ALL THE COMPONENTS WITH DIESEL / KEROSENE.
7 CHECK THE MECH.-SEAL, IF REQUIRED REPLACES IT.
8 CLEAN ALL ORIFICES & DRAINS
9 CLEAN BALANCING LINE.
10 CLEAN ALL DRAINS &LINES
CHECK ALIGNMENT BETWEEN PUMP & MOTOR AND FILL
11
DATA - SHEET (F.MM-21).

1 Lube Oil.
2 Seal Oil.
3 LPG (venting)
4 Solid Waste.
5 Kerocene
2 Seal oil handling
3 LPG handling.
fVIi.kh Remarks :

,y ih th esu ykbu iEi dk ekfld vuqj{k.k
MONTHLY MAINTENANCE OF LPG MAINLINE PUMP-MOTOR (XX-PA-CF-101 A/B/C) AT IPS
EQUIPMENT No.: fnukad Date :
RH: MO No. :

Sr. No. ACTIVITIES (QMS) Observation Action REMARKS
Check Oil Level Of Lube Oil Tank And Seal Pots

2
Replenish If Required.
3 Check For Any Oil Leakage, Rectify It.
Check For Any Major Leakage / Mech. - Seal

5
Leakage /If Required Repair Or Replace It.
6 Clean Seal Oil Cooling Fins And Lube Oil Radiator.
Check Discharge Pressure Of Aux. Lube Oil

7
Pump And Mountings
Check Differential Pressure Of Lube Oil Filter If
8
Required Clean.


1 Lube Oil.
2 Seal Oil.
3 LPG (venting)
2 LPG handling
fVIi.kh Remarks :

,y ih th esu ykbu iEi dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF MAINLINE PUMP - MOTOR (XX-PA-CF-101 A/B/C) AT IPS
RH: MO No. :
1 REPLACE LUBE OIL AND SEAL OIL.

CHECK THE BEARINGS BASED ON

2
VIBRATION ANALYSIS.
3 CLEAN THE SUCTION STRAINER
4 CHECK THE NRV FOR PASSING.

CHECK FOUNDATION BOLTS FOR
5
TIGHTNESS.
CHECK THE MECH.-SEAL FOR LEAKAGE, IF
6
REQUIRED REPLACES IT.
CHECK ALIGNMENT BETWEEN PUMP &
7
MOTOR AND FILL DATA - SHEET MM21
8 CLEAN BALANCING LINE AND ORIFICE.


1 Lube Oil.
2 Seal Oil.
3 LPG Venting.
2 LPG Handling
fVIi.kh Remarks :
uke Name: uke Name :

,y ih th esu ykbu iEi dk estj vuqj{k.k
MAJOR MAINTENANCE OF MAIN PUMP-MOTOR AT IPS (XX-PA-CF-101 A/B/C)
RH : MO No. :

REPLACE OF OIL OF LUBE OIL TANK AND SEAL
1
POTS.
2 CHECK THE BEARINGS.
3 CHECK THE SUCTION STRAINER
4 CHECK THE NRV. (IF IN LINE).


CARRY OUT THE COMPLETE OVERHAUL OF PUMPS
6
AND CHECK THE FOLLOWINGS.
a) CHECK IMPELLER RING. REPLACE IF REQUIRED.
CHECK IMPELLER FOR ANY CORROSION / PITTING /
b)
DENTS / CRACKS. REPLACE IF REQUIRED.
CHECK IMPELLER DISTANCE SLEEVE FOR ANY
c)
DAMAGE.
CHECK ALL BEARINGS. MUST BE FREE
d)
FROM CHIPPING, CRACKS, ABRASION, ETC.
e) CHECK SHAFT FOR ANY CRACKS / DENTS ETC.
CLEAN ALL THE COMPONENTS WITH SPIRIT /
f)
KEROSENE.
CHECK THE MECH.-SEAL, IF REQUIRED REPLACES
7
IT.
CHECK ALIGNMENT BETWEEN PUMP & MOTOR AND
8
FILL DATA - SHEET MM-21

1 Lube Oil.
2 Seal Oil.
3 LPG (venting)
4 Solid Waste.
5 Kerosene
2 Seal oil handling
3 LPG handling.
fVIi.kh Remarks :
iqujh{kk fVIi.kh Review Remarks ;

fofHkUu iEiks dk tujy ,ykbuesaV
ALIGNMENT OF PUMPS
iz- ,oa vuq- csl O&M Base: Format No. : MM-21
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad Date :
RH : PUMP No. :
{A} RECOMMENDED TOLERANCES
Sr
EQUIPMENT TOLERANCES OBSERVATION ACTION
No.
1 DAVID BROWN PUMP 0.05 mm
2 BOOSTER PUMP 0.05 mm
3 RAW WATER PUMP 0.1 mm
4 FIRE WATER ENGINE 0.1 mm
5 JOCKEY PUMP 0.1 mm
6 DIESEL HANDLING PUMP 0.1 mm

{B} FIELD READINGS :

BEFORE ADJUSTMENT AFTER ADUSTMENT
(AXIAL) (RADIAL) (AXIAL) (RADIAL)
{C} COORECTIVE ACTION TAKEN :

1 SHIM THICKNESS ADJUSTED : AT :
fVIi.kh Remarks :


vU; iEiks dk ekfld vuqj{k.k
MONTHLY MAINTENANCE OF WATER & OTHER PUMPS
esaVsusal csl /O&M Base Format No. : MM-22
Equipment No.: fnukad / Date
RH: MO No. :
2 Check Oil Level Replenish If Required.
3 Check For Any Oil Leakage / Grease Leakage.
Check Gland Packing For Any Major

5
Leakage / Mech. - Seal Leakage.

1
2
1
2
ekunaM /
1
2
3
fVIi.kh Remarks :

vU; iEiks dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF WATER & OTHER PUMPS
Equipment No. : fnukad / Date

RH: MO No. :
1 Replace The Oil Of Bearing Housing.
Check The Bearings Based On Vibration
2
Analysis.
3 Clean The Suction Strainer
4 Check The NRV.
5 Check Foundation Bolts For Tightness.
Carry Out The Complete Overhaul Of Pumps
6 And Check
The Followings.
a) Check Impeller Ring. Replace If Required.
Check Impeller For Any Corrosion / Pitting /
b)
Dents / Cracks. Replace If Required.
c) Check Shaft Sleeve For Any Damage.
d) Check Shaft For Any Cracks / Dents Etc.
Clean All The Components With Spirit /
e)
Kerosene.
Check The Mech.-Seal / Gland Packing
f)
If Required Replace It.
Check Alignment Between Pump & Motor ,
8
Fill Data- Sheet (MM21)


1
2
3
ekunaM /
Sr. No.
Parameters(OHSAS)
1
2
3
fVIi.kh Remarks :

psu iwyh Cyksd dk okf”kZd vuqj{k.k
ANNUAL MAINTENANCE OF CHAIN PULLEY BLOCK
RH : Not Applicable MO No. :

1 Complete Overhaul Of C.P. Block.

2 Grease Bearings
Check Hoist Brakes And Do Necessary
3
Adjustments
Check Chain For Any Damages And
4
Lubricate It.
5 Load Test.

1 Kerosene waste.
2 Grease waste
3 Solid waste
2 Load Testing
fVIi.kh Remarks :


lis;j ikVZl dh [kir ,oa vko’;drk
ANNUAL UPDATION OF SPARE PARTS CONSUMED AND REQUIREMENT
EQUIPMENT No. :
Vendor Name & Address:
Part Name
Part No.
Code No.
Available Stock
Consumption of spare
Balance Quantity
Required Quantity
Required Quantity
Shall Last For (YRS)
Additional Information
(If Any)
Remarks
Prepared By
Designation
Date
Review Remarks
Reviewed By
Designation
Date
Note :
(1)Consumption and requirement of spares and consumable shall be reviewed quarterly by HOD(Mech)
(2) Monthly spare consumption shall be prepared for ORM.


midj.k dh foojf.kdk
ANNUAL UPDATION OF EQUIPMENT DATA SHEET
esaVsusal csl /O&M Base : Format No. : MM-26
Vendor Name And Address:
Phone No.
Fax No.
E-mail ID
Equipment Name
Model No.
Serial No.
Year Manufacture
PO No.
Date Of Commissioning
Date Of Commercial Operation
Any Other Information
Prepared By
Name
Designation
Date
Review Remarks
Reviewed By
Name
Designation
Date


midj.k ds vuqj{k.k dh foojf.kdk
ANNUAL EQUIPMENT HISTORY SHEET

esaVsusal csl /O&M Base : Format No. : MM-27
Equipment Name and No.:
Nature Of
Job Spare Part
Job Job Nature Of Used(With
MO Running Prepared Reviewed
Starting Completion Fault / Part No. / Date Date
No. Hours By By
Date Date Inspection Part
Carried Name)
Out


djsDfVo @czsd Mkmu esaufVusal fjiksZV
CORRECTIVE/BREAK DOWN MAINTENANCE REPORT
iz- ,oa vuq- csl O&M Base: Format No. : MM-28
Sl No. Item Description
1.0 Name of Equipment:
1.1 Sub-system:
2.0 Nature of fault:
3.0 Cause of fault:

Date of
4.0
Observation/occurrence:
5.0 Action Details:
Manpower / Machinery
6.0
Used:
7.0 Safety system used:

8.0 SPARES / CONSUMABLES USED
Sr.
No. ITEM NAME PART NO. CODE NO. QUANTITY REMARKS
1
2
3
4
1
2
1
2
fVIi.kh Remarks
Iqujh{kk fVIi.kh Review Remarks :
Iqujh{kk drkZ Reviewed By : fujh{k.k drkZ Inspected By
uke Name : uke Name ;


ikbi ykbZu ,;j losZfy;sal
PIPELINE AIR SURVEILLANCE
iz- ,oa vuq- csl O&M Base: Format No. : PM-02
mm+ku Hkjus dk LVs’ku Take off station: vkxeu LVs’ku Arrival Station:
mm+ku Hkjus dk le; Take off time : vkxeu le; Arrival Time :
Dz0 la0 SIZE/ SHAPE/TYPE fd0 eh0 psust / izs”k.k /

ekunaM / Parameters
S. No. K.M. Chainage Observation
ikbZi ykbZu vukoj.k / Pipeline
1
Exposure
2 e‘nk {kj.k / Soil Erosion
3 vfrdze.k / Encroachment
4 mr[kuu / Excavation
utnhd esa dksbZ fodklRed dk;Z /
5
Development activities nearby
ikbiykbZu ekdZjksa dh fLFkfr /
6
Pipeline Markers Status.
LaknfX/k xSl fjlko fLFkfr /
7
Suspected Gas leak conditions
1 Sound Bearable/ unbearable
Sr. No. ekunaM / Parameters (OHSAS) Safety Adopted Observation
1
2
fVIi.kh Remarks


ykbu okWd isVªksfyax
LINEWALK PATROLLING
easuVsaUl vkns’k la[;k Maintenance Order No. : Date :
Sr. No. Description Chainage Observation
Boundary Pillar
1 a) Missing
b) Damaged
2 Warning Post / OFC Markers
a) Missing
b) Damaged
c) Status of Painting
3 KM marker
a) Missing
b) Damaged
4 Aerial Marker
a) Missing
b) Damaged
5 Manual Test Station
a) Missing
b) Damaged
6 Direction Marker
7 R.O.U. Washouts
8 Distance of W/O From P/L
9 Pipeline Exposure
10 ROU Encroachments
a) New
b) Old
c) Trees
Conditions of Crossings
111
a) Railway Crossing
b) Road Crossing
c) Canal Crossing
d) River Crossing
12 New Dwellers
13 Description of any other damages
1 LPG leak ( if any).
1
fVIi.kh Remarks
iqujh{kk drkZ Reviewed By fujh{k.k drkZ Inspected By
uke Name uke Name
inuke Designation inuke Designation


unh / ugj / vU; ty dzkflax dk fujh{k.k
INSPECTION OF RIVER/CANAL/OTHER WATER CROSSINGS
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad Date
dzkflax dk uke Name of Crossing : pSusat Chainage :
dz0 la0
ekunaM Parameters izs{k.k Observation Action Proposed
Sr. No.
1 fdukjs dk dVko ABank Washout

xsfc;u dh fLFkfr / Gabion
2
Condition
esVªsl dh fLFkfr / Mattress
3
Condition
4 ikbZi vukoj.k / Pipe Exposure
xsfc;u ds ihNs e‘nk Hkjko dh fLFkfr
5 / Settling of Backfill behind
gabion
dzkflax ds fdukjs dh vofLFkfr esa
6 dksbZ cnyko / Any change in bank
of crossing
unh esa ikuh ds cgko dh fLFkfr /
7
Flow Condition of water
psrkouh cksMZ dks {kfr / Warning
8
boards damage
dksbZ vU; Ikzsi.k / Any other
9
observation
Dz0 la0
Sr. No.
2
Dz0 la0
ekunaM / Parameters (OHSAS) Safety Adopted Observation
Sr. No.
1
2
fVIi.kh Remarks:
uke Name : uke Name:
inuke Designation: inuke Designation :

dslM jsyAlM+d dzkflax dk fujh{k.k

INSPECTION OF RAIL/ROAD CASED CROSSING
jsy lM+d dk uke
Name of Rail Road Crossing: pSusat Chainage:
dz0 la0
ekunaM Parameters izs’k.k Observation Action Proposed
Sr. No.
1 feVzVh dk dVko A Soil Washout
fudkl ikbZi dh {kfr / Drain Pipe

2
Damage
fuokZlu ikbZi dh {kfr / Vent Pipe

3
Damage
psrkouh cksMZ dh {kfr / Warning

4
Board Damage
feVzVh dk mR[kuu / Excavation

5
of Soil.
dksbZ vU; Ikzsi.k / Any other

6
observation

2
Sr. No. ekunaM / Parameters (OHSAS) Safety adopted Observation
1
2
fVIi.kh Remarks:

vfrdze.k dk fujh{k.k
INSPECTION OF ENCROACHMENTS
Maintenance Order No. : Psusat Chainage: fnukad Date :
dz0 la0
ekunaM Parameters Detail
Sr. No.
1 Date Reported
2 Reported By
3 Date of Site Inspection
4 Details of encroachment fooj.k Description izs’k.k Observation
a) Type of Encroachment
b) Name & Address of Encroacher
c) Village
Encroachment distances from
d) pipeline
5 Action Taken
6 Notice Issued
1

1
2
fVIi.kh Remarks:
inuke Designation : inuke Designation


ikbZiykbZu vkj- vks- ;w ds dVko A mr[kuu dk fujh{k.k
INSPECTION OF ROU WASHOUT / EXCAVATION
Psusat Chainage: XkkWo dk uke Name of village :
dz0 la0
ekunaM Parameters Detail
Sr. No.
1 Type of Washout / excavation
2 Cause of washout /excavation
Washout /excavation distance
3
from Pipeline
4 Extent of Damage
a) Length
b) Width
c) Depth
5 Action Taken
Dz0 la0
Sr. No.
LPG Leakage
1
(Any due to damage to pipeline)
2 Land degradation
3
Dz0 la0
Sr. No.
1
2
3
fVIi.kh Remarks :


ikbZiykbu ds vukoj.k @{kr dk fujh{k.k
INSPECTION OF PIPELINE EXPOSURE/VULNERABLE LOCATION
fnukad Date :
pSusat Chainage: XkkWo dk uke Name of village :
dz0 la0
ekunaM / Parameters DETAIL
Sr. No.
1 Date Reported
2 Reported By
3 Cause of pipeline exposure
4 Any damage to coating
5 Extent of damage
a) Length
b) Width
c) Depth
6 Action Taken
Dz0 la0
Sr. No.
1
2
3
Dz0 la0
Sr. No.
1
2
3
fVIi.kh Remarks
uke Name uke Name
inuke Designation inuke Designation


vkbZ ih @,l oh@ Vh vks Vh ds okYoks dk ijQkWjesUl VsLV
PERFORMANCE TEST OF VALVES AT SV/TOT/IP
iz- ,oa vuq- csl O&M Base: fnukad Date: Format No.: PM- 09
easuVsaUl vkns’k la[;k MO No. : SV/TOT/IP No.:
{A} MAINLINE GATE VALVE
Valve status in MCR : Open /Close Remote /Local Any alarm in MCR:
FSPU /HPU /Actuator Tag No : Operation of FSPU /HPU /Actuator :
1. Oil Level: OK / Not OK 4. Qty of Hydraulic oil filled : ............Lts. 1. Venting during closing: Sec
2. Oil Leakage: Yes / No 5. N2 Pr in Accumulator Cylinder No.1 : .....Kg/cm2 2. Venting during opening: Sec
3. Oil Pressure : .............Bar 6. N2 Pr in Accumulator Cylinder No.2 : .....Kg/cm2 3. TEG, vaporizer shut off : Min.
HPU Actuation
Operation of Valves Remarks
Local Remote
Close Sec. Sec.

Open Sec. Sec.
{B} OTHER VALVES
Sl. Close Sealant
Open Operation
No Location Size Ok/Not Injection Remarks
Ok/Not Ok Smooth / Hard
. Ok Yes / No
1 U/S Ball Valve
2 D/S Ball Valve
3 Bypass Globe Valve
4 By Pass Ball Valve
5 Drain Valve (BV)
{C} SEAT TEST OF VALVES
Sl.
Sealant Final Seat
No Location Size Seat Test LPG Escape Remarks
Injection Test
.
1 Mainline Valve
2 Upstream
3 Downstream
Local Parameters MCR Parameters
U/S Pr D/S Pr U/S Tr D/S Tr U/S Pr D/S Pr U/S Tr D/S Tr
{D} FLARE LINE {E} TEG SUPPLY LINE
1. Operation of Ball Valve: 1. Operation of TEG Line Valves:
2. Insulating Joint /Flange Condition: 2. Greasing of Valves:
3. Valve Condition: 3. Insulated joint condition:
4. P/L Support condition: 4. Any LPG Leak from TEG:
5. Condition of other instruments :(if Not OK please describe)
1
2
3
1
2
3
fVIi.kh Remarks :
inuke Designation : inuke /Designation :


fDyfuax vkSj baVsfytsUV ihfxax
CLEANING/INTELLIGENT PIGGING OF PIPELINE
Maintenance Order No. : fnukad Date :
LFkkud dk uke A dzekad Installation Name /Number :
Launching station: Receiving station:
Launching date &time : Receiving Date &time :
Type of PIG
launched (with
specification)
Average
Pig speed
km/hr
Condition of
the pig when
received
Debris received
with pig (kg)
Major
Observations
Preventive
action taken
Sr. No. ekunaM Parameters (EMS) Measurable Observation

1
2
3
Sr. No. ekunaM Parameters (OHSAS) Safety Adopted Observation
1
2
3
4
fVIi.kh Remarks:
inuke Designation : inuke Designation:
Note: For each pig run separate format is to be maintained .

ikbi ykbu fFkdusl losZ

PIPELINE THICKNESS SURVEY

LFkkud dk uke Installation Name:
Thickness Gauge Details Sr No. Model No.
Type of sensor
Std.
Retiring
Sl. no. of test Pipe Ident- Pipe thickness as
Pipe size Thickness of
Point ification No. Schedule per pipe
Pipe-line
schedule
Previous readings As per site measurement & pipe position

12 3 6 9 12 3 6 9
Std.
Retiring
Pipe-line
schedule

12 3 6 9 12 3 6 9
Std.
Retiring
Pipe-line
schedule

12 3 6 9 12 3 6 9
Sl. No. ekunaM Parameters (EMS) Measurable Observation
1
2
3
Sl. No. ekunaM Parameters(OHSAS) Safety Adopted Observation
1
2
fVIi.kh Remarks :

CHECK LIST OF SV
O&M BASE: Format No. : PM-12
SV STATION: DATE OF VISIT: MO NO.:
MECHANICAL SYSTEM

S.
ACTIVITY STATUS OBSERVATION REMARKS
No.
Check Oil leakage from
1
HPU and Actuator
2 Check OIL Level in HPU
3 Check Oil Pressure of HPU
4 Check HPU motor running status
5 Check AV Status (Travel/Open)
6 Check HPU in local or Remote
7 Check Bypass valve (Open/close)
8 Check Painting of P/L and Valves
9 Check earthing of Piping and HPU
10 Check for any Leakage at SV
11 Check Valve/Piping support
ELECTRICAL SYSTEM
S.No. ACTIVITY STATUS/VALUE OBSERVATION REMARKS
1 Check PRS Inlet and outlet Pressure
2 Check TEG out Put Voltage
3 Check general Lighting of Buildings
4 Check Grid Power availability
5 Check Battery Electrolyte Level
Check Earthpit Inspection

6
and due date
7 Check Charger output Voltage
8 Check Inverter/Converter
9 Check all exhaut fan
10 Check PSP at SV
11
GENERAL INSTRUMENT-STATUS
S.No. ACTIVITY STATUS OBSERVATION REMARKS
1 Check Mainline inlet/outlet PT
2 Check Mainline inlet/outlet TT
3 Check Mainline inlet/outlet TG
4 Check Mainline inlet/outlet PG
5 Check Smoke & Fire Detector Alarm

TELECOM/SCADA
S. No. ACTIVITY STATUS OBSERVATION REMARKS
Check DC/DC converter Voltage
1
(RTU)
Check DC/DC converter voltage
2
(Telecom)
3 Check Telephones at SV
4 Check Telephone list
5
SAFETY AND SECURITY STATUS
Check Fire extinguishers Inspection

1 and due date & general physical
condition.
2 Check CO2 System pressure

Check First-Aid Box
3 (Date of expiry & adequacy of
medicine)
4 Check Fire Alarm Panel (SIGNAL)
Check Security Register

5
(for Proper entry etc)
BUILDING STATUS
1 Check Electrical Room
2 Check Telecom Room
3 Check Battery Room
4 Check Security cabin
5 Check General area
6 Check Boundary wall and Fence
7 Check Water logging in the valve Pit
Check Painting of Building

8
and Boundary wall
9 Check Roof of Building
10 Check Cable Trench
11
GENERAL STATUS
S.No. ACTIVITY STATUS OBSERVATION REMARKS
1 Check Tool box
2 Check safety Board
3 Check Safety sign and Instructions

4 Check items as kept for emergency
5 Check Painting of Markers
Check Line Walk Report

6
(By security Guards)
7 Check Hand Pump
8 Check ground condition & vegetation
9 Check overall Housekeeping
10
Note:
OBSERVED BY
CHECKED BY REVIEWED BY
SIGNATURE
SIGNATURE SIGNATURE
NAME DESIGNATION
NAME DESIGNATION NAME DESIGNATION
DATE:
DATE: DATE:

Vh. vks. Vh. ij ckLdsV fQYVj dk vuqj{k.k
BASKET FILTER MAINTENANCE AT TOTs

esaVsusal csl O&M Base: Format No. : PM-13
ikbi ykbu [k.M Pipeline Section: fnukad Date :
Equipment No.: MO No. :
Sl. No. Activities Observation Action REMARKS
Check Differential pressure

1 of filter. (if high clean/
Back flush of filter elements.
2 Check the tightness of the bolts
3 Check the pressure Gauge/PT etc.
4 Check impulse tube of PT.
Dz0 la0
Sr. No.

2 Water consumed for cleaning of Basket.

3 Waste material.
Dz0 la0
ekunaM / Parameters(OHSAS) Safety Adopted Observation
Sl. No.
1 LPG Vapor in the basket
2 Work at height
3 LPG Liquid handling
LIST HERE-UNDER ANY EXTRA WORK PERFORMED OR WHICH MAY WARRANT ATTENTION IN FUTURE
:
1
2

Sl. No. ITEM NAME. PART NO. CODE NO QUANTITY REMARKS
fVIi.kh Remarks

IkkbZi ykbZu dh ejEer
PIPELINE REPAIR
pSust Chainage: xkWo dk uke Name of village:
Upstream SV /IP : Downstream SV /IP :
Sl. No. Activities Observation Action REMARKS
Isolation of affected
1
section
2 Assess damage
3 Arrange F&S facility
Communication as per
4 Emergency Response
Plan
5 Repair the section
6 Normalization of section
Dz0 la0
Sr. No.

LPG Vent for isolation of

1
equipment.
2 Water consumed for F&S
3 Waste material.
5 DCP/CO2 used for F&S
Dz0 la0
ekunaM / Parameters (OHSAS) Safety adopted Observation
Sr. No.
1 LPG vapor/liquid handling
2 Welding activity
3 Radiography activity
4 Coating repairing
1
2
Sr. No. ITEM NAME PART NO. CODE NO. QUANTITY
fVIi.kh Remarks:

fix ykWpj] fjfloj ,oa idM+ iz.kkyh dk vuqj{k.k
MAINTENANCE OF PIG LAUNCHER, RECEIVER & HANDLING SYSTEM
Station DT/IP/IPS/RT/TOT No. : Maintenance Order No.:
Observation Action Remarks
Sl. No.Activities (QMS)
Pig Receiver/ Pig Launcher
1 Check pressure of Barrel (if any, Vent/ drain it)
2 Any leak of LPG from end-closure
3 Opening of end closure
Open end closure and check the condition of
4
seal /O-ring (if required replace)
5 a Condition of Pig Trolley inside barrel
5 b Does the trolley require painting
6 Tightness of the locknut
7 Condition of Pressure Gauge
8 Operation of isolation valves of Kick off line
9 Operation of valves in drain and vent line
10 a Check main isolation valves of Barrel Valve #1
10 b Valve #2
10 c Any sealant injection done
fix gSMfyax iz.kkyh Pig Handing System
1 Operation of pig pusher /retractor
2 Movement of outside pig trolleys
3 Lubrication /greasing of the system

Dz0 la0
Sr. No.
2 Water consumed for F&S
3 Waste material.
Dz0 la0
Sr. No.
1 LPG Vapor/liquid handling
fVIi.kh Remarks


vU; IkkbZi ykbZu dzksflax
FOREIGN PIPELINE CROSSING
ikbi ykbu [k.M Pipeline Section: fnukad / Date :
PSust Chainage Location:
Detail of foreign pipeline: Owner of foreign pipeline:
Sl. No. Description Observation Action REMARKS
1 MTS Sr No. (JLPL)

2a PSP of JLPL
2b PSP of foreign pipeline
Circulating current between two
Pipelines
( Measure mV drop across shunt
3
provided in the MTS
keeping JLPL +ve. Convert mV to
amps, as per the shunt rating)
4 Any other detail.
fVIi.kh Remarks:
iqujh{kk drkZ Reviewed By: Fujh{k.k drkZ Inspected By :
inuke Designation: inuke Designation:

dsifVo ikoj iz.kkyh vkSj mlds lgk;d midj.kks dh ekWuhVfjax ,oa vuqj{k.k
MONITORING & MAINTENANCE OF CAPTIVE POWER SYSTEM AND ASSOCIATED
EQUIPMENT.
ikbi ykbu [k.M Pipeline Section: fnukad Date :-
LFky dk uke ,oa Øe lñ Name and Number of location SV/ IP / TOT No. :
Sl. Sl.
No. EQUIPMENT /SYSTEM OBSERVATION No. EQUIPMENT /SYSTEM OBSERVATION
1 DCDB 4 DC-DC Converter
a Incomer voltage Volts Telecom /SCADA
b Incomer current amps a Output voltage volts
c Indication lamps b Output current amps
d Battery Bank #1 Voltage Volts RTU
e Battery Bank #1 Current amps a Output voltage volts
f Battery Bank #2 Voltage amps b Output current amps
g Battery Bank #2 Current amps CP System
h Telecom /SCADA feeder current amps a Output voltage volts
i RTU feeder current amps b Output current amps
j CPPSM feeder current amps
5
k lighting /inverter feeder current amps Fire Alarm Panel
l Fire alarm panel feeder current amps a Mode AUTO /Manual
m HPU /MOV feeder current amps b CO2 cylinder system Main /Standby
n HPU /MOV feeder current amps c Status of zone(s)
o HPU /MOV feeder current amps Indicates if any one is isolated
p HPU /MOV feeder current amps 6 Pressure of
a Pilot cylinder( Elect Room) kg/cm2
2 Anode Lead Junction Box
b Pilot cylinder(SCADA Room) kg/cm2
a Physical condition c Pilot cylinder(Battery Room) kg/cm2
Vegetation
7 Lighting System & Exhaust Fans
b (if vegetation is there clear it)
c Condition of ground Location Lights Exhaust Fans
a Battery Room
3 Housekeeping
b Tel/SCADA Room
a TEG area c Equipment Room
b Equipment Room d Security Room
c Battery Room
e Switches
d Telecom /SCADA Room
fVIi.kh Remarks:
iqujh{kk drkZ Reviewed By Fujh{k.k drkZ Inspected By

ih ,l ih ekWuhVfjax ,oa fdzfjd lSy dk vuqj{k.k
PSP MONITORING AND MAINTENANCE OF KIRK CELL
easuVsaUl vkns’k la[;k fnukad Date


ON time....................Second OFF time-.............Second
OFF
Other Readings
Test Chai Test ON PSP PSP
Sl. Location Remark
Statio nage Station Volts Volts Date
No. Description Type of (Status of MTS)
n No No Type (-VE) Value
Reading*
(-VE)
Operating Parameters of CPPSM /TR units

CPPSM/TR Unit Lowest PSP
SL. DC Output DC Output Anode Bed
Location Target PSP Value w.r.t
No. current Voltage Resistance
description RC#1 /#2
Foreign pipeline crossing

CHAINAGE PSP of JLPL PSP FORIGN. P/L CIRCULATING CURRENT
fVIi.kh Remarks:

Note:
1. The PSP Monitoring Table can be extended as per actual Chainage lying under the jurisdiction of
respective O&M Base.
2. Off PSP, ON time and OFF time to be noted (applicable during ON-OFF survey only)
3. *Indicate whether unprotected side, casing, anode voltage, foreign pipeline etc. as per your region
wherever applicable)


cSVjh cSad dk ekWuhVfjax ,oa vuqj{k.k
MONITORING AND MAINTENANCE OF BATTERY BANKS
LFky dk uke ,oa Øe lñ SV/ IP / TOT No. :
BATTERY BANK – I BATTERY BANK – II
SP.
SP SP SP
Cell Voltage Cell Voltag Gravit Cell Voltage Cell Voltag
Gravity Gravity Gravity
No. (Cell) No. e (Cell) y No. (Cell) No. e (Cell)
(Cell) (Cell) (Cell)
(Cell)
1 19 1 19
2 20 2 20
3 21 3 21
4 22 4 22
5 23 5 23
6 24 6 24
7 25 7 25
8 26 8 26
9 27 9 27
10 28 10 28
11 29 11 29
12 30 12 30
13 31 13 31
14 32 14 32
15 33 15 33
16 34 16 34
17 35 17 35
18 36 18 36
fVIi.kh Remarks:
Inuke Designation : inuke Designation:
Note: The sample value of SG In NI-CAD Battery shall be measured in selected cells only instead
of measuring in each cell.


vFkZfiV dh ekWuhVfajax ,oa vuqj{k.k
MONITORING & MAINTEANCE OF EARTH PIT
iz- ,oa vuq- csl O&M Base:: Format No. : PM-20
Grid Resistance
Earth Pit No & Type Electrode Resistance
Sr. No (Should be < 1
(Ohms)
Ohms)
1
10
11
12
13
14
15
16
Electrical (Earth resistance to be measured by 3-pin wenner method)
Make Model Sr. No

Earth resistance meter details
fVIi.kh Remarks:

Vh bZ th dh ekWuhVfajax ,oa vuqj{k.k
MONITORING & MAINTENANCE OF TEG / FCBC SYSTEM


easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad /Date :
TEG SYSTEM
Pressure Reduction System
PRS Inlet Pressure PRS Outlet Pressure
kg/cm2 kg/cm2
( PI --01) (PI --06)
Voltage set in System Controller (at TEG SCP) volt (Note: * to be measured
System Controller (at TEG SCP) selector Remote/ Local inside TEG cabinet)
Pressure Voltage* Current* Power developed by
TEGs Voltage Current Temp. of PCV* (at TEG/ Array
shunt)
TEG-2 V A ºC V A watt
FCBC SYSTEM
Operation MODE : FLOAT / BOOST FCBC MODE : AUTO / MANUAL
AC INPUT VOLT R-Ph Y-Ph B-Ph N - Earth
LOAD
LOAD VOLT
CURRENT
BATTERY
BATTERY VOLT
CURRENT
MODULE Voltage Current MODULE Voltage Current
MODULE 1 V A V A
MODULE 2 V A V A
MODULE 3 V A V A
MODULE 4 V A V A
MODULE 5 V A V A
MODULE 6 V A V A
fVIi.kh Remarks:
uke /Name: uke / Name:
Inuke Designation : inuke / Designation :


dEi;wVjhd‘r VsLV LVs’ku dk ekWuhVfajax
MONITORING OF COMPUTERIZED TEST STATION (CTSU)
LFky dk uke ,oa Øe lñ Number of Test station No. :
SR. NO ITEM DETAILS
1.0 S NO (ADDRESS) OF C.T.S.U.
1.0 MAKE OF CTSU
2.0 OPERATING PARAMETERS
2.1 SR NO OF PTSR USED
2.2 SAMPLING RATE
2.3 NO. OF READINGS
VOLTAGE OF PERMANENT REF. CELL VOLT
2.4 W.R.T. PORTABLE REF. CELL
2.5 PSP MEASURED VOLT

2.6 DATA UNLOADING DONE ON (DATE)
2.7 PRINT OUT TAKEN YES / NO
SYSTEM GENERATED REPORT TO BE ATTACHED

fVIi.kh Remarks:


dksjkstu lsaflax izksc dh ekWuhVfajax
MONITORING OF CORROSION SENSING ( E/R) PROBE
LFky dk uke ,oa Øe lñ Number of ER Probe. :
SR. NO.ITEM DETAILS
1.0 MANUAL TEST STATION SERIAL NO. & TYPE
2.0 CORROSION SENSING PROBE
2.1 ER PROBE ID NO.
2.2 MODEL:
3.0 TEST & MEASUREMENT
3.1 MODEL NO. OF MEASURING INSTRUMENT
3.2 SERIAL NO. OF MEASURING INSTRUMENT
3.3 CORROSION RATE IN MILS
SYSTEM GENERATED REPORT TO BE ATTACHED

fVIi.kh Remarks :
uke Name : uke Name. :

, th ch ,oa , ,y ts ch dh ekWuhVfajax ,oa vuqj{k.k

MONITORING & MAINTEANCE OF ANODE GROUND BED AND A.L.J.B.
LFky dk uke ,oa Øe lñ Name and Station No. :
Sr. No. Activities Observation Action
1 GROUND BED DETAILS
1.1 Ground bed configuration
1.2 Anode type
1.3 Anode quantity
2 VISUAL INSPECTION
Cable glands in anode lead
2.1 OK/NOT OK 2.4 Operation of all locks OK / NOT OK
junction box
Permanent identification
2.2 YES /NO 2.5 Shunt & Variable Resistance OK NOT/ OK
tags on all anode cable
2.3 Cable connection tightness OK / NOT OK 2.6 Painting OK/ NOT OK
3 Parameters of CPPSM / TR Unit
3.1 Output Voltage volt
3.2 Output Current amp
3.3 Target PSP volt
3.4 PSP value with respect to-
3.5 RC1 volt
3.6 RC2 volt
3.7 Total indicative Circuit Resistance ohms
Total Anode Ground Bed to Earth Resistance
(to be measured by Wenner 3 pin method) ohms
4. Parameters of Individual Anodes (for other than LEEDA anodes)
Shunt Shunt
Anode Current Resistance Anode Current Resistance
Measurement Measurement
No. (mA) (Ohms) No. (mA) (Ohms)
(mV) (mV)
1 ----
2 ----
fVIi.kh Remarks :
iqujh{kk drkZ Reviewed By fujh{k.k drkZ / Inspected By
Inuke Designation : inuke Designation:

Vh vkj ;wfuV @lh ih ih ,l ,e dh ekWuhVfajax ,oa vuqj{k.k
MONITORING & MAINTENANCE OF TR UNIT/ CPPSM


LFky dk uke ,oa Øe lñ Name and Station No. :
Sr. No. Activities Observation
1 VISUAL INSPECTION & MAINTENANCE
1.1 Earthing of Enclosure Ok /Not Ok
1.2 Cleaning & Air Blowing Done/ Not required
1.3 Indicating lamps / LEDs Ok /Not Ok
1.4 Tightening of connections Done/ Ok
2 Working parameters of CPPSM/ TR Unit
2.1 Input Voltage* AC/DC volt
(Note: * AC in case of TR Unit; DC in case of CPPSM )
2.2 Input Current* AC/DC amp.
2.3 Mode Selector AUTO / AVCC
2.4 Controlling Electrode Ref. # 1 / Ref. # 2
2.5 Reference Electrode Selector AUTO / Ref #1 / Ref #2
2.5 Target (Internal Reference) volts
PSP AUTO AVCC
2.6 w.r.to Ref. cell#1 volts
w.r.to Ref. cell#2 volts
2.7 Anode Voltage (DC output voltage) volts
2.8 Anode Current ( DC output current) amp.
2.9 Settings
a Ref. Cell failure volts b Under Protection volts
c Over Protection volts
2.10 Interrupter Timer Setting (Correct if found wrong)
a Date OK/ Not OK b Time OK/ Not OK
c Operation of (Check the operation of Interrupter by Switching
Interrupter OK/ Not OK ON ‘TSW-8’ and pressing START on Interrupter
Timer)
fVIi.kh Remarks :
iqujh{kk fVIi.kh / Review Remarks:

djsDfVo @czsd Mkmu esaufVusal fjiksZV
CORRECTIVE & BREAK DOWN MAINTENANCE REPORT

LFky dk uke ,oa Øe lñ

Name and Number of location SV/ IP / RT/DT/TOT No. :
Sl No. Item Description
1.0 NAME OF EQUIPMENT:
1.1 SUB-SYSTEM:
2.0 NATURE OF FAULT:
3.0 CAUSE OF FAULT::
DATE OF
4.0 OBSERVATION/OCCURRENCE:
5.0 ACTION DETAILS:
6.0 MANPOWER / MACHINERY USED:
7.0 SAFETY SYSTEM USED:
8.0 SPARES / CONSUMABLES USED

Dz0 la0
Sr. No.
Dz0 la0 ekunaM /

fVIi.kh Remarks:
uke Name: uke Name:
Inuke Designation: inuke Designation:

,;j loZysUl vkSj ykbu okd isVksfyax ds mij dk;Zokgh vkSj vuqlj.k
ACTION TAKEN AND COMPLIANCE REPORT ON AIRSURVEILLANCE AND LINE WALK
PATROLLING
iz- ,oa vuq- csl O&M Base: Format No.: PM- 27
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad Date %
pSusat Chainage from: pSusat Chainage to:
vkbZVe xqe’kqnk [kjkc isfVax LVsVl dk;Zokgh Compliance
Item Missing Damage Painting Action Status
(In No.) (In No.) Status Taken

ckmaMjh ihyj
Boundary Pillar
ih ,y MCyw
cksMZ
P.L.W Sign
Board
vks ,Q lh ekdZkj
OFC Marker
ds ,e ekdkZj KM
Marker
Vh ,y ih LVs’ku
TLP Station
MkbjsD’ku ekdZj
Directional
Marker
fooj.k
Ekk=k fLFkfr Description dk;Zokgh
vkbZVe Condition Compliance
Qty. (Size & Action Taken
Item (OK/NOT OK) Status
(No.) Type)
dVko o mr[kuu
P/L Washout/
Excavation
jksM+ dzksflax
Road Crossing
jsy dzksflax Rail
Crossing
unh dkzsflax
River Crossing
vfrdze.k
Encroachment
Remark fVIi.kh %
Review Remark iqujh{kk fVIi.kh %
iqujh{kk drkZ Reviewed By % fujh{k.k drkZ Inspected By :

fudy dsSMfee cSVjh fMlpkZftax
DISCHARGING OF NI-CAD BATTERY
easuVsaUl vkns’k la[;k Maintenance Order No. : fnukad / Date :-
NAME OF CONTRACTOR: WORK ORDER NO. :
Detail of discharge Load: DISCHARGE STARTING TIME:
DISCHARGE CURRENT: DISCHARGE ENDING TIME:
Battery Bank Voltage DISCHARGE PERIOD:
at Start of DISCHARGE:

Battery Bank Voltage

after DISCHARGE:
SP SP SP SP
Cell Voltage Voltage Voltage Voltage
Gravity Cell No. Gravity Cell No. Gravity Cell No. Gravity
No. (Cell) (Cell) (Cell) (Cell)
(Cell) (Cell) (Cell) (Cell)
1 23 1 23
2 24 2 24
3 25 3 25
4 26 4 26
5 27 5 27
6 28 6 28
7 29 7 29
8 30 8 30
9 31 9 31
10 32 10 32
11 33 11 33
12 34 12 34
13 35 13 35
14 36 14 36
15 37 15 37
16 38 16 38
17 39 17 39
18 40 18 40
19 41 19 41
20 20
THIRD PARTY INSPECTION REPORT

fVIi.kh Remarks :


DAILY CHECKS & ALARMS ANALYSIS OF MANNED STATIONS
iz- ,oa vuq- csl O&M Base: Format No. : TCM-02
SL.
Name of Activities Procedure Status Remarks
No.
1 General Cleanliness Visual inspection of rooms
& equipments
2 Visual Alarms Visual inspection of
OFC based transmission system Alarms
 STM-16
 STM-1
 PDH
 PRC/GPS/SASE
 NMS100/10
 MF /2
3 Check of Dial the stations of the
(i) EOW1 region from respective

(ii) EOW2 telephone & check the

(iii) Pig Telephone ring back tone.
(iv) Watchman Phone
(v) Acoustic Booth Telephone
4 EPABX a) Run the
CONFIG/TRKSTAT/
4A a) EPABX at station SUPROTAGE command
and check the status of
the card /NDDI &
EMTL/PRI links
respectively.
b) Check by dialing/calling
4B b)Status of Video conferencing VC system to other VC
equipment system
4C c) Status of INMARSAT c) Check the ring back

tone.
5 Satellite Earth station a) Measure power output
5A a) Transmit level at SSPA and compare with
standard specified.
5B b) Receive level Measure the receive level
for carriers using
spectrum analyzer &
compare with standard
specified
fVIi.kh Remarks :



NMS REPORT FROM JAMNAGAR AND LONI
iz- ,oa vuq- csl O&M Base: Format No. : TCM-03
DIGITAL TRANSMISSION SYSTEM
STATION
DESCRIPTIO STATUS
SL. JURISDICTION/ NO. DATE OF REMARKS /
N OF THE OF
No. STATION (TS/SV ALARM PROBABLE CAUSE
ALARM ALARM
NO.)
a) 861 (RPL to IP-1)
b) 862 (SV08 – IP1)
c) 863 (SV-19 to IP-2)
d) 865 (SV-35 to SV-45)
e) 880 (SV-46 to IP-4)
f) 870 (SV-60 to Loni)
EPABX SYSTEM
STATION
DESCRIPTION STATUS
SL. JURISDICTION/ NO. DATE OF REMARKS/
OF THE OF
ALARM ALARM
NO.)
VIDEO CONFERENCING SYSTEM
STATION
DESCRIPTION STATUS
OF THE OF
ALARM ALARM
NO.)
SCPC EARTH STATION AT JAMNAGAR & LONI
STATION
DESCRIPTION STATUS
OF THE OF
ALARM ALARM
NO.)
fVIi.kh Remarks :

Sec. No. 6.0 REFERENCE DOCUMENTS Page 94 of 94

Mechanical Maintenance Manual

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ISO FORMAT

Doc. No. : JLPL/JMM

JAMNAGAR-LONI LPG PIPELINE

Jamnagar-Loni LPG Pipeline System

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 2 of 94

24. NGR –TR-01 Resistance

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 3 of 94

Jamnagar-Loni LPG Pipeline System

TAP POSITION (OLTC)

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 4 of 94

Jamnagar-Loni LPG Pipeline System

1 General cleaning of motor

External corrosion effect on

Checking of Ventilation / Cooling

Condition of Guards for moving

Sr. No. Parameters (EMS) Measurable Measurable Measurable Measurable

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 5 of 94

Jamnagar-Loni LPG Pipeline System

iz- ,oa vuq- csl O&M Base: Format No. : EM-05

PARAMETERS (OHSAS) Safety Adopted Observations

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 6 of 94

Jamnagar-Loni LPG Pipeline System

1 General cleaning of motor, panel

External corrosion effect on

Condition of Guards for moving

PARAMETERS (OHSAS) Safety Adopted OBSERVATION

Fujh{k.k drkZ / Inspected By

iqujh{kk fVIi.kh / Review Remarks

iqujh{kk drkZ / Reviewed By

Jamnagar-Loni LPG Pipeline System

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 7 of 94

ANNUAL L.T. MOTOR MAINTENANCE

ACTIVITIES Observation Action

Jamnagar-Loni LPG Pipeline System

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 8 of 94

MEASUREMENT OF NGR RESISTANCE

iqujh{kk fVIi.kh / Review Remarks

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 9 of 94

Jamnagar-Loni LPG Pipeline System

5 Control supply availability

10 IR Value Phase To Phase R-Y Y-B B-R

Fujh{k.k drkZ / Inspected By

iqujh{kk fVIi.kh / Review Remarks

iqujh{kk drkZ / Reviewed By

Jamnagar-Loni LPG Pipeline System

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 10 of 94

esaVsusal csl /O&M Base: Format No. : EM-10

Tightness of cable Connection

3 Checking of panel sealing

Meter Calibration and Checking

PARAMETERS (OHSAS) Safety Adopted Observations

iqujh{kk fVIi.kh / Review Remarks

Jamnagar-Loni LPG Pipeline System

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 11 of 94

NOMINAL CURRENT (IN) NO. OF OPERATIONS:

III INSULATION LEVEL : (MAIN POLES)

IV . AUXILIARY & POSITION CONTACTS OPERATION CHECK:

Sec. No. 0.1 ANNEXURE-ISO FORMAT Page 12 of 94

Jamnagar-Loni LPG Pipeline System

VOLTAGE AND WAVE FORMS

PHYSICAL INSPECTION OF UPS

TIGHTNESS OF ALL FRC

O/P FILTER CONNECTIONS