CALIBRATION AND MAINTENACE OF SADC

This Procedure is intended to provide guidance and instructions for carrying out the Calibration and maintenance of SADC as per standard practices prescribed by OEM or General Industry best practices in safe manner while ensuring minimization of environmental impacts to the extent possible.

GENERAL INSTRUCTIONS FOR COMPLIANCE:

Work permit as should be secured and instructions provided in the permit should be complied. Where instructions are not clear, clarification should be requested from the concerned Supervisor/Engineer. Work should only be commenced after ensuring that proper work environment is created (Authorizations are secured, Isolations are confirmed, and required mobilization is done).

Access to Emergency evacuation and other emergency services such as medical and Fire protection shall be readily available and contact details are readily available concerned supervisor as well as contactor.

Access to drinking water, toilet and other essential infrastructure for both company and contract personnel should be ensured.

Job specific responsibilities:

Sl. No	Particulars	Responsibility
1	Issue and Closure of  work permit	Engineer in charge/ Operation unit & shift in charge
2	Ensuring isolation	Operation shift/unit in charge
3	Monitoring availability of required tools & tackles and implementation of relevant OH&S and Environmental Procedures	Engineer in charge/Supervisors
4	Checking the Quality of Job and Providing feedback to ensure task Completion as per the procedure	Engineer in charge
5	Performing of tasks in compliance with Instructions and safe working with Equipment	Technicians

WORK INSTRUCTION:

A. Check the proper air pressure in the AFR gauge as follows :

•  1.5 kg/cm For I/P converter 

•  3.5 kg/cm For supply pressure of cylinder.

B. Flush all the Air Filter Regulators for following locations  :

•  At SADC Station (20 nos.)

•  At Corner Pneumatic Station (8 nos.)

• At each Cylinder (80 nos.)

C. Check the I/P converter functioning by using mA source & test pressure gauge of 0-1kg/cm as follows:

•     For 4 mA input the I/P converter output should be 1.0 kg/cm.

•     For 20 mA input the I/P converter output should be 0.2 kg/cm.

D. If the pressure is not adequate then check for the leakage or flush the copper tube at joints 

E. If the leakage is from the copper tube or associated fittings then arrest it.

Examine hoses for holes or leaks. Test all hose clamps for tightness. If there is a leakage then replace it.

G. Use the 0-1 kg pressure gauge to trace the leakage in signal airline.

H. If Cylinder is not working then remove the cylinder as follows:

•  Remove the Connecting pin of damper with cylinder.

•  Take out the SADC cylinder and check properly. Check AFR and POSITIONER, if damaged then change it.

•  Use service air to clean the JB if the dust is accumulated inside.

•  Close the JB of the cylinder and fix the cylinder and lock it properly in the hanger pin.

•  After erection of cylinder connect the copper tube in the cylinder and ensure there should not be any kind of leakage.

•  Connect the cylinder link to the damper link properly.

I.  Check all cable healthiness and should be properly gland.

J.  After all such checkup, performs the calibration.

a. Connect the mA source to the I/P converter and give the step command locally.

b. At 0 % command cylinder should fully open (damper is fully closed) and at 100% command cylinder should fully closed (damper is fully opened).

c. Check the pressure switch feedback for damper full open at 100% command.

d. Repeat the above procedure for remote operation. After normalization, return the PTW.

CHECK BEFORE RELEASE OF PERMIT:

a.   All T & P’s and manpower are removed.

b.  Clean the maintenance area properly.

c.  Normalize all isolation  & Return PTW.

HANDLING OF CONCESSIONS OR DEVIATIONS:

a.  In the Event of Any Changes or Deviation from Procedure are required due to Urgent business requirements or system/Equipment approval should be obtained from Head O&M.

b. The report for the concerned task should clearly Captured the details of deviations and reason for the same.

GENERAL SAFETY PROCEDURES:

Safety Helmet must be worn at all times in work place.

Ensure proper physical and Electrical isolations and availability of work permit.

Safety Shoes must be worn at all times in work areas.

Safety Goggles must be worn in work areas whenever required.

Rings & Jewellery must not be worn & Mobiles to be turned Off where it is forbidden.

Use Safety Belt whenever required.

 

Close fitting/protective clothing must be worn at all times in work areas.

Usage of Ear Plug whenever required

Use Hand gloves if required.

Ensure all flammable materials are safely stored

Long and loose hair must be avoided.

Ensure proper Fire Fighting Devices whenever required