A

INDUSTRAIL TRAINING REPORT

at
INDIANOIL ADANI VENTURES LIMITED

As a requirement of the academic course

“ADVANCED DIPLOMA IN INDUSTRIAL SAFETY”

Submitted by
DEEPAK PANDEY

Course Conducted by
THANE BELAPUR INDUSTRIES ASSOCIATION
TECHNICAL INSTITUTE: 0408

Course Recognized by
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(MSBT) MUMBAI

ACADEMID YEAR: 2024-25

Page 1 of 84
 CERTIFICATE

TO WHOMSOEVER IT MAY CONCERN

This is to certify that DEEPAK PANDEY, a student of the Advanced Diploma in Industrial
Safety at Thane Belapur Industries Association, Rabale, Navi Mumbai, has successfully
completed eight weeks of industrial training at IndianOil Adani Ventures, Navghar Terminal,
during the academic year 2024-2025.

During his in-plant training, he demonstrated exceptional performance, successfully

completing all assigned tasks with dedication and professionalism. He exhibited sincerity,
discipline, and a strong work ethic throughout the training period.

We extend our best wishes for his bright and successful future.

For INDIANOIL ADANI VENTURES

Guttula Uma Mahesh

Manager-HSSE

Navghar Terminal

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 ACKNOWLEDGEMENT

I would like to take this opportunity to express my heartfelt gratitude to my training guide and
all the esteemed faculty members for their invaluable knowledge, guidance, and
encouragement throughout the training period. Their support has been instrumental in the
successful completion of my training.
I am deeply grateful to the management of IndianOil Adani Ventures Limited, Navghar
Terminal, for providing me with the opportunity to undertake this training as part of my
course.
I extend my sincere appreciation to all the officers, workers, and management staff who
assisted me in completing this project with their valuable insights and cooperation.
I am especially thankful to Mr. R.M. Kedia (Principal, T.B.I.A.) and Mr. Anil N. Coougule
(Course Coordinator) for their continuous support and guidance, along with all the faculty
members of this course.
A special note of appreciation to my project guide for their invaluable guidance and insightful
inputs, which greatly contributed to refining this training report.

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 TABLE OF CONTENTS

Chapter No Name of Chapter Page No.

1.0 Abstract 6
2.0 Organizational Structural & Layout 7-8
2.1 Organization structure 7
2.2 Plant Layout 8
3.0 Introduction 9-12
3.1 About Indianoil Adani Ventures limited 9
3.2 History 9-10
3.3 Training plant location 10
3.4 Number of Employees 11
3.5 Type of products, services, and facilities 11-12
4.0 Equipment and its maintenance 13-20
5.0 Maintenance of Equipment’s 21-26
6.0 Description of Operations 27-45
6.1 Tank Truck Loading Operation 27-30
6.2 Cross Country Line Pigging Operations 31-34
6.3 OWS Operations 35-39
6.4 Booster Station Operations 40
6.5 Preparation For Vessel Receipt & Loading 41-42
6.6 Cross Country Pipeline Operation 43-44
6.7 Pump Operations 45
6.8 Strainer cleaning operations 45
7.0 Safety procedures followed 46-
7.1 Work Permit Procedure 46-51
7.2 LOTO Procedure 52
7.3 Scaffolding Procedures 53-62
7.4 MOC Procedures 63-64

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8.0 Practical experience in industry. 65
8.1 Inspection of oil storage tanks 65-66
8.2 Different types of pressure relief systems & Testing 67-68
8.3 Inspection and Testing of Fire-fighting system 68-71
8.4 Preventive maintenance of Pipelines 72-76
8.5 Different type of valve and its maintenance 77-79
9.0 Special/Challenging experience encountered during training 80-81
10. References/Bibliography 82

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 1. ABSTRACT

This abstract encapsulates the essence of an eight-week industrial training program conducted at a
petroleum storage terminal. The training aimed to provide a comprehensive understanding of the operations
and safety protocols involved in managing a petroleum storage facility.

The training program covered various aspects, including the fundamentals of petroleum storage, handling,
and distribution processes. Participants gained insights into the importance of safety measures,
environmental regulations, and emergency response procedures within the terminal.

Through hands-on experience and theoretical sessions, trainees familiarized themselves with the equipment
used in storage terminals, such as storage tanks, pipelines, pumps, and safety mechanisms. They learned
about maintenance routines, quality control checks, and inventory management techniques essential for
efficient terminal operations.

Furthermore, the training emphasized the significance of adhering to industry standards and best practices
to mitigate risks associated with handling petroleum products. Participants were exposed to real-life
scenarios and simulations to develop critical thinking and problem-solving skills in managing unforeseen
challenges.

Overall, the eight-week industrial training in the petroleum storage terminal provided participants with
valuable knowledge, practical skills, and a heightened awareness of safety protocols essential for ensuring
smooth and secure operations in the petroleum industry.

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 2. ORGANIZATIONAL STRUCTURAL & LAYOUT

1.1 Organization structure

HSSE Head Safety Officer

Shift Incharge
-4
Operation
Manager
Officers - 28

Mechanical - 2
Terminal
Manager Maintenance Electrical - 2
Incharge

Pipeline Instrumentati
Incharge on - 2

Sales & Officers - 3

Distribution

Projects - 3

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1.2 The Plant layout

Page 8 of 84
 3. INTRODUCTION

3.1 ABOUT INDIANOIL ADANI VENTURES LIMITED

IndianOil Adani Ventures (IAVL), formerly known as Indian Oiltanking, is a leading midstream
infrastructure service provider catering to the Oil, Gas, and Chemical industries. With expertise in
terminalling services, infrastructure development, and renewable energy solutions, IAVL delivers end-to-end
services, from project conception to commissioning, as well as operation and maintenance of bulk liquid
storage facilities.

Since its inception in 1996, IAVL has played a pivotal role in addressing the storage and logistics needs of its
customers. The company is a joint venture between Indian Oil Corporation (IOC), a Maharatna PSU, and
Adani Ports and Special Economic Zone Ltd (APSEZ), India’s largest transport utility. This powerful
partnership enables IAVL to offer cutting-edge logistics solutions, technical expertise, and seamless storage
infrastructure for the petroleum, petrochemical, chemical, and gas sectors.

Backed by a global legacy in energy and chemical storage logistics, IAVL has built a strong reputation for its
ability to develop, execute, and operate complex storage facilities across diverse geographies. A hallmark of
the company is its unwavering commitment to the highest standards of Health, Safety, Security, and
Environmental (HSSE) practices. With millions of safe man-hours recorded, IAVL continues to earn national
and international recognition for its excellence in safety, sustainability, and operational efficiency.

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3.2 History

In 1996, Indian Oiltanking Limited commenced its operations in India. IndianOil Corporation Limited and
Oiltanking GmbH, Germany, (a group of company of the Marquard & Bahl's AG) were joint venture
companies of Indian Oiltanking. The company was formed to provide transportation and storage solutions
for crude oil and petroleum products.

In January 2023, Oiltanking GmbH divested its entire stake (49.38%) in Indian Oiltanking Ltd, and Adani
Ports and Special Economic Zone Ltd acquired the same. The organization was renamed as IndianOil Adani
Ventures Ltd (IAVL).

The Navghar terminal was built in the year 1997-98 and commissioned in the year 1998. The POL
(Petroleum, Oil, Lubricants) terminal has been built for receipt, storage, and distribution of petroleum
products. The Petroleum Products ranging from Class A to Class C under the classification in The
Petroleum Act 1934 are stored in various sizes atmospheric tanks, as per the Petroleum Act 1934.

The terminal relates to Jawaharlal Nehru Port Trust (JNPT) liquid cargo Jetty Bharat Petroleum Corporation
Limited (BPCL) by 2 Numbers of 24” NB pipeline used to receive and load ocean tankers. The terminal is
also connected with Oil and Natural Gas Corporation (ONGC)-Uran with a 12” NB pipeline to receive
naphtha from Oil and Natural Gas Corporation (ONGC). The terminal consists of 250,000 KL of storage of
various capacities both Fixed Roof and Floating Roof tanks.

3.3 Location

The terminal is located at 9 km stone from Jawaharlal Nehru Port Trust (JNPT), South East of Mumbai. The
distance to Panvel is 19 km and to Vashi 21 km. The distance from the jetty is approximately 13 km. The
booster station is located at IOC plot in JNPT area, 6½ km from the terminal in front of JNPT Port Users
Building. The site is located at Navghar, Dronagiri node NH-4B, Navi Mumbai. The terminal is located
inland about 13 Km from harbor (JNPT).

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3.4 Number of Employees

Number of persons working on site.

Department Nos of Employee

Head - Terminal 01
Operation Department 45
Maintenance Department 8
HSSE 02
Project 03
Admin & IR 03
Sales & Distributions 04
Occupational Health Center 01 (Visiting Doctor)
Contract workman 100
Security Guard 15
Total 182

3.5 Type of Products & Services

Sr. Name of Mode of Storage MOC Capacity

No chemical
1 Naphtha/ Motor Fixed Roof / Internal Floating roof / MS 1,20,000 KL
Spirit External Floating roof Tanks

2 HSD Fixed Roof Tanks. MS 1,20,000 KL

3 Furnace oil Fixed Roof Tanks. MS 1,20,000 KL
4 LSHS Fixed Roof Tanks MS 40,000 KL

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The terminal comprises the following facilities to handle class A, B & C petroleum products.

 Vessel unloading / loading facilities at BPCL liquid cargo jetty.

 Cross-country pipelines from jetty to terminal with a booster station.

 Cross country pipeline from ONGC tap-off point to terminal for pipeline receipt.

 Product Storage tanks.

 Automated loading bays for Tank Trucks.

 Rail Gantries for loading and unloading of Rail wagons.

 Variety of pumps with assorted capacities to carry out operations.

 Fully computerized Central Control Room.

 22 KV electrical supplies from MSEB.

 Air Compressors & Driers

 Fire Fighting System

 Automation

 Nitrogen Tank and Vaporizers

 Oily Water Separator (OWS)/ ETP (Newly commissioned)

 Ethanol and Additive Dosing System

 Sewerage Treatment Plant

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 4.0 EQUIPMENT AND ITS MAINTENANCE

Cross-Country Pipelines

Terminal has two 24” Cross-Country Pipelines from BPCL Jetty to terminal (13.5km) and one 12” (8km)
line from ONGC tap-off to terminal.

Out of two, one 24” pipeline is used for B.O. while the other is used for W.O. All the lines are piggable.

Booster Station

It is located approximately at 6km from BPCL jetty occupying space near to IOC JNPT Terminal. It has been
set up to boost the cargo in case of insufficient flow rate.

There are four Pig Barrels for Pig Receiving/Launching, pumps for Boosting Operation, Air Compressors,
Nitrogen Vaporizer, Air Eliminators, DG Set, Electrical Set-up, and Fire Fighting Set-up, etc.

Tanks & Pipelines

Terminal is equipped with Seventeen product tanks of various capacities with a total shell capacity of
250,000KL. Terminal encloses both Fixed Roof (Dome Roof) and Floating Roof tanks. Each tank has
dedicated set-up of pipelines for receipt and dispatch through Vessel, Rail, PLT and Tank Truck. All tanks
and pipelines are provided with proper earthing and bonding to avoid accumulation of static charge.

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Page 14 of 84
Page 15 of 84
Pumps

Terminal has different capacities of pumps for Truck Loading/Unloading, Tank Wagon Loading/Unloading,
Vessel/Barge Loading, Inter-Tank Transfer, Tank Recirculation, Pipeline Transfer, Fire Fighting, OWS
operation, etc. Electrical driven Centrifugal and Positive Displacement type pumps and Diesel driven pumps
for Firefighting fulfils the requirement of Terminal Operation. Pneumatic operated Diaphragm pump is
used for Tank Stripping and Line stripping operation. All pumps are flameproof type as per norms of The
Petroleum Act 1934.

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TLF Facility details.

TLF is designed to load Tank Trucks. It has total 16 numbers of bays and 21 loading arms, which can load
16 trucks simultaneously. It is fully automated. Weigh Bridge facility connected with TAS is provided.

Tank Wagon Siding

Tank Wagon Siding is meant to load/unload railway Tank wagons. Two spurs are there for handling
operations of two rakes simultaneously.

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Loading Facilities:

Three different grades of cargo can be loaded in maximum 50 wagons using 50 Loading Arms each.
Batch controllers serve the purpose of Automation.

Unloading Facility:

Two different grades of cargo can be unloaded. 96 numbers of decanting points for White Oil and 72
numbers of Decanting points for Black Oil.

Electrical System

At Terminal, two 22KV feeders fulfil the requirement of electric power supply. Main Substation, Substaion-
1, Substation-2, and Rail gantry Substation are meant for uniform Distribution.

At Booster, one feeder of 22KV fulfil power requirement. It also supplies power to IOCL, JNPT Terminal
on sharing basis.

Three Diesel Generators Sets of 625KVA capacity at terminal and one Diesel Generators Set of 625KVA
capacity at Booster ensure undisturbed power supply in case of State Board power supply failure. DG’s
provide alternative source of power supply. All electrical equipment connected to earthing made as per
IS:3043.

Air Compressors & Dryers

At Terminal, four Air Compressors & one Dryer are installed to meet the Air requirement. Out of above,
one compressor (35CFM) is meant for TLF Truck Loading, one Compressor (440CFM) to serve
requirements through terminal area and two Compressors (100CFM) are meant for Tank Wagon Loading,

Two Air Compressors (one of 440CFM & other 700CFM) at Booster to meet the Requirement of Air
pressure while pigging.

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Automation

Terminal is equipped with State-of-the-Art Automation. It comprises of Fully Automated Tank Farm
Management System, Truck loading Bays, Automated Weigh Bridge, Auto operated OWS and Remotely
operated Pumps, valves etc.

Nitrogen Tank & Vaporizer

Nitrogen Tank of 10.4 Cubic Feet per Minute (CFM) installed

near Pig trap fulfils the requirement of Nitrogen that is required
for class A product pigging. Two vaporizers, one each at Booster
and Terminal are provided for Nitrogen vaporization during
pigging.

Oily Water Separator (OWS) & ETP

Oily Water Separator at Terminal and Booster are provided for separation of oil from oily water that enters
the system. Main OWS at terminal located near PH-1 handles oily water from all over terminal area. Rail
Gantry OWS handles oily water from Rail gantry facilities. Booster OWS handles Oil water from Booster
Area.

Ethanol & Additive Dosing System

Ethanol Dosing Set up: Two tanks of 25 KL each are available with dosing pump along with 4 dosing bays
at TLF. The system is provided with full automation.

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 ELECTRICAL SYSTEM: Location-wise Electrical Equipment’s in Terminal:

Sr.no Description Rating Qty

1 22kv 6 pole structure 22kv ,300A 2
2 22kv SF6 circuit breaker 22kv,1250A 8
3 22kv VCB 22kv, 630A 4
4 Transformer 22KV/415V,1500 KVA 5
5 Generator 415 V,625 KVA 5
6 Generator 415 V, 75 KVA 1
7 415 V Air circuit Breaker 415 V,2500/2000/1600 A 22
8 3 Ph. Induction motor 415 V,15-315 KW 51
9 Air compressor 415 V,37-101 KW 6
10 UPS 415 V,40/20KVA 2
11 UPS 415 V, 2KVA 1
12 Earthing pit 154

Equipment’s in Main Substation (22 KV)

The Main Substation in our terminal is a High-tension substation of rating 22000 volts. The Main
Substation consists of three panels namely.
1. Panel no.1 Incomer from 6-POLE structure
2. Panel no.2 outgoing to Substation-1
3. Panel no.3 outgoing to Substation-2
The switching device used in the Main Substation panel is SF6 Circuit Breaker.

Equipment’s in Substation-1 (22 KV/415V)

Sr. no. Description Ratings Qty
1 HT panel 22KV 3
2 Transformer 1 & 2 1500 KVA, 22KV/415V 2
3 Generator 1 & 2 625 KVA,415 V 2
4 Motor Feeders 11.5 TO 200 KW 20
5 Outgoing feeder to rail gantry Substation 5

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 5.0 MAINTENANCE OF EQUIPMENT’S

Preventive maintenance is a proactive approach to maintaining equipment, machinery, or systems to prevent

breakdowns, malfunctions, or other issues before they occur and extend asset lifespan.

 Minimize downtime.
 Ensure safety.
 Optimize efficiency.
 Extend equipment lifespan.
 Ensure compliance with regulations.
 Achieve cost savings.

IAVL implements a system-based preventive maintenance schedule, providing monthly preventive

maintenance plans. In the event of any breakdown or corrective maintenance being required, the operations
department can raise a request within the system. This request will then be forwarded to the maintenance
head, who will delegate it to the relevant department personnel for further execution.
Figure 1: Basic maintenance structure

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Responsibilities amongst departments - maintenance activities workflow

While executing all the maintenance activities there are several interactions and responsibilities between
different departments, some of those responsibilities are described below.

Operations department responsibilities:

 Owner of the installation.

 Operate the facility according the IndianOil Adani Ventures Limited Operating Manual.
 Authorizing and issuing safe work permits.
 Deciding when an activity could take place.
 Preparing the installation for technical activities (Cleaning, LOTO)

Maintenance department responsibilities:

 Responsible for proper maintenance activities and that all equipment are fit for purpose according to
the applicable code/standard or regulation.
 Responsible for creating an ordered and updated data base with all the maintainable equipment
installed in the facility.
 Verify and approve all work orders that are created in the Inform System.
 Carry out risk assessments to identify critical equipment, (information required to define the
appropriate maintenance strategy). The outcome of any type of risk assessment shall be validated,
reviewed and applied by the maintenance department of each installation.
 Maintenance departments of the operational facilities can execute maintenance activities subject to a
proper qualification, certification, preparation and authorized/supported by the local and international
standards.
 Responsible for managing all maintenance activities carried out by contractors /vendors. Ensure that
the activities carried out by contractors are according to the applicable code/standard or regulation.
 Ensure that all repair/maintenance activities shall restore the integrity of the assets to warranty safe
operations.
 Carry out reliability-centred approaches.

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 HSSE department responsibilities towards maintenance.

 Advising and supporting the maintenance department by reviewing the work scopes and assist with
risk assessments of method statements and job/task descriptions.
 Audit, review, and approve all critical activities to be executed during maintenance activities.
 Provide suggestions, solutions and the barriers necessary to mitigate, the risks associated with the
maintenance activities.

Maintenance Strategy of Company:

IAVL Maintenance Policies.

“The company is committed to execute all maintenance tasks in accordance with applicable codes, standards,
and regulations within the established timeframe and with the required quality levels.

IAVL’s main objective is to guarantee a safe working environment for all personnel working every day in our
facilities, comply with all the parameters established in our HSSE manual, accomplish the IAVL
Maintenance program & objectives, and fulfil all of their customers’ needs”.

The IAVL maintenance policies are aligned with the HSSE policies of our organization.

a. Focus to extend the asset life cycle by:

 Warrant the availability and reliability of assets.

 Carry out a combination of engineering strategies based on preventive maintenance tasks, reliability,
and risk-based inspection.
 Apply a rigorous QA/QC approach to ensure the highest quality and efficiency.
 Execution of the activities on time according to the applicable maintenance / inspection frequencies.
 Use certified personnel for the execution of the activities.
 Implement an Asset Management Program.
 Identify assets with high frequency of failures (bad actors) and establish the proper barriers to mitigate
the undesirable effects.

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b. Preventing undesirable consequences for the organization.

 Compliance with statutory regulations.

 Carry out risk evaluations to identify the potential consequences in case of undesirable effects.
 Establish the appropriate barriers to mitigate the effects.

c. Contributing to create a reliable / profitable / safe atmosphere for personnel and assets.

 Always provide safe and cost-effective maintenance approaches according to our internal standards.
 Carry out audits and reviews to ensure a continuous optimization and improvement of our processes.

IAVL’s Maintenance program.

The IAVL Maintenance program is a combination of systematic processes that ensures a solid preservation
approach for all equipment according to company’s policies. The program is structured in 3 steps
described below:

A. Engineering evaluations: this step covers all the technical assessments carried out to develop the
Maintenance program applicable for each equipment. The engineers of the maintenance department of
our facilities shall combine the following approaches / strategies / methodologies / considerations to
create the maintenance program for the facilities: Reliability – Centred Maintenance approach, Risk
Evaluations (FMECA), considerations made during the design phase of the asset, maintenance costs,
applicable regulations/codes/standard and manufacturer recommendations. Other factors that shall be
also considered during the engineering evaluations phase are:
 Operational conditions, change of service, new external factors.
 HAZOP, HAZID, redundancy philosophy, SIL certifications / requirements.
 Other integrity assessments.
 Personnel technical experience.
 Historical data (maintenance background).

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B. Maintenance program development/execution: based on the results of the previous step and
combining the technical knowledge of the maintenance personnel of our facilities, a
maintenance/inspection program has been assigned and executed for all the equipment included in the
Asset Breakdown structure of the facility.

There are 2 types of maintenance activities that can be assigned to the assets:

Preventive maintenance/inspection activities and corrective maintenance activities (both types will be
explained in detail further in this document). The execution of the maintenance activities shall be carried
out by third party qualified, certified, and authorized by local regulation and applicable standards
contractors. IAVL staff can also carry out maintenance activities when all the following aspects are met:
 Tasks to be executed are covered inside the roles and responsibilities profile of the personnel.
 The personnel have the required certification, qualification, and experience according to the
applicable code/standards/regulation to execute the task.
 All the risks associated to the activity to be executed are covered, evaluated and mitigation actions
have been applied to reduce it to an ALARP level. Risks of not having warranty of the job have been
evaluated, considered, and mitigated.
 The execution of the task is supported / recognized by local authorities, insurance companies and the
applicable national/international code or standard.
 When applicable, the activity will be executed using certified tools, equipment and under controlled
conditions, such as specialized workshops according the applicable code/standard or regulation.
 Required QA/QC activities will be met as per applicable code/standard or regulation.

A maintenance report shall be created after the execution of the activity according to this standard.

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C. Maintenance reports / feedback: all the maintenance activities executed in the facilities shall be
registered/supported by auditable reports according to our maintenance document management system
policies (part 4 of this document). The functions of the maintenance reports are: create the maintenance
historical data of each equipment, provide support during audits and feedback to improve/update the
maintenance programs.

Schedule of Preventive Maintenance

STANDARD QUALITY ASSURANCE PLAN & MAINTANENCE
Preventive Maintenance Schedule
SL.
File No. Equipment Half
No.
Daily Monthly Quarterly yearly Yearly
1 MM-1 Pump & Motors * * * *
2 MM-2 Storage Tanks * * *
3 MM-3 Fire Engines * * * *
4 MM-4 DG Set * * * *
5 MM-5 HOVs (Product) * *
6 MM-6 MOVs (Product) * *
7 MM-7 Foam Monitors & Water Monitors *
8 MM-8 Loading Arms * *
9 MM-9 Above Ground Pipelines * *
10 MM-10 Under Ground Pipelines *
11 MM-11 Pump Strainers *
12 MM-12 Flow meter Strainers *
13 MM-13 Pumps (Water) * * *
14 MM-14 AMC of Fire engine *
15 MM-15 AMC of D.G. Sets *
16 MM-16 Testing of PVRV *
17 MM-17 Testing of TSV *
18 MM-18 Pumps Vibration Checking *
19 MM-19 PG Checking *
20 MM-20 CC Pipelines

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 6.0 DESCRIPTION OF OPERATIONS

A bulk liquid terminal consists of storage tanks with related facilities such as doc-lines & internal pipelines,
product pumps, tanker lorry filling shed, weigh bridges, firefighting system & other special equipment to
store and handle bulk liquid products.

Based on the terms agreed with customers the terminal generally offers handling and storage services such
as

MODES OF OPERATION FOR RECEIPTS & DISPATCHES

1. Receipt modes

Product is received through Vessel, Tank Wagon & Pipeline.

2. Dispatch modes

Product is dispatched through Vessel, Tank Wagon, Tank Truck and Pipeline.

General Operation of the terminal

 Receipt of product from ship to shore tank.

 Receipt of product from rail cars to shore tank
 Loading of product from shore tank to vessels and barges.
 Loading of product from shore tank to truck.
 Loading of product from shore tank to rail-car.
 Transfer of product from one shore tank to another.
 Circulation of product in tank.

Sampling :

Sampling is to be done as per Sampling SOP, pertaining to the guidelines in IQCM (Industrial Quality
Control Manual)

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6.1 TANK TRUCK LOADING OPEARTION:

The chapter outlines the procedure for execution of the Tank truck loading operation.

PRE OPEARTION-CHECKS:

TT at main NOT ALLOWED WITH

TT is checked for all safety BATTERY LIMIT
gate fittings as per 1. No match box, lighter.
explosive rules** 2. No mobile phones
3. No additional jars/cans
4. No tobacco or alcohol
consumption

Check TT
has all
No safety Yes
TT denied
entry fittings.
into terminal.

TT is leakage
free and in
operational.
No
condition

**DAILY CHECK:
12. PESO License
1. 24-volt battery 13. Calibration chart
2. Master switch 14. Fitness certificate
3. Fire extinguisher- 15. Hazchem card
10kg dcp, 1kg co2 16. Explosive license Yes
4. Master valve lever 17. Driver license
5. Quick shutter lever 18. Training certificate
6. UN Emblem 19. TREM card Entry through main gate
7. Spark arrestor 20. Basic PPEs.
8. PV valve/vent pipe
9. Fusible plug
10. Proper dome cover Clean
11. earthing strip

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TYPICAL P&ID OF A TT BAY:

IAVL Strict Following CMVR 1989 (Sec 129 to 137) requirements for loading and unloading of
flammable liquid tank-lorry.

Section 129. Transportation of goods of dangerous or hazardous nature to human life

Section 129-A. Spark arrester
Section 130. Manner of display of class labels
Section 131. Responsibility of the consignor for safe transport of dangerous or hazardous goods
Section 132. Responsibility of the transporter or owner of goods carriage
Section 133. Responsibility of the driver
Section 134. Emergency information panel
Section 135. Driver to be instructed.
Section 136. Driver to report to the police station about accident.
Section 137. Class labels

IAVL security checks the TT before entering to terminal and maintain the records as per regulatory
requirements w.r.t CVMR 1989 ( Sec 129 – Sec 137)

1. Whether valid license, Fitness, Calibration, and explosives Certificates are available in the vehicle?
2. Whether the vehicle has two fire extinguishers?
3. Whether there are any sources of ignition like match box etc. in the vehicle?
4. Whether the vehicle has at least a driver and a cleaner as its crew member?

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 5. Whether the driver has a valid driving license with endorsement for having undergone training for
carrying hazardous goods as per Motor vehicle act.
6. Whether approved quality flame arrester provided on the engine exhaust and muffler/silencer is
properly bolted without any leaks?
7. Whether each compartment of tank is fitted with independent vacuum and pre-operated vents (PV
Valve)?
8. Whether vehicle’s cabin is checked for presence of any flammable/explosive substance being carried
by the crew?
9. Whether TT has CCOE approved type spark arrestor & without any defects?
10. Whether the availability of the TREM card with the driver?
11. Whether the exhaust is wholly in front of the TT.
12. Tyre pressure of the tank-truck shall be as that mentioned in the calibration chart.
13. Whether there is facility to shut off the drain valves from the cabin in case of emergency?
14. Whether the vehicle has First Aid Box, Tool Box and Emergency Lighting?
15. Whether the driver has a copy of standing instructions and TERM card?
16. Whether the exhaust is wholly in front of tank truck and has ample clearance from fuel oil system
and combustible material.
17. Whether all electric wiring is properly insulated?
18. Whether all junction boxes are sealed properly?
19. Whether electrical equipment like generator switches, fuses and circuit breakers are located inside
the cabin or engine compartment?
20. Whether battery is in easily accessible position with a heavy duty switch close by, to cut off the
battery in emergency?
21. Whether battery terminals have protective rubber covers?
22. Does the vehicle have a reverse horn?
23. Whether the availability of separate wire braided rubber hose bearing ISI mark (as per IS 10733)
With both ends should be a brass coupling.
24. Whether Brass earthing strips welded at the body of Tank-trucks (used for earthing/bonding)

Checklist for Safe Unloading

 Park the Tank-truck in neutral gear and position the wheel chokes and apply the hand brakes.
 Ensure switch off master switch / cut off from battery.
 Ensure master valve is in open position.
 Ensure vehicle to be effectively earthed and bonded at the top & bottom throughout the Unloading
operation. Earthing and Bonding clamps should be clamped to Brass earthing strips i.e provided in
the TT. (None painted area).
 Place fire extinguisher (10kg) at the indicated position in front of the truck.

Page 30 of 82
 6.2 CROSS COUNTRY LINE PIGGING OPERATION:
Pipeline inspection gauge or PIG is a mechanical device that can be inserted into pipeline and used to carry out
pre-defined task at critical points along the full length of pipeline.

They are primarily used to perform the following operations: Cleaning: Internal cleaning of pipeline.

Batching: Physical separation between different liquids being transported in pipeline.

Displacement: Delivery of defined pipeline quantity.

Inspection: Estimation of inline condition and recording of geometric information with to the pipeline.

PRINCIPLE:

Pigs are propelled by a differential pressure maintained in the direction of PIG movement.

MEDIUM OF PIGGING:

Based on the class of product to be pigged, the following media are used for propelling PIG during an
operation:

Class B and C: - Air via air compressor at terminal and booster. At jetty, air compressor is rented.

Class A:- Nitrogen via nitrogen tank coupled with vaporizer at booster and terminal. At jetty via nitrogen
tanker coupled with vaporizer
PIG INSPECTION:

Hard cup pigs:

Minimum thickness:- 6-8 mm Minimum

circumference:- 188.5 cm

Preparation of hard cup pig:

Dimensions of hard cup pig should be as per the following table:

Cup No. Thickness in mm Circumference in cm Cup condition Pig condition
1 14 192 New
2 6-8 189 Ok OK
3 7-9 189.5 Ok
4 13-14 191.5 New

BASED ON THE USAGE THE FOLLOWING PIGS ARE USED:

Page 31 of 84
 Hard cup pig:

Hard cup pigs have cups mounted on to a mandrel and is primarily used to push high density products.

Pig cups are made from:

 Neoprene cup for general use.

 Polyurethane for special cargos like MTBE etc.

Mandrel is the steel shaft of the pig with provision for fixing
of 4 cup shown in the above diagram. Length of the mandrel is
less than pig trap length.

 Foam pig (Polly-pig):

Foam or Polly PIG is made up of polyurethane foam and is

primarily used for pipeline cleaning, drying and pushing low
density products.

Based on the density of foam they are classified as

 low density(2 lbs./ft3)

 medium density(5-8 lbs./ft3)

 high density(9-10 lbs./ft3)

 Caliper pig or intelligent pig: It includes smart sensor for

assessment of pipeline health.

Page 32 of 84
LAUNCHING PROCEDURE:

Assemble the
following:
Isolate the pig trap by closing the
“O”Ring Depressurize the pig trap inlet
Grease completely. and outlet valves completely.
Cotton waste
Tools

Open the pig trap door slowly

and
collects sludge in tray.

Insert pig in the right orientation (conical

portion
into the line).

Push the pig as close to the reducer section as

Place the pig stopper of proper size to hold the pig

in
its place.

Clean the pig trap door, apply grease, and place

the
“O” ring properly.

Close the pig door properly and pressurize the

pig
barrel to check for leakage.

Page 33 of 84
PIGGING FACILITY:

Be in close co-ordination with shift in charge and determine

approximate
arrival of pig with respect to quantity and pressure.

As the pig approaches:

Booster: close the bypass and lineup through kicker At terminal/jetty:

close CC line direct receipt valve and lineup through kicker/pigging
line valve

On receipt of pig in pig barrel:

Close pig trap MOV
Strip out the pig barrel by pressurizing Isolate pig
barrel and depressurize Drain remaining cargo if any
in tray Open bleeder vents on pig door Repeat
stripping

Pull out the pig from the barrel and do the following:

Close Drain valve

Clean and inspect the pig for reusability Check and clean pig barrel of
debris Close the pig door properly.
Ensure lineup is closed.


Page 34 of 84
6.3 OWS-OILY WATER SEPARATOR
Schematic of OWS facility:

Page 35 of 84
Sr. Item Description capacity
No
1 Pumps
Slop oil pumps To transfer slop oil with sludge to overhead sludge 5 kl/hr
collection tank
Sludge oil transfer pump To transfer sludge for disposal 10 kl/hr

De-oiled effluent To pump out de-oiled water to out creek 500 kl/hr
transfer pump
Treated water re- To transfer treated effluent back to inlet of TPI unit. This 30 kl/hr
circulation pump is done to maintain minimum
flow for effective operation of TPI
Oil monitor pump To pump sample to analyzer for measurement 2 kl/hr

2 Bar screen It removes large bulky objects, rugs, debris 1

etc. from effluent
3 TPI(tilted plate interceptor) It is provided to remove free oil from the oily water to 8 chambers
make it suitable for discharge
4 Oily water collection sump It is provided for collection of raw effluent and
transfer to TPI via channels
5 Slop oil pit It is provided to collect slop oil from the top
of TPI unit via skimmers
6 De-oiled effluent reservoir It is provide for collection of de-oiled effluent

7 Skimmers Skimmer pipe are provided for collection of oil from

the TPI chambers
8 Overhead sludge collection To collect slop oil transferred from slop oil tank

9 De-oiled analyzer It is provided to measure oil content(PPM level) in water

10 Tank farm OWS drain pits It is provided to collect oily water from tank farm area

11 Manhole chambers Collects oily water from nearby drain pits

12 Tank farm OWS drain These valves are provided to control flow of oily
valves water to main OWS
13 Tank farm storm water These are provided to release tank farm oil free
drain valves water directly to storm water drains

14 Rail gantry OWS This is provided to store and transfer effluent from
railway gantry.

Page 36 of 84
Basic component:

Page 37 of 84
TYPICAL PROCESS FLOW:

Process flow:

 Oily water from Tank farm, TLF, Pump-Houses and RG collection tank comes to main OWS.
 Oily water passes through Bar Screen that separates bulky objects, debris from the effluent.
 Oily water free from debris passes through the TPI separators by gravity from the oily water
collection sump.
 Baffle plates maintain a laminar flow condition which helps in effectively separate water, free oil
and sludge.

Page 38 of 84
 The separate oil rises upwards through inclined plates to the top surface of units, where it will be
removed by rotating skimmer and drained to the oil pit by gravity
 The sludge moves towards the bottom of the plate pack , where it is to be removed while
maintenance.
 The treated oil-free effluent will be pumped out to storm water drain with the help of de-oiled
effluent transfer pumps.
 The free oil collected at oil pit shall be pumped using vertically installed screw pump for further
disposal.
 A provision is made to re-circulate treated effluent back to inlet of TPI separator to maintain
minimum flow under dry conditions.
 Quality of treated water shall be constantly monitored with Oil PPM meter to ensure that oil &
grease limit shall not exceed 8 ppm.

Page 39 of 84
 6.4 BOOSTER STATION OPERATION:
It describes the various activities like line-up while Vessel Loading and Receipt, Air compressor operation, pigging
etc.
Navghar terminal receives products from the ocean tankers from BPCL / IOCL Jetty at JNPT Port. There are 2
cross-country pipelines connecting jetty to terminal for receipt and loading operation of ocean tankers.
To boost the ship discharge rate, booster station was designed near IOCL terminal at around 5.2 KM from the
jetty.
However, booster pumps are not being used as there is very little back pressure during vessel discharge and without
the booster pumps, vessels are able to pump more than 1000 KL/HR.
In addition to above, booster station holds greater significance due to -
o PIGs are received and re launched from booster station.
o IOCL has been provided connectivity from booster station, this enables IOCL to receive and load ship
using IOTL pipeline and pump.
o Reliance tank farm has been provided connectivity from booster station. This enables Reliance to
receive product from jetty using IOTL pipeline, in addition Reliance can pump product to IOTL
terminal and vice versa. This line up is currently not in use
o There is connectivity from BPCL cross-country pipeline to IOTL cross-country pipelines at the booster
station. This enables IOTL to use BPCL pipelines, which run from jetty to IOCL terminal.
It is the duty of shift manager to post one of the engineers, who is conversant with the booster station, during
the above operations at the booster station.
Booster Pump details:
Sr. No. Pump Capacity(m³/hr) Rating(KW) Max Pump Type Head
No. FLA(amp)

1 52 1000 315 545 Centrifugal 8

2 61 800 315 545 Centrifugal 8
3 62 800 315 545 Centrifugal 8
4 63 800 315 545 Centrifugal 8

Page 40 of 82
6.5 PREPARATION FOR VESSEL RECEIPT & LOADING
Before commencing the vessel discharge / loading operation, the Booster engineer would ensure the
following:

 All other lineups (tapings to Reliance, IOCL, BPCL pipelines) are closed and positively segregated.
 A good condition PIG has been inserted into the PIG launcher and the stopper has been put behind
the PIG. The O – ring of the PIG trap door is in good working condition.
 There is no stopper lying in the receiving PIG trap.
 The DG set is operational and has got sufficient fuel in the fuel tank.
 Check the operability of the 24 inch bypass valve on the cross country pipeline & 24inch PIG trap
valves on PIG launcher and receiver.
 Check for ullage in the slop tank.
 Ensure that all the pumps suction and discharge headers as well as Air eliminator pipelines are free
of any earlier product (especially when the earlier product is not compatible with the current cargo).
 For class A product, keep the vaporizer system ready for nitrogen pigging. Keep the firefighting
system ready at booster station.

PROCEDURE: Vessel Discharge

Page 41 of 84
Vessel Loading

Page 42 of 84
6.6 CROSS COUNTRY PIPELINE OPERATION:
Cross-country pipeline operation implies to operations by using cross-country pipeline.

Preparations:

Check for operational

condition of all related valves, Perform emptying line
drain points, vent points and pigging to make line
Pipeline to be made
line compatibility to carry out compatible to receive or load
ready for operations.
the operation. product.

Prepare for Hard Cup/Foam Pig

pigging.
Make suitable arrangements
of pigging medium. Acquire line fitness &
commencement Certificate
from the client ‘s
representative or surveyor.
.

Make launching pig traps ready

by inserting pigs. Confirm
operational
condition of all valves physically.

in
written before starting

Page 43 of 84
Procedures:

CP system to be kept energized to

ensure the integrity of the pipeline. To
Check and confirm minimize Corrosion, Line to be kept
readiness of CC line pressurized with Nitrogen that is
Limit line pressure to
to receive/load cargo pushed in while class A products
7.5 kg/cm2. pigging.
to OM/JGM.

Product pigging is carried

out to push the Continuously monitor line.
remaining quantity of Report leakage or CC line to be lined up for
product in the pipeline. vandalizing act immediately receipt/loading operation as
to the Shift I/C, OM/JGM/VP and when required.
Pigging to be carried out
as per SOP.

Check for pressure at regular intervals

and record hourly, in case of Vessel
Cargo Discharge/Loading operation or
PLT operation and on half hourly
basis in case of Pigging operation.

Page 44 of 84
6.7 PUMP OPERATION:
Pump operation implies to procedure for running pumps for various operations. Navghar installation has
mainly two types of electric driven product pumps:

Centrifugal Pump.

Positive Displacement pump.

Apart from product pumps, small capacity portable pneumatic pumps are available for evacuating smaller
quantities from tank and pipelines.

Positive displacements pumps are for transferring/pumping viscous products and are also used for stripping
tank or pipeline of remaining product. Foam pump is also positive displacement pump.

Centrifugal pumps are for transferring/pumping volatile products.

Pneumatically driven small diaphragm or rotary submersible pumps are used for stripping remaining
quantity from tank, pipelines.

6.8 STRAINER CLEANING OPERATION

Strainer cleaning of the pumps, PD meters etc. is done to remove solid matters, debris and sludge trapped in
the wire mesh of the strainers. By cleaning, obstruction to flow due to clogged wire mesh removed and free
flow of liquid is ensured.

Preparations & procedures

Keep empty metal drums along Strip out the pump suction Keep relevant tools,
with earthing clamps ready to line / connected line gaskets, cleaning
completely. material, etc ready.
collect the product if any while
opening strainer.

Isolate the line system /

pump totally.

Page 45 of 84
 7.0 SAFETY PROCEDURES FOLLOWED

At IndianOil Adani Ventures- NAVGHAR, has developed SOP’s for all routine activities/operation
works. The SOP’s available in system as well as hard copies with signed by Department Head and Terminal
Manager.
All employees are responsible for executing any work with reference of SOP’s.
Which activities are not routine which are executed through work permit system with proper risk
assessment.
SOPs are detailed instructions that outline the steps necessary to perform a particular task safely and
efficiently. SOP’s developed based on industry standards, regulations, best practices, and the specific
requirements of the organization. SOPs covered various aspects of operations, including setup, operation,
maintenance, troubleshooting, and emergency procedures.

IndianOil Adani Ventures have standard manual & procedures as listed below apart from SOP’s.
1. Work Permit Procedures
2. LOTO Procedure
3. Work Permit Procedures
4. Scaffolding Procedure
5. MOC

Above manuals include information on emergency procedures, hazard communication, personal protective
equipment (PPE) requirements, safe work practices, and regulatory compliance. Safety manuals are
regularly reviewed and updated.

Page 46 of 84
 Various procedures
7.1Work permit system.
The work permit system is followed as per OISD – 105. The permit-to work (PTW) system is a formal
written system used to control non-routine and any activity involving dangers requires issuance. A permit to
work is a document which specifies the work to be done and the precautions to be taken to complete that
work. Work permit is a signed statement by the permit Applicant, Authorized permit issuer and permit
receiver that a job may be carried out under stated precautions.

IndianOil Adani Ventures has its online system for the application, safety check and issuing of permit.
This is helpful in long term record keeping.

Also, terminal specific work permit flow procedure has been prepared and circulated amongst employees.

HSSE-managers and HSSE department officers are supposed to carry out work permit audits on ad hoc
basis. All high-risk potential jobs are to be performed under adequate supervision only.

Before issuing a work permit, the person responsible should satisfy himself/herself that the conditions at the
site, or on the equipment, are safe for the work to be undertaken. If any of the conditions cannot be met, the
work permit should not be issued. Work permits al- ready issued may also be subject to suspension or
extension. All parties involved, including operators, should be informed about what work is being carried
out and where. A general overview of what type of work is ongoing at which location(s) on the terminal
should be always on display in the control room.

Types of Permits:
 Cold Work,
 Hot Work,
 Confined Space Entry,
 Vehicle Entry,
 Electrical Work,
 Working at Height,
 Radiation Work

Permit Authorities:
a) Authorized Permit Applicant (APA): Initiates work permits and coordinates with managers to
ensure work doesn't disrupt other activities.
b) Authorized Permit Issuer (API): Issues work permits, ensures safety checks, provides necessary
equipment, and educates workers on safety measures.

Page 47 of 84
c) Authorized Permit Receiver (APR): Responsible for executing the work outlined in the permit and
ensuring compliance with its requirements.
d) Safety Checker: Ensures safety measures are in place and workers understand risks; may or may
not be the API.
Online Work Permit Flow Chart

Page 48 of 84
Job safety analysis (JSA)
Job Safety Analysis (JSA), also known as Job Hazard Analysis (JHA), is a systematic process used to
identify and mitigate workplace hazards associated with specific job tasks. The primary goal of a JSA is
to prevent accidents and injuries by analysing each step of a job, identifying potential hazards, and
implementing appropriate controls to reduce or eliminate risks.

APA together with contractor shall prepare Job Safety Analysis and get it validated from all HODs. Then
attach it with the permit system and change the status to IN REVIEW stage.

Based on the risk assessment/JSA, determine if any additional permits and documentation are required.
All safety requirements/precautions/controls shall be planned for or implemented.

Ensure equipment preparation including ECP as applicable, draining, depressurizing, purging,

verification of isolation etc.

Certify all identified equipment (Portable power tools, vehicles, crane, welding machine, grinding
machine etc.)

Inspect temporary electrical installations and inspect work area with respect to permit conditions and
JSA.

Finalize and Issue Permit to Work

The API ensures all necessary safety checks performed, ensure all permit conditions satisfied, all
precautions are taken, ensure supporting documents e.g. Gas-free certificates, JSA, Equipment
certification checklist, excavation clearance checklist, vehicle route map, ECP and drawings are attached
to the Work Permit.

The API or Safety Checker shall check that the equipment and location of work area are correct and in a
safe condition, as required by the Work Permit.

Then permit shall be issued to undertake work.

Conducting a Pre-Job Safety Briefing: The APR conducts a pre-job safety briefing with all workers at
the worksite whenever a Work Permit is issued or extended.

Last Minute Risk Assessment

Page 49 of 84
A Last-Minute Risk Assessment (LMRA) is an informal, on-the-job risk assessment in- tended to
encourage people to concentrate on the job and carry it out safely. Several of a LMRA have been
developed in the oil and gas industry. Similar to these well- known versions of LMRA, "Take 5 for
Safety" was developed internally and consists of the following five steps:

Stop and Look

Think Through the Job

Identify Hazard

Control and Communicate

Do the job Safely

Executing and Monitoring the Work: Work defined in the Work Permits only start within an agreed
time period, as designated by the API when the permit is issued.
A copy of the Work Permit and any attachments are kept in the Control Room while the work proceeds.
The Permit Holder (APR) keeps the original at the worksite (displayed in a visible location), available
for inspection and updating of relevant sections at any time.
The APR provides effective supervision in order to ensure that all applicable control/mitigation measures
set out in the Work Permit, ECP and any risk assessments/JSA are maintained throughout the work and
that the personnel working under the Permit Holder and the activities are conducted within the limits (in
respect of area, types of work, time) specified in the Work Permit.
The APR can stop work and seek advice from the API if conditions at the work-site change or if any of
the requirements on the Work Permit cannot be complied with, or if additional risks, which have not
been previously identified by a risk assessment/JSA, materialize.
API, HSSE Personnel carry out WOPAR audit/spot check to verify the effectiveness of the system.
Closing the Permit: Upon completion of the work, the work site must be cleared and cleaned. API
finally close the permit in the system.

Cancellation/ Suspension of Permit

Page 50 of 82
The API / HSSE Department can cancel a Work Permit whenever work scope has changed, permit
conditions or safety requirements are violated or work-site conditions change permanently.
In case of any emergency within the terminal, all on-going permits shall be suspended automatically.
In case of SIMOPS operation, the permit may be suspended.

Evaluation of permit
Permits are being evaluated on a periodic basis to strengthening work permit system. The evaluation
WOPAR system (template attached separately) is being used.
VALIDITY
No work permits are having validity of longer than 8 hours. In case of extension of job apply fresh
permit.

Contractor Equipment Certification

Wherever contractor equipment is being used, the equipment inspected and certified by IAVL authorised
person. IAVL has standard checklists of equipment checklists.
To manage a smooth operation of work permits IAVL has implemented its own online Benchmark
system which insures management of Work Permit, HIRA/JSA, LOTO & ECP.

Page 51 of 84
7.2Lock Out-Tag Out-Try Out
IndianOil Adani Ventures developed their own procedure establishes the requirements for the Lock-out
Tag-out Try-out (LTT) of energy isolating devices. It’s use to ensure that the equipment is isolated from all
potentially hazardous energy, and LTT is performed by the equipment owner (typically
Operations/Maintenance) before employees or contractors perform any servicing or maintenance activities
where the unexpected energization, start-up or release of stored energy could cause injury.

LTT procedure is applicable to all facilities and project activities (construction/ servicing/ maintenance/
inspection) within the operational control of Adani Ventures limited.

The LTT requirements do not apply to the following as per IAVL LOTO Procedure.

Hot tap work covered by a hot tapping procedure with strict safety measures and special equipment to
ensure service continuity without equipment shutdown. Risk assessment required.

Mothballed equipment permanently disconnected from

energy sources.

Minor, routine, and integral in-service equipment work

meeting specific criteria such as standard operating
procedures with precautions, equipment energization,
no guard removal, and no exposure to energized
equipment.

Plug and cord connected electrical equipment if the

plug remains within sight and reach of the person
performing maintenance, with control over unplugging
to prevent unexpected energization.

Conduct risk assessment/JSA considering possible isolation failures, their likelihood, and consequences and
choose appropriate isolation type and control level, prioritizing the lowest risk option carried out before
executing the work.

Before equipment shutdown (excluding emergencies), Operations department develops an ECP, accounting
for related systems and ongoing tasks.

Page 52 of 84
7.3Scaffolding Inspection Procedure at Navghar Terminal
Scaffolding inspection procedure shall be followed as below

 Requirement of scaffolding erection will be decided depending upon the activity at site. Concerned
department executor along with the executing agency (contractor) will appeal with a Scaffolding
Request Certificate as per attached Annexure:-1 depending upon the load and same shall be
approved by the Department head for the execution.
 Scaffolding request certificate will be submitted to the scaffolding inspection cross functional team
comprises with HSSE, Maintenance and Operation personnel.
 After the approval of Scaffolding request certificate contractor shall stack the required scaffolding
material at Site conforming the Work Permit System.
 Scaffolding CFT will inspect all parts of the scaffolding material as per checklist attached in
Annexure -2.
 After successful verification of the scaffolding materials contractor shall be allowed to start erection
procedure with the valid Work permit. Yellow Tag shall be displayed at site during scaffolding
erection.
 Once the erection procedure will be completed the CFT will inspect the scaffolding as Per
Scaffolding inspection checklist (Annexure: 3).
 Any punch point as per inspection checklist shall be rectified prior to final scaffolding certification.
 Once the scaffolding erection shall comply the check points as per scaffolding Audit checklist
(Annexure-4) contractor to display Green Tag prior to any maintenance activity on the scaffolding.
 Any maintenance activity which shall take more days, inspection shall be carried out in every 15
days depending as per Annexure 4.

Inspection Team: Pradeep Kumar, Shibasis Roy, Amit Sahu, Nishat

Karim HOD to approve the Request: Deepak Naik, Satish Mhatre

Page 53 of 84
SCAFFOLDING REQUEST CERTIFICATE

REQUEST FOR SCAFFOLDING

I hereby request that the scaffolding for purpose of …………………….. be erected for the duty (select
from load table as given below) and height.............Mtr..
Load duty Light Medium Heavy/Special
Maximum
Safe load in 75 150 225 300 450 600
Kg
Maximum
bay length /
width 2.7 2.2 1.8 1.4 1 0.8
in Mtr.
Tick
whichever
applicable

(Name & Signature of Executing Agency) (Name & Signature of Executing

officer) M/s Name:-

Signature Signature:-
Date:- Date:-

(Approved By Department Head)

Name:-
Signature:-
Date:-

Scaffolding checklist
Sl Description Okay Not Remark
Okay
1 Base plate & Sole board
Base plate of 150mm X 150 mm & 6mm thick

1.1

1.2 Sole boards at least 225 mm width & 38 mm thick.

Sl Description Okay Not Remark

Page 54 of 84
 Okay
Plank not to be used as sole boards

2 Plank (Scaffold board)

Fabricated metal antiskid platforms with minimum 2 mm
thick

2.1

Standard plank coupler used for fixing planks while making

platform. Planks secured by plank coupler at both ends to
prevent vertical & horizontal movement

2.2

Plank Overlap & Overhang

2.3  Plank overlap is only on the support (bearer)

 Plank overlap span is at least 300 mm
 Plank end not extended beyond 300mm from the centre

Sl Description Okay Not Remark

Page 55 of 84
 Okay
line of support bearer

Plank laying on platforms

 Plank laid flush side by side each other
 Each ends of planks placed end to end are independently
supported
 Corner Turnings : Planks that rest on a bearer, an angle
other than a right angle shall be laid first and planks
which rest at right angles over the same bearer laid
second on top
 Scaffold platforms, landings, and walkways laid at least
675 mm (3 planks) wide
 Platforms : Free of obstruction, unwanted material &
2.4 other tripping hazards
 Platform unit laid with a gap less than 25mm wide

3 Posts, Runners & Bearer

3.1 Sleeve coupler used for connecting two pipes

3.2 Post Joints : Joints in the posts are staggered & not
occurring in same lift height

Sl Description Okay Not Remark

Page 56 of 84
 Okay

3.3 Runners & Bearers are connected to the posts with right
angle coupler

Load should is on hinge and not against the bolt

3.4 Runners & Bearers fixed inside of each post
3.5 Bearers are installed on top of the runners and not installed
as hung from runner
3.6 At lifts to be planked, putlog couplers are used to attach
bearers to runners. This would not hinder placing planks.

3.7 Bearers coupled to supporting runner are placed as close to

post & not more than 300mm from the post
3.8 Bearer shall extend at least 100 mm beyond runner centre
line
3.9 Runner & Bearer (Base lift) shall be located at least 150mm
above scaffold base

Sl Description Okay Not Remark

Okay

Page 57 of 84
3.10 Runner & Bearer Joints: Joints close to the post and
staggered. No more than one joint between adjacent post

4 Bracings

Page 58 of 84
Sl Description Okay Not Remark
Okay
Transverse : Installed from base to adjacent lifts with an
angle of diagonal brace between 35° to 55°
Additional bracings in zig zag diagonal alternating
directions. For wide scaffolds not more than 3 adjacent bays
are left without transverse bracing

4.1

4.2 Longitudinal bracing : Scaffold length > Height

Diagonal bracing installed from base of first post to upward
with angle between 35° to 55° degrees to the extreme top.
Repeated at every 5th post

Page 59 of 84
Sl Description Okay Not Remark
Okay
4.3 Longitudinal bracing : Scaffold length < Height
Diagonal bracing installed from base of first post to upward
with angle between 35° to 55° degrees along entire length
to the last end post. Repeated at every 5th post

4.4 Swivel coupler used for connecting two Pipes at any angle
other than right angle for eg in bracings

5 Scaffold tubes
5.1 If not galvanized, tubes and frames are painted or varnished
through their exposed surface.
5.2 Steel tubes of 40 mm nominal bore with 4mm thickness
6 Working platform
6.1 Guardrails & Toe board
Guard rail at a height of 1200mm
Toe-boards not less than 150mm
Mid-rail shall at a height of 750mm

Platforms are fully decked without any openings. If opened

for tasks they are adequately guard railed

6.2 Landing platform at every 6m with guard rails & toe board

Page 60 of 82
Sl Description Okay Not Remark
Okay

7 Rope pulleys
7.1  Ring / hook type pulley used for lifting
 Rope pulley mounted on cantilever pipe projecting
outward not more than 750mm
 Hook type pulley is with a proper hook latch
 Couplers mounted on either side of hook to prevent
slippage
 Permissible load on pulley is 50 Kgs and ensured
 Gin wheel conforming BS 1692 or equivalent
 PP rope 18 – 20 mm dia

 Gin

wheel arrangement and personnel at ground level are not

in line of fire with load lifted
8 Beam Clamp
 Beam clamp used for a connecting a scaffold pipe to a
flange of steel beam.
 Beam clamps are used in pairs and one on each flange
in opposite direction
8.1

9 Ladder clamp

Page 61 of 84
 Sl Description Okay Not Remark
Okay
9.1 Ladders are fitted with ladder clamps

10 General
All steel fittings, Couplers and scaffold pipes are free from
defects and in proper working order.
Scaffold tag are displayed and in proper order

Date of Inspection: Inspecting Team (Name & Sign):

Page 62 of 84
7.4 Management of Change (MOC) Procedure at Navghar Terminal
Since even small changes may have significant unintended consequences, IAVL MOC procedure is to
ensure that all changes (other than replacement-in-kind) to an infrastructure, process or utility are properly
evaluated for their impact on HSSE, product quality, functionality or other consequences that may have
adverse effects, prior to implementation.

The changes could be driven by changes in laws, regulations or permits as well as by the strategy of
continuous improvements in our processes. All temporary and permanent changes (exceptions indicated in
Section 3) shall be evaluated and managed to ensure that risks arising from changes remain at acceptable
levels with no new hazards related to HSSE and quality and shall not compromise the existing safeguards.

Practical reasons for Management of Change (MOC) mainly include the following:
 When a “change” is introduced, there may be increased hazards/risks.
 Changing one or more pieces of equipment/system/process/procedure can directly or indirectly
affect the entire equipment/system/process/procedure.
 The downstream effects of a change may not be immediately apparent unless they are investigated
and evaluated.
 Implementing a MOC process provides a chance to allow qualified personnel to verify risk and
feasibility assumptions prior to making the proposed change.
 Changes are communicated to the right stakeholders and are properly documented.
 Provides an information repository over time to allow an easy access to lessons learnt and
considerations made in the evaluation of the changes.
 To maximize the effectiveness of the MOC, the following key steps shall be included:
 Define safe limits for process conditions, variables, and activities, and train personnel to recognize
significant changes.
 Use appropriate hazard analysis techniques.
 Authorize changes at a level appropriate to the risks and hazards.
 Communicate the essential elements of new operating procedures, in writing.
 Communicate potential hazards and safe operating limits, in writing.
 Provide training for new procedures that is appropriate to their complexity.
 Conduct periodic audits to determine whether the MOC process is effective.
 Provide limited timescales for temporary changes to avoid being accepted as normal practice.

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Page 64 of 84
 8.0 PRACTICAL EXPERIENCE IN TESTING AND MAINTENANCE

Working in testing and maintenance within an oil storage terminal requires a combination of technical
expertise, adherence to safety protocols, and efficient management practices. Here's a breakdown of
practical experiences encounter during my training period.

1. API inspection of tanks

2. Health Assessment of Pipeline

3. Scaffolding erection and spray painting of oil storage tank

4. Blasting and painting.

5. Preventive maintenance equipment

6. Fabrication and erection of pipelines

7. Miscellaneous operation and maintenance work

8.1 API Inspection of tank

IAVL has awarded job to 3rd specialised vendor for carrying out NDT and Health Assessment of tank as per
API 653, during tank maintenance and inspection. The tanks are located at Navghar, Navi Mumbai.
Following inspection carried out by my supervision.
Visual Inspection, thickness measurements of bottom plate, shell plate, roof plate, bottom sump, MFL, shell
& bottom settlement survey, Verticality & roundness as per requirement of API 653 guidelines.

External and Internal visual inspection carried out by API-653 inspector. Internal inspection of subject tank
i.e. VI, MFL, UT Crawler, thickness measurement, shell & bottom. Settlement survey, roundness &
verticality was carried out and the condition assessment is carried out based on Visual Inspection findings &
NDT results.

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Inspector prepares field data in accordance with generally accepted standards and code & good engineering
practices.

Inspections:

Health Assessment of Tank # 21 was carried out by

 Visual Survey of Tank as per API Inspection (External & Internal)

 Tank Settlement Survey (Bottom Settlement, Shell Settlement, Plumbness, Roundness)

 Magnetic Flux Leakage (MFL) for Bottom Plates Survey to detect, locate and measure the extent of

corrosion and pitting if any in the Tank Bottom Plates.

 Wet Fluorescent Magnetic Particle Inspection (WFMPI) for Bottom Plate Weld Joints

 Ultrasonic Thickness Measurement (UT) for Inspection of Shell Plates & Dome Roof Plates (at 16

compass directions – 5 spots on each plate along the shell course with help of UT Crawler, Shell Nozzles, at

approachable area.

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8.2 8Different types of pressure relief systems provided in the plant and some
testing done during my training period.
IAVL Navghar terminal has robust pressure relief systems to ensure the safe storage and handling of
various petroleum products. These systems are designed to prevent over-pressurization, which can lead to
catastrophic failures and potentially dangerous situations.

A pressure-relief device is actuated by inlet static pressure and designed to open during emergency or
abnormal conditions to prevent a rise of internal fluid pressure in excess of a specified design value.

Following pressure relief systems are available in our terminal and all has been checked and testing
recently.

Pressure Safety Valves (PSVs): Pressure safety valves are commonly used in petroleum storage terminals.
These are spring-operated valves that automatically open when the pressure in a vessel or storage tank
exceeds a predetermined set point. PSVs are essential for preventing excessive pressure buildup in storage
tanks and pipelines.

Pressure Safety
Valves

Emergency Venting: Emergency venting systems are designed to release large quantities of vapor and
gases rapidly in the event of a fire or other emergency. These vents can be triggered manually or
automatically and help prevent tank rupture or explosion in critical situations.

Weight-loaded Emergency Vent are installed on fixed roof tanks.

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Pressure Vacuum (PV) Valve:

PV Valve is fitted on volatile product tanks in place of free vents for regulated ventilation, thereby
minimize precious product loss. It is activated at pre-set pressure and vacuum created in the tank, thus
facilitating release of excess pressure and entry of fresh air respectively.

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8.3 Fire-fighting system checked and tested
A fire-fighting system for a flammable hydrocarbon storage tank is designed to
prevent, detect, and suppress fires effectively, ensuring the safety of personnel,
protecting valuable assets, and mitigating environmental damage.
Following fire fighting system are provided of flammable hydrocarbons storage tanks.
Fire water sprinkler system:
These systems protect the tank by releasing water in case of a fire. Water cools
the tank to prevent catastrophic failure.

Foam Systems:
Foam is used to suppress fires involving flammable liquids. It forms a blanket on the
liquid's surface to prevent fire spread.

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The high volume long range water cum foam monitors:
Minimum two HVLR monitors shall be provided for each tank farm containing
storage tanks of Class A products to meet the requirement. Monitors shall be placed in
opposite direction. The remote-control panel for HVLR monitor shall be min. 60 M
away from the tank / hazard to be protected and the projectile of the foam & target
object must be visible to the operator.

Rim seal fire detection and extinguishing system

All the floating roof tanks for Petroleum Class A application in various tank farm
areas are installed with metallic hollow tube type fire detection and actuation system.
 The automatic rim seal fire detection & extinguishing system immediately detects
& suppresses a rim seal fire till such time the external foam pourer system is
activated.
 Rim Seal Linear Heat Detection and Foam based Fire Protection System for
floating roof tanks is specially designed for extremely fast detection and effective
suppression of fires.
 The extinguishing media is AFFF (3% low expansion) premix foam solution,
which has excellent film formation & cooling properties to prevent re-ignition after
suppression.

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RIM SEAL FIRE DETECTION AND ACTUATION SYSTEM

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8.4 PREVENTIVE MAINENANCE OF PIPELINE
The following standards, codes and publications have been referred while writing this manual:

i. OISD-130 : Inspection of Piping System

ii. OISD-233: guidelines on inspection of on land non-piggable pipeline
iii. API 570 -Piping Inspection Code (Inspection repair, alteration, and re-rating of in- service piping
systems)
iv. ASME B 31.3 –Process Piping

1. PREVENTIVE MAINTENANCE & INSPECTION OF ABOVE GROUND PIPELINE

Visual Inspection External Corrosion Instrument aided inspection.

Leaks Bulging, Bowing and Sagging Ultrasonic Thickness Survey
Alignment Mechanical Damage from External Hammer Testing
Supports Forces Pressure Testing
Vibration Paint and Protective Coating Hydro Testing
Cracks
Insulation
Concrete Lining

2. Maintenance & Inspection of Underground Pipeline

For Inspection of underground piping, special care is required to be given due to significant external
deterioration caused by corrosive soil condition. Underground piping is mainly checked off-stream.
However, development of exigencies may require inspection of the same on the run after exposing the line.
If any industrial effluent is flowing over ground, where piping are laid or any environmental change is
noticed, the soil samples shall be tested to check the corrosive nature of soil and to determine the efficacy of
the existing coating and wrapping of the piping.

Types of Underground (U/G) Piping are broadly of two types in IAVL Plant.

U/G Piping with Coating & Wrapping

U/G Piping with Coating & Wrapping and Cathodic Protection

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Sr. No Test During/Frequency
1 External On Stream Inspections-Class II Pipelines. Not more than 3
(Note: External On-stream inspection to monitor deterioration shall Years OR Half
be visual and instrument-aided (ultrasonic, radiographic, Remaining Life
Thermographic) whichever is earlier
-- Visual Inspection to Include:
i) Leaks, ii) Alignment, iii) Supports, iv) Vibration,
v) External Corrosion, vi) Bulging, Bowing and Sagging,
vii) Mechanical Damage from External Forces,
viii) Paint and Protective Coating, ix) Cracks,
x) Insulation, xi) Concrete Lining )

-- UT Survey,
-- Radiography Inspection where UT not Possible,
-- Corrosion Probes, Corrosion Coupon
2 External On Stream Inspections-Class III Pipelines Not more than 4
(Note: External On-stream inspection to monitor deterioration shall Years OR Half
be visual and instrument-aided (ultrasonic, radiographic, Remaining Life
Thermographic) whichever is earlier
--(Visual Inspection to Include:
i) Leaks, ii) Alignment, iii) Supports, iv) Vibration,
v) External Corrosion, vi) Bulging, Bowing and Sagging,
vii) Mechanical Damage from External Forces,
viii) Paint and Protective Coating, ix) Cracks, x) Insulation,
xi) Concrete Lining )
-- UT Survey,
-- Radiography Inspection where UT not Possible,
-- Corrosion Probes, Corrosion Coupon
3 Comprehensive Inspections-Class II Pipelines. Not more than 10
(This is Shut Down Inspection. In addition to External Onstream Years OR Half
inpsection, additional inspections shall be carried out as Remaining Life
mentioned below.) whichever is earlier
(Inspection for Corrosion, Erosion and Fouling, Inspection for
Cracks, Inspection of Gasket Faces of Flanges, Inspection of
Hot Spots, Hammer Testing, Pressure Testing)
4 Comprehensive Inspections-Class III Pipelines. Not more than 10
(This is Shut Down Inspection. In addition to External Onstream Years OR Half
inspection, additional inspections shall be carried out as Remaining Life
mentioned below.) whichever is earlier
(Inspection for Corrosion, Erosion and Fouling, Inspection for
Cracks, Inspection of Gasket Faces of Flanges, Inspection of
Hot Spots, Hammer Testing, Pressure Testing)
5 Inspection of Underground Piping. Once in Five

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 -- Coating Survey (CAT, DCVG, Pearson) Years
6 Inspection of Underground Piping. Once in Ten Years
-- Random Dig Examinations
7 Inspection of Underground Piping. Once in Five Years
-- CIPS for pipes with CP
8 Inspection for Corrosion Under Insulation. Atleast Once in
-- check for corrosion by removing the insulation at the location Twelve Years
suspected

Corrosion rate and remaining life calculation :

The process/ procedure for Corrosion Rate calculation/ estimation shall be duly approved.

Remaining life of the in service piping system shall be calculated as per the following procedure

Corrosion Rate = (𝑇 𝑝𝑟𝑒𝑣𝑖𝑜𝑢𝑠 − 𝑇 𝑝𝑟𝑒𝑠𝑒𝑛𝑡)

𝑇𝑖𝑚𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑝𝑟𝑒𝑠𝑒𝑛𝑡 & 𝑝𝑟𝑒𝑣𝑖𝑜𝑢𝑠 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛

𝑇 𝑝𝑟𝑒𝑣𝑖𝑜𝑢𝑠 ∶ 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑎𝑑𝑖𝑛𝑔 𝑡𝑎𝑘𝑒𝑛 𝑑𝑢𝑟𝑖𝑛𝑔 𝑖𝑛𝑠𝑝𝑒𝑐𝑡𝑖𝑜𝑛

𝑇 𝑝𝑟𝑒𝑠𝑒𝑛𝑡 ∶ 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑟𝑒𝑎𝑑𝑖𝑛𝑔 𝑡𝑎𝑘𝑒𝑛 𝑎𝑡 𝑝𝑟𝑒𝑠𝑒𝑛𝑡

 Remaining Life
Remaining Life (years) = (𝑇 𝑎𝑐𝑡𝑢𝑎𝑙 − 𝑇
𝑚𝑖𝑛𝑖𝑚𝑢𝑚)
Where:
𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑅𝑎𝑡𝑒
𝑇 𝑎𝑐𝑡𝑢𝑎𝑙 ∶ 𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
𝑇 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 ∶ 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠

 Calculation of Minimum Required Thickness: T (minimum)

Minimum required thickness for carbon steel and alloy steel under internal
pressure shall be calculated as per the following procedure:

𝑇 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 = 𝑃x𝐷
(2𝑆𝐸 + 2 𝑌𝑃)

Where P = Internal Design gauge Pressure

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D = Outside diameter
S = Allowable stress at design temperature
E = Joint Efficiency
Y = Coefficient that takes material properties and design temperature into account

Page 75 of 84
For new piping system and for piping system for which service conditions are being changed, the probable
corrosion rate for determination of remaining life shall be determined using following method

- Corrosion rate for a piping system may be calculated from data collected on the piping system of
similar material and service.

- If data on similar material or service is not available, then it can be estimated from published data

- If corrosion rate cannot be established from above, the thickness determination shall be made within
3 months of service by thickness measurement of the piping system. Subsequent measurements shall
be made after appropriate intervals until corrosion rate is established.

REPAIRS AND ALTERATIONS:

The thickness reduction, damages etc. shall be ascertained to determine adequacy for continued service in
line with the design standards. In case pipeline sections fail to qualify the minimum requirements, affected
sections of the pipeline shall be replaced or repaired in line with the design code.

Non-Welding Repairs:

Clamping: Temporary repairs of locally thinned out sections or circumferential linear defects can be made
on stream by installing a properly designed and fabricated bolted clamps. The effect of clamping (crushing)
forces on the component shall be considered.

different size of pipe clamps

Composite Sleeves- Non-leaking corroded area and certain other types of defects may be repaired by the
installation of composite sleeve provided that design and installation method are proven for the intended

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service prior to application. Composite sleeves shall not be used to repair leaks, metal loss with a depth
greater than 80% of the nominal wall thickness, cracks, or circumferentially oriented defects.

Repairs by Welding-

Temporary Repairs: Temporary repairs, including on stream or off stream, a full encircle split sleeve or box
type enclosure designed to take care of internal pressure can be considered over damaged or corroded area.
Area with longitudinal cracks shall not be repaired by encircle sleeve.

If repair area is small and localized, temporary repair may be carried out using properly designed split
coupling or fillet plate patch. The material of repair will match with base metal.

Temporary repairs shall be removed and replaced with permanent repairs at the next available maintenance
opportunity. Temporary repairs may remain in place for a longer period of time only if approved and
documented.

Permanent Repairs: All repairs and alteration welding shall be done in accordance to the code to which
the piping system has been built.

Repairs to defects in piping component can be made by preparing a groove that completely removes the
defects and then filling the groove with weld metal deposits.

Corroded areas may be restored with weld deposits. However, Surface irregularities and contaminations
shall be removed before welding.

Insert plates may be used to repair the damaged or corroded areas provided following are met;

Following techniques being used in Terminal for health assessment.

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8.5 PREVENTIVE MAINENANCE OF VALVES
Preventive maintenance of these valves is critical to prevent leaks, ensure proper functioning, and minimize
the risk of accidents. Here are some common types of valves found in oil storage terminals and the
preventive maintenance activities typically carried out for each during my training period.

1. Gate Valves:

 Lubrication of stem and gate mechanisms to ensure smooth operation.

 Inspection for signs of leakage, corrosion, or damage to valve components.
 Testing of the valve's sealing integrity through pressure tests.
 Adjustment of packing gland bolts to prevent leaks.

2. Ball Valves:

 Inspection and lubrication of ball and stem assemblies.

 Checking for proper seating and tight closure to prevent leakage.
 Verification of actuator functionality (if applicable).
 Replacement of seals or seats if worn or damaged.

3. Butterfly Valves:

 Inspection of valve disc and seat for wear or damage.

 Lubrication of shaft and bearings to ensure smooth operation.
 Testing for proper sealing under different operating conditions.
 Adjustment of packing gland bolts to prevent leakage.

4. Check Valves:

 Inspection of internal components for wear, corrosion, or fouling.

 Cleaning or replacement of check valve internals to prevent blockages.
 Testing for proper opening and closing to ensure backflow prevention.
 Verification of sealing integrity through pressure tests.

5. Pressure Relief Valves:

 Testing of pressure relief set points to ensure they meet design specifications.
 Inspection of valve internals for corrosion, erosion, or fouling.
 Adjustment or replacement of spring mechanisms as necessary.
 Calibration of pressure relief valves to maintain accurate pressure settings.

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 6. Control Valves:

 Verification of control valve operation through stroke testing.

 Inspection of valve trim components for wear or damage.
 Calibration of control valve positioners or actuators.
 Cleaning or replacement of control valve internals to maintain
performance. Following different type of valve available in IAVL Terminal.

Function of
Valves

Isolation Regulation Non Return Special

Regulation

Regulation or Throttle or Control Valves control the flow, or pressure, through a system. Control valves can be
moved into any position, including fully opened and fully closed. They can be operated with a manual hand
wheel or can be equipped with an automated actuator. This is done by introducing resistance to flow either
by change in direction, or by causing restriction, or combination of both. Following are most commonly
used regulation/ control valves are

Non-Return

Non-return or check valves control the direction of flow. Flow in the desired direction opens the valve, while
flow in the opposite direction forces the valve to close. These valves are important for preventing backflow
to systems in some applications such as systems that have varying pressures and must be kept separate. Two
major types of such used valves are

Special

These valves are made to meet special functions like pressure relief, Multi directional flows basis the process
requirements. Typical examples of such valves are

Isolation Regulation Non-Return Special

Gate Valve Ball Globe Valve Swing Check Valve Pressure Relief Valve
Valve Plug Needle Valve Lift Check Valve Pressure/vacuum Relief
Valve Butterfly valve
Valve Multi-Port valves

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Page 710 of
84
9 SPECIAL/CHALLENGING

During my 8-week training period, I have encounter various challenges, here is a sorted list of these
challenges:
1. Safety Regulations: Understanding and adhering to strict safety protocols to prevent accidents and
ensure the well-being of all personnel.

2. Equipment Familiarity: Learning how to operate and maintain various equipment such as pumps,
valves, and meters used in oil storage and distribution.

3. Environmental Concerns: Managing potential environmental risks associated with oil storage,
including spill prevention and containment procedures.

4. Product Quality Control: Ensuring the quality and integrity of stored oil through proper
monitoring and maintenance practices.

5. Emergency Response Training: Being prepared to respond effectively to emergencies such as

fires, leaks, or other incidents that may occur at the terminal. Participation in on site and off side
mock drills.

6. Communications: Developing effective communication to collaborate with team members,

supervisors, and external stakeholders.

7. Maintenance Challenges: Addressing maintenance issues promptly to minimize downtime and

ensure the smooth functioning of equipment and facilities.

8. Training and Development: Continuously improving knowledge and skills through ongoing
training programs and professional development opportunities.

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 9. Team Collaboration: Working effectively as part of a team to achieve common goals and address
challenges collectively.

10. Risk Management: Identifying and mitigating potential risks associated with storage, handling, and
transportation of oil products.

10. DISLIKING:

 Shift Work: Many oil storage terminals operate 24/7, requiring employees to work irregular
hours, including nights, weekends, and holidays, which can disrupt work-life balance.

 Regulatory Compliance: Compliance with strict regulations and safety standards can be
challenging and demanding, leading to added stress for employees.

 Safety Concerns: Working in an oil storage terminal can pose significant safety risks due to the
handling of hazardous materials and the potential for accidents or spills.

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10.REFERENCES/BIBLIOGRAPHY

DOC-0201, IAVL-Maintenance Standard, Jan-2023, VERSION: 3

DOC-202, IAVL -Operation Manual, Jan-2023, Version:03
DOC-203, IAVL- HSSE Manual, Version: 3.1
DOC- PCS - 0027 -Assets & Operations Manual Lock-out Tag-out Try-out (LTT)
DOC-039-Standard Operating Procedure- Work Permit System
DOC-215-Management Of Change (MOC) -IAVL/COPR/HSE/MOC

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