STANDARD OPERATING PROCEDURES

STANDARD OPERATING PROCEDURES

A set of instructions having the force of a directive,

covering those features of operations that lend
themselves to a definite or standardized procedure
without loss of effectiveness.

Standard Operating Procedures can be effective

catalysts to drive performance improvement and
improving organizational results.

Every good quality system is based on its standard

operating procedures (SOPs).
 SOP contains ..

A Structured guidance document that

details a series of steps for achieving desired
outcomes
SOP describes Technical and Fundamental
Operational Elements.
A set of Written Instruction for routine
activities followed by an Organization.
Emergency Procedures
Standard Operating Procedures
Further more Standard Operating Procedures ........
STANDARD OPERATING PROCEDURE

Every Time

Performed in same way

Task on Time

Task are done Correctly

Better Performance in
all Respect
 STANDARD OPERATING PROCEDURES – BPCL LPG PLANT

Need of SOP LPG Operation Manuals were prepared based

on old age equipments and documentations. Thereafter lot
many changes occurred ………

Manual Filling Station / Carousel to Electronic Carousel

Mechanical Weighing Scale to Electronic Check Scale /
Dynamic Check Scale
CVT to Electronic GD / VLD and PT / OLD System.
Overhead Storage Tank to Mounded Storage Tank.
BPCLIP / BPCASH – Fortnight DTN etc to SAP System.
Incorporated New Technology – Machine for Valve
Changing without Evacuating Cylinders, Hot Air Sealing
System, BMCG, LOT System etc.
Changes in OISD Standards and in other Statutory norms
Quality Assurance Plan – Seller’s market to Buyer’s market.
 SOP FOR LPG PLANTS Referred to –

LPG Operation Manuals

Different Circulars issued time to time.
Security Manual
Financial Guidelines
Engineering Manuals
Operating Manuals of OMCs
OISD Standards
Different Statutory Acts, Rules - - Factories Act,
Labour Laws, Legal Metrology, PCB, Gas Cylinder
Rule, SMPV Rule etc.
Different License Conditions
SOP for LPG Plants Broadly Divided into Following Steps :

1. Start up Checks.
2. In Operations checks.
3. Action for Deviations.
4. Emergency Operations.
5. Closing of Shift Operations
6. Controls
7. Responsibilities
 Our SOP for LPG Plant Contains …

1.Production Process of LPG, its Properties / MSDS, definitions –

associated hazards

2.Admin & Security including Security Gadgets & facilities,

administrative / security controls – even frisking of incoming &
outgoing Security Personnel.

3.LPG Bulk Handling – Tank Lorry Loading / Unloading, Tank

Wagon Loading / Unloading, Storage Vessel Operation, PLT
Receipt, Operation of LPG Pump and Compressors etc.

4.LPG Bottling Operation – Starts from Cylinder Receipt, bottling,

quality checks of cylinders, SQC, dispatches including Do’s &
Don’ts for each operation.
 Our SOP for LPG Plant Contains …

5.Auxiliary Operations – Purging of Cylinders, Salvaging SC Valves / Safety

Caps, Straightening of Stay Plate, Foot ring, VP rings etc, In-House Pressure
Testing of Cylinders, Crushing of Cylinders, Crushing SC Valve, DPRs,
Handling of HSD, SKO, Lub Oils, Brown Soap etc, Waste Material Disposals,
Purging of Tank Lorry / Tank Wagon.

6. Planning & Financial activities - procedure for receipt and dispatch of

packed LPG /Bulk LPG / Non hydro carbon materials from LPG Plant &
maintain financial discipline.

7. Fire Prevention & Controls including different classes Petroleum Products,

Zones, Fires & its control measure, Fire Fighting Facilities, Passive Fire
Fighting Measures, Action during Fire & Leakage scenario – Fire Drill, DCMP
and other safety measures.

8. Fire Fighting Equipment Monitoring System – Maintenance & Inspection

schedule of different type of Fire Fighting Equipment / system, Safety
Tripping, Logic Operation complete.
 Our SOP for LPG Plant Contains …

9. Plant Utilities – Mainly deals with Dry Air Supply

System – Cooling Tower, Air Compressors – Reciprocating
& Screw Compressors both, Air Dryer System –
Absorption / Adsorption type & Refrigeration Type both.

10.Plant Maintenance – Different Type Maintenance & Its

documentations including SAP Transactions, Preventive
Maintenance Schedule of different Equipments,
Inspection & Maintenance of Safety Fittings, Storage
Vessels, Pipelines, Working in Confined Space & at Height.

11. Calibration & Testing of different measuring

equipments & their schedule.
 Our SOP for LPG Plant Contains …

12. Utility – Electrical System covers Two Pole Structure,

Transformer, MCC Panels, DG Rooms, Electrical
Equipments and their Do’s & Don’ts.

13.Statutory Regulations – different statutory Rules &

regulations applicable to LPG Plant.

14.Training – Including Identification of Training Need,

Training Calendar, Course Module, Feed Back Mechanism,
Evaluation System.

15.Audits – Different Type of Audits as per OISD, Statutory

Norms and Corporate Policy.
SOP FOR GATE – A &B (SECURITY CHECKS)

ADVANTAGES OF FOLLOWING / ADHERING TO SOP:

1.Ensures that Security systems & procedures are intact.

2.Ensure that the Security alert is at the highest level.
3.Traceability documents are updated & readily available.
4.Categorized entry of men & material is ensured.
5.Screened entry of vehicles, men & material.
6.Readiness in dealing with any eventuality/emergencies.
7.Before hand up to date ready information.
8.Better off-shift handling.

NON ADHERENCE TO SOP LEADS TO :

1.Vulnerability to external threats.
2.Violation of security & safety norms.
3.Loss of property & value to the Company.
4.Incapability in dealing with threats / exigency.
5.Violation starting from Main Gate.
 FILLING SHED AREA (EMPTY CYL. RECEIPT)

ADVANTAGES OF FOLLOWING / ADHERING TO SOP:

1.Ensures safer operations, accident free movement.
2.Correct accounting of stocks.
3.Proper & authentic information to shed & planning officer.
4.Regulated & proper control on bottling operations.
5.Ensuring safety of plant & customers.
6.Generation of authentic data base for improving overall bottling
operations and regulating market.
7.Proper recoveries from contractors, distributors & transporters.
8.Ensures stacking of cylinders as per OISD norms as per the pre
determined pattern.

NON ADHERENCE TO SOP LEADS TO :

1.Creation of hazardous, accident prone conditions for both the plant &
market.
2.Dissatisfied customer.
3.Increased cylinder maintenance cost.
4.Frequent breakdowns & increased repetitive maintenance Costs.
 FILLING SHED AREA (BOTTLING OPERATIONS)

ADVANTAGES OF FOLLOWING / ADHERING TO SOP:

1.Rules out the probability of any accident / near-miss.

2.Ensures efficient, safe , on time & risk free batch operations.
3. Fewer breakdowns leading to trouble free production.
4.Nil violations of statutes. (As listed in OISD-144).
5.Nil wastage of consumables.
6.Proper usage of power, water and air resources.
7.Optimum utilization of available manpower.
8.Regulated and disciplined working amongst workmen & staff.
9.Increased life of the machinery / plant equipment.
10.Better operating gains with high accuracy of filling.
11.Reduced defective cylinder generation for correction.
12. Reduced online maintenance. Improves maintenance practices
(Preventive & Predictive).
13.Satisfied & motivated work force.
14.Achievement of Benchmarking standards.
16.Ease & efficient handling of various audits with nil adverse remarks.
17.Nil rejection of cylinders in market.
18.Nil accidents at customers premises. Improved market image.
19.On time statutory testing of various safety fittings and equipment.

NON ADHERENCE TO SOP LEADS TO :

1.Creation of hazardous, accident prone / near miss conditions.
2.May cause severe accident at customers premises.
3.Increased generation of market defectives.
4.Loss of product / operating losses.
5.De-motivated and in disciplined workforce. IR issues.
6.Frequent failure & breakdowns.
7.Bypassing of safety interlocks & trip mechanisms.
8.Increased Maintenance & revenue expenditures.
9.Breakdown of set norms, rules & regulations and guidelines.
 FIRE FIGHTING SYSTEM

ADVANTAGES OF FOLLOWING / ADHERING TO SOP:

1.Rules out the probability of any accident.
2.Faster, timely & efficient work execution.
3.No statutory violation.
4.System reliability & enhanced system performance.
5.Better preparedness to deal with any exigency.
6.Better Maintenance Cost Management.

NON ADHERENCE TO SOP LEADS TO :

1.Creation of hazardous, accident prone conditions.
2.Non availability of system when in need.
3.Under rated performance of the system & equipment.
4.Frequent failures.
5.Violation of set statutory norms. May lead to prosecution.
6.Higher Maintenance costs.
INSPECTION , MAINT. & OVER HAULING OF EQUIPMENT

ADVANTAGES OF FOLLOWING / ADHERING TO SOP:

1.Rules out the probability of any accident.
2.Faster, timely & efficient work execution.
3.Elimination of unprecedented breakdown. Less downtime.
4.Lesser Maintenance cost. Increased performance &
efficiency.
5.Increased production.
6.No Violation of statutory rules & regulations.
7.Prolonged life of the equipment.

NON ADHERENCE TO SOP LEADS TO :

1.Creation of hazardous, accident prone conditions.
2. Loss of reputation & social status.
3.Loss Time Accident. Loss of limbs & life.
THANK YOU