STANDARD OPERATING PROCEDURE (SOP)

Tata Steel Meramandali

Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 1 of 6

Step Details of Activity Associated safety Hazards/ Env. Impacts/ Responsibility Safe process (tools & Equipment, PPEs, Training etc.) (HOW) Remarks /
No. (WHAT) Quality Requirements (WHO) Reference

1 Six directional Safety Hazard: Manger/ Safe Process:

hazards checking 1. Uneven surface, damaged/ Engineer/ 1. Take care during site visit, avoid damaged/ nonstandard platform & staircase. Avoid slippery
before issue corrode / nonstandard platform & Foreman/ walkway / platform, avoid the area where material deposition found, avoid the area where
work permit. staircase. Supervisor/ projected structure on the platform. Do not proceed if any abnormalities found.
(Site visit). 2. Hot process surface & pipeline. Technical 2. Do not touch any process line. Keep safe distance from hot process surface & pipeline.
3. High pressure & temperature support/ 3. Keep safe distance from energized process line. Do not proceed if any leakage observed.
steam / water / oil / flue gas. Technician. 4. Do not touch any sharp edge of structure/pipeline, insulation sheet & plate.
4. Sharp edge. 5. Before reaching the job site, see the six-side area for any job is under progress, housekeeping is
5. Falling object / tools / structure. under progress, any process fluid/material leakage, bed drain is under progress.
6. Bad weather for outside job. 6. Check the weather condition: rain, excess hot weather, high velocity wind flow, thunderstorm.

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Environment: 7. Ask to owner department for any work permit already issued nearby the area, which is major
1. Fatigue dust. job and shall be affected engaged manpower related to this job.
2. BF/CO gas (for gas prone area).
3. High noise.
Quality:
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8. Wear all TSM standard PPE before site visit.
9. Manpower physical & mental condition checking.

2 Issue Work
Permit, Toolbox
Safety Hazard:
1. Slippery floor.

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Manger/
Engineer/
d Safe Process:
1. Avoid the slippery floor, wet floor, avoid housekeeping area.
talk, others
permit.
Manpower
2. Uneven surface, damaged/
corrode / nonstandard
platform & staircase.
movement to site. Environment:
NIL V a
Foreman/
Supervisor/
Technical
support/
2. During moving to site avoid uneven surface, damaged/ corrode / nonstandard platform &
staircase, do not use shortcut pathway, use tool bag to carry tools and accessories, do not
engage both hands to carry the tools and material, during using staircase always use one hand
to hold the railing. Does not use mobile phone during walking to site.
Technician. 3. Fill up work permit form, and take clearance from operation, ensure no row/column are left as
blank. Work permit, SOP and other permits shall be kept at job site.
Quality: Proper filling of work permit. 4. Physical & mental condition checking of manpower. Do not engage over staying manpower
working more than 8 hrs. continuously. No manpower engaged other than specified in permit.
5. Ensure all manpower having sufficient experience regarding the present job. No new manpower
engages as a leading position before training. engage as a support role.

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6. Check gate pass, & height pass of all manpower, supervisor should have high risk gate pass.
7. Take ESI (if applicable), height pass (height job), hot permit (cutting, welding job).

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open spanner uses. Provide training for hand not tools.

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8. All tools should be as per TSM standards, take written permission (TSM format) for hammer &

9. No single use plastic bottle is used for water, designated color-based container / bottle shall be

PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy
used to carry chemical / oil / rustolene etc.

a l i
APPROVED BY
Name and Designation: H. P. Singh (Head)
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025
V
Signature with Date:
SOP Valid Till - 24-Apr-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 2 of 6

10. Instruction for mobile using restriction during job for communication, use walkie talkie.
3 Replacement and Safety Hazard: Manger/ Safe Process: Refer OEM
checking of 1. Electric shock. Engineer/ 1. Take power ESI & lock the MCC feeder for card replacement. Use power tester, use LV hand Manual
Electrical cards, 2. Uneven surface / damaged/ Foreman/ gloves. Use insulated tools. Check all connection before box up to avoid flash over. Remove the
components, corrode/ nonstandard platform & Supervisor/ Power ESI lock for testing, use temporary power supply kit (equipped with MCB & RCCB) for
motors, switches. staircase. Technical actuator electrical testing. Use only CAT IV multimeter.
3. Hot process surface & pipeline. support/ 2. Avoid damaged/nonstandard platform & staircase. Avoid slippery walkway / platform, avoid the
4. High pressure & temperature Technician. area where material deposition found, avoid projected structure on the platform. Made
steam / water / oil / flue gas. scaffolding as where required. Use full body harness as where required.
5. Sharp edge. 3. Do not touch any process line. Keep safe distance from hot process surface & pipeline. Wear
6. Falling object / tools / structure. heat proof PPE (LV flash Jacket, hand gloves, goggles). Do not perform the job where insulation
7. Bad weather for outside job. is not present in energized steam, hot water, oil, and flue gas line.
8. High noise. 4. Do not proceed if any leakage observed from gland or nearby line. If not then proceed for job,
9. CO/BF gas.
Environment:
Steam, hot water, hot air, Dust, oil, grease,

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Wear LV flash jacket, safety goggles, face shield, cotton hand gloves.
5. Do not touch any sharp edge of structure/pipeline, insulation sheet & plate. Barricade the area,
cover the sharp edge by clothes, wear hand gloves. Avoid touching inside the actuator parts with
Noise, COG/BFG
Quality: Proper filling of work permit.

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6. Kept the loose accessories on the solid platform, if grizzly floor, use mat/tarpaulin, hold the tools
and accessories properly.
Environment:
Steam, hot water, hot air, Dust, oil, grease,
scrap, Noise, COG (WHRB)
Quality: Tools, PPE.
a l i 7. Check the weather condition: rain, excess hot weather, high velocity wind flow, thunderstorm.
Wait for normal weather condition.
8. Use earmuff / ear plug.

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9. Use personal CO gas detector (calibrated). Mandatory for gas prone area.
Check points:
1. If required remove the actuator (separate SOP) from valve parts for easy maintenance.
2. Check all cards and components are healthy, card version is OK and suitable for this actuator
before installation, check other electrical components ratings, like contractor, O/L relay etc.,
better testing before installation. Check the actuator body earthing.
3. Remove fuse at DCS/PLC end.

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4. Check the TB and lugs condition, replace if damaged. Check the looseness between cable
terminal & cable lugs. Check cable gland condition, re-gland if required.

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5. Check for any damaged internal wire condition (cable got hard due to heat, insulation damaged,
low-capacity wire used).
6. Check no oil/grease leaking and comes out inside the electrical card section. If found replace
the seal.

l i d
Signature with Date:
PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy a
APPROVED BY
Name and Designation: H. P. Singh (Head)

V
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025 SOP Valid Till - 24-Apr-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 3 of 6

7. Check & note down the wiring diagram before removing any connection, better take
photograph for reference, put cable ferrule if any found missing.
8. Check the cover seal/O-ring to avoid water ingress inside electrical section, replace if found
damaged / hard.
4 Replacement and Safety Hazard: Manger/ Safe Process: Refer OEM
checking of 1. Electric shock. Engineer/ 1. Take power ESI & lock the MCC feeder. Use power tester. Remove the Power ESI lock for testing, Manual
Mechanical parts 2. Uneven surface / damaged/ Foreman/ use temporary power supply kit (equipped with MCB & RCCB) for actuator testing.
& components. corrode/ nonstandard platform & Supervisor/ 2. Avoid damaged/nonstandard platform & staircase. Avoid slippery walkway / platform, avoid the
staircase. Technical area where material deposition found, avoid projected structure on the platform. Made
3. Hot process surface & pipeline. support/ scaffolding as where required. Use full body harness as where required.
4. High pressure & temperature Technician. 3. Do not touch any process line. Keep safe distance from hot process surface & pipeline. Wear
steam / water / oil / flue gas. heat proof PPE (LV flash Jacket, hand gloves, goggles). Do not perform the job where insulation
5. Sharp edge of mechanical part. is not present in energized steam, hot water, oil, and flue gas line.
6. Falling object / tools / structure.
7. Bad weather for outside job.
8. High noise. P
4. Do not proceed if any leakage observed from gland or nearby line. If not then proceed for job,
Wear LV flash jacket, safety goggles, face shield, cotton hand gloves.

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5. Do not touch any sharp edge of structure/pipeline, insulation sheet & plate. Barricade the area,

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9. CO/BF gas cover the sharp edge by clothes, wear cut resistance hand gloves. Avoid touching inside the
Environment: actuator mechanical parts with necked hand as actuator equipped with so many sharp edge
Steam, hot water, hot air, Dust, oil, grease,
Noise, COG/BFG
Quality: Tolls, PPE
l i d parts inside the mechanical portion. Avoid put hand or finger in between gear teeth or rolling
shaft t to avoid crush injury.
6. Kept the loose accessories on the solid platform, if grizzly floor, use mat/tarpaulin, hold the tools

V a and accessories properly.

7. Check the weather condition: rain, excess hot weather, high velocity wind flow, thunderstorm.
Wait for normal weather condition.
8. Use earmuff / ear plug.
9. Use personal CO gas detector (calibrated). Mandatory for gas prone area.
10. Few special tools are required for mechanical parts removal & erection, check tools list before
starting the job, otherwise injury hand injury may be happened.
11. Few spring tension parts are equipped inside the actuator, during opening those parts use
special tools and take special attention by the expert.
Check points:
1. If required remove the actuator (separate SOP) from valve parts for easy maintenance.

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2. Check all parts and components are healthy and suitable for this actuator before installation.

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3. Check all the cover seal/O-ring to avoid water ingress inside actuator mechanical parts section.
4. Check the grease quantity & quality, replace if found hard or moisture found in grease.

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5. Check oil level & quality, top up if level is found low. Replace the oil if moisture found.

PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy a l
APPROVED BY
Name and Designation: H. P. Singh (Head)
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025
V
Signature with Date:
SOP Valid Till - 24-Apr-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 4 of 6

6. Replace all oil seal if found hard or damaged.

7. Put handle shaft cover to avoid water ingress inside the actuator.
8. Check the mechanical coupling at valve shaft end slot for proper engaging of actuator.
9. Check the clutch ring & fork for any bend / damaged condition.
5 Limit switch Safety Hazard: Manger/ Safe Process:
setting & testing 1. Electric shock. Engineer/ 1. Use power tester, use LV hand gloves, shock proof safety shoe, insulated tools. Use only CAT IV
of actuator 2. Uneven surface / damaged/ Foreman/ multimeter. Only expert person shall be engaged for limit/torque setting with power on
(Power on corrode/ nonstandard platform & Supervisor/ condition of actuator. Connect earthing wire with the actuator body before power on the
condition) staircase. Technical actuator. Use electrical insulation mat on the floor. Always standby person shall be available
3. Hot process surface & pipeline. support/ nearby the working person at actuator end, another person shall be available in the MCC feeder
4. High pressure & temperature Technician. with online communication mode (mobile / walkie talkie) to isolate the power if any electrical
steam / water / oil / flue gas. shock hazard observed. Kept insulating rod at field (actuator end) to rescue if person come
5. Sharp edge of mechanical part. contact with live electric voltage. Ensure no mobile/walkie talkie used by the person who are
6. Falling object / tools / structure.
7. Bad weather for outside job.
8. High noise. P
engaging in actuator for limit/torque switch setting or actuator function testing.
2. Avoid damaged/nonstandard platform & staircase. Avoid slippery walkway / platform, avoid the

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area where material deposition found, avoid projected structure on the platform. Made

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9. CO/BF gas scaffolding as where required. Use full body harness as where required.
Environment: 3. Do not touch any process line. Keep safe distance from hot process surface & pipeline. Wear
Steam, hot water, hot air, Dust, oil, grease,
Noise, COG/BFG
Quality: Tolls, PPE
l i d heat proof PPE (LV flash Jacket, hand gloves, goggles). Do not perform the job where insulation
is not present in energized steam, hot water, oil, and flue gas line.
4. Do not proceed if any leakage observed from gland or nearby line. If not then proceed for job,

V a Wear LV flash jacket, safety goggles, face shield, cotton hand gloves.
5. Do not touch any sharp edge of structure/pipeline, insulation sheet & plate. Barricade the area,
cover the sharp edge by clothes, wear cut resistive hand gloves.
6. Kept the loose accessories on the solid platform, if grizzly floor, use mat/tarpaulin, hold the tools
and accessories properly.
7. Check the weather condition: rain, excess hot weather, high velocity wind flow, thunderstorm.
Wait for normal weather condition.
8. Use earmuff / ear plug.
9. Use personal CO gas detector (calibrated). Mandatory for gas prone area.
Check points:

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1. If R, Y & B phase of power cable to be inter changed, do it at MCC end instead of actuator end
with isolate the power. Standby person shall be available with all electrical safety PPE
mentioned in point no. 1 (safe process).
2. Check all the covers are with seal/O-ring and tightening properly.

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3. All switch function with indication shall be checked at field and DCS/PLC end.

PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy a l
APPROVED BY
Name and Designation: H. P. Singh (Head)
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025
V
Signature with Date:
SOP Valid Till - 24-Apr-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 5 of 6

4. Torque shall be set as per valve OEM recommendation.

5. All fuse rating at actuator and DCS end shall be checked.
6. Overload setting shall be checked as per motor rating/as per motor name plate.
7. Check for any abnormal sound during opening/closing of actuator.
8. Check for any oil/grease leakage from actuator.
6 Visual inspection Safety Hazard: Manger/ Safe Process:
of actuator 1. Electric shock. Engineer/ 1. Use power tester before opening the actuator cover for any leakage current in the actuator
internal condition 2. Uneven surface / damaged/ Foreman/ body, re-check with CAT-IV multimeter. Use LV hand gloves, shock proof safety shoe, insulated
(When MOV corrode/ nonstandard platform & Supervisor/ tools. Only expert person shall be engaged for this job. Always standby person shall be available
actuator is in staircase. Technical nearby the working person at actuator end, another person shall be available in the MCC feeder
service condition). 3. Hot process surface & pipeline. support/ with online communication mode (mobile / walkie talkie) to isolate the power if any electrical
4. High pressure & temperature Technician. shock hazard observed. Kept insulating rod at field (actuator end) to rescue if person come
steam / water / oil / flue gas. contact with live electric voltage. Ensure no mobile/walkie talkie used by the person who are
5. Sharp edge of mechanical part.
6. Falling object / tools / cover.
7. Bad weather for outside job. P
engaging in actuator for visual inspection.
2. Avoid damaged/nonstandard platform & staircase. Avoid slippery walkway / platform, avoid the

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area where material deposition found, avoid projected structure on the platform. Made

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8. High noise. scaffolding as where required. Use full body harness as where required.
9. CO/BF gas 3. Do not touch any process line. Keep safe distance from hot process surface & pipeline. Wear
Environment:
Steam, hot water, hot air, Dust, oil, grease,
Noise, COG/BFG
l i d heat proof PPE (LV flash Jacket, hand gloves, goggles). Do not perform the job where insulation
is not present in energized steam, hot water, oil, and flue gas line.
4. Do not proceed if any leakage observed from gland or nearby line. If not then proceed for job,
Quality: Tolls, PPE

V a Wear LV flash jacket, safety goggles, face shield, cotton hand gloves.
5. Do not touch any sharp edge of structure/pipeline, insulation sheet & plate. Barricade the area,
cover the sharp edge by clothes, wear cut resistive hand gloves.
6. Kept the loose accessories on the solid platform, if grizzly floor, use mat/tarpaulin, hold the tools
and accessories properly.
7. Check the weather condition: rain, excess hot weather, high velocity wind flow, thunderstorm.
Wait for normal weather condition.
8. Use earmuff / ear plug.
9. Use personal CO gas detector (calibrated). Mandatory for gas prone area.
Important notes:

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1. In this activities, only visual inspection to be done, strictly avoid for any setting changing of
actuator.

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2. Very careful during cover removal & fixing job, only expert person executes this job.

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PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy a l i
APPROVED BY
Name and Designation: H. P. Singh (Head)
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025
V
Signature with Date:
SOP Valid Till - 24-Apr-2025
 STANDARD OPERATING PROCEDURE (SOP)
Tata Steel Meramandali
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01.04.2009
SOP NO. IMS/M/CEM/PH/E&I/SOP-02 Effective Date 10-04-2024 REV. No. 02
SOP DESCRIPTION Motorized Valve Actuator - Maintenance / Accessories SECTION CEM-PH-E&I (C&I)
replacement / Switch setting / Visual checking
DEPARTMENT CEM-PH-E&I PAGE Page 6 of 6

7 Return from job Safety Hazard: Manger/ Safe Process:

site to Control 1. Uneven surface / damaged/ Engineer/ 1. During moving from site avoid uneven surface, damaged/ corrode / nonstandard platform &
room. corrode/ nonstandard platform & Foreman/ staircase, do not use shortcut pathway, use tool bag to carry tools and accessories, do not
Return of work staircase. Supervisor/ engage both hands to carry the tools and material, during using staircase always use one hand
permit. 2. Slippery floor. Technical to hold the railing. Does not use mobile phone during walking to site.
Environment: support/ 2. Avoid the slippery floor, wet floor, avoid housekeeping area.
Technician. 3. Remove all scrap material, unused material, tools, cotton, oil/grease from the job site. Housing
keeping being done before leaving the site.
Quality: 4. Remove all manpower from the job site before moving to returning the work permit.
5. Remove the ESI lock before returning the work permit.
6. Fill all the required filed before returning of work permit to the owner department.
7. Put the used cotton, oily cotton, scrap to designated bins, do not mix each other.
8. Put actuator signals fuse at DCS/PLC end after clearance from owner department.

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9. Power on the actuator after taking permission from owner department.
10. Handover the actuator to owner department.

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a l i
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PREPARED BY
Name and Designation: Manmath Sahoo, Ashu Ranjan Behera, Pramod Subudhi, Ranjan Roy a l i
APPROVED BY
Name and Designation: H. P. Singh (Head)
Signature with Date:
Printed By -Rupender Singh(910722) Print valid till - 31-Jan-2025 Printed on - 21-Jan-2025
V
Signature with Date:
SOP Valid Till - 24-Apr-2025