PowerPoint Presentation

[Audio] Standard Operating Procedure for T.M.A.l Gas Vacuum Pump Replacement at the T.P.R.E.L Bangalore Manufacturing Plant. This video demonstrates the safe and controlled procedure for replacing the T.M.A.l cabinet vacuum pump as per plant safety standards..

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[Audio] The objective is to ensure the T.M.A.l exhaust pump is replaced safely and efficiently, while preventing fire, explosion, and toxic exposure hazards.".

[Audio] Scope and Responsibilities: This procedure applies to all personnel involved in T.M.A.l vacuum pump maintenance and replacement. The Maintenance team is responsible for carrying out the vacuum pump replacement strictly in accordance with the SOP. The Production team ensures proper system isolation and complete purging before and after the activity. The HSE Officer verifies that all safety controls are implemented and oversees the activity throughout..

[Audio] "Why This Activity Is Critical: T.M.A.l is pyrophoric and highly flammable—it ignites instantly when exposed to air, and even small leaks can cause a fire or explosion. It also reacts violently with humidity, producing heat and releasing flammable and toxic by-products..

[Audio] In addition to fire hazards, T.M.A.l presents severe health risks. Inhaling its vapours can damage the respiratory tract and cause breathing difficulties. Direct contact can result in severe skin burns requiring immediate medical care, and splashes may cause permanent eye damage. Strict controls are required from the very beginning— to prevent any exposure of T.M.A.l to air, avoid accidental ignition during pump removal, protect personnel from toxic vapours, and ensure safe isolation, purging, and handling. Only trained personnel with appropriate PPE should perform this activity following all safety protocols meticulously.".

[Audio] "Preparation and Planning: Before starting the pump replacement, several critical steps must be completed. First, obtain a valid Permit to Work and prepare the Job Safety Analysis by evaluating the risks. Conduct a Toolbox Talk together with the Last Minute Risk Assessment to brief the team on safety measures, emergency procedures, and the specific tasks to be carried out. Emergency preparedness must be ensured, with fire control measures are taken. All personnel must confirm compliance with personal protective equipment requirements. The system must then be properly isolated, and the T.M.A.l gas line purged to remove any residual gas. Only after these precautions can the pump be safely removed and the new pump installed. Following installation, a pre-start up safety review (PSSR) before recommissioning the system. Careful planning and strict adherence to these steps are essential to guarantee both safety and operational integrity.".

[Audio] "Mandatory protective gear for safe work on the T.M.A.l system includes a fire resistant suit with face shield, fire resistant gloves, chemical resistant fire boots, and a full face respirator fitted with a B type cartridge. In addition, self contained breathing apparatus units and extra fire suits must be kept ready at the work location to ensure full emergency preparedness.".

[Audio] "For fire safety arrangements, personnel should wear fire‑resistant PPE at all times. Vermiculite powder and dry sand should be kept ready at the work area, and a dedicated fire watcher should be deployed. Backup fire suits and self‑contained breathing apparatus units should be available, while the T.M.A.l Material Safety Data Sheet should remain easily accessible. Finally, the scrubber should be running and its performance verified before starting the activity.".

[Audio] On‑site emergency response and rescue arrangements must be in place before starting work. SCBA sets and respirators shall be kept ready for immediate use. An ambulance must be positioned on standby at the site. Additional fire suits shall be available at all times. Ensure the exhaust system is operational. Emergency communication devices must be checked to confirm readiness. The rescue plan shall be clearly explained and briefed to all team members prior to commencement of work..

[Audio] Isolation: Ensure the main isolator is switched off and the process is completely stopped on both sides. Close all canister manual valves and apply lock‑out tag‑out on the TMAl supply valve. Switch off the vacuum from the HMI in manual mode and remove the CDA line from the three‑way valves to achieve complete isolation..

[Audio] Purging: Select any side to initiate nitrogen purging of the vacuum line and confirm that the Alox‑2 scrubber is in proper working condition. Open the left‑side valves 1.5 and 1.2 to start the purge. Maintain a constant nitrogen flow through the vacuum line for five hours to prevent backflow of air. After completion of purging, close valve V4.1 and remove the pneumatic hose. Finally, verify that the buffer tank level sensor LS4.1 indicates green, confirming the tank is empty and the system is safe and free of residual TMAl before proceeding..

[Audio] Pump Removal: Manually rotate the V4.2 handle to isolate the line. Disconnect the electrical power supply to the pump to ensure it is completely de‑energized. Remove the gas ballast nitrogen connection, followed by the KF25 flange connection. Unscrew the four mounting screws securing the pump base plate, then remove the four screws underneath the base plate to detach the pump safely for removal..

[Audio] Replace the pump and reassemble all components in the reverse order of removal. While handling and positioning the pump, follow proper lifting techniques, as the unit weighs approximately 25 kilograms, to prevent ergonomic strain or injury. Once correctly positioned, secure the pump to the base plate using four screws. Next, reinstall and secure the cabinet using four additional screws. Reconnect the KF25 flange connection, ensuring proper alignment and secure tightening. Finally, reconnect the power supply. After installation is complete, carry out a thorough system inspection before recommissioning to ensure safe, reliable, and correct operation..

[Audio] "Recommissioning: After installing the new pump, begin by opening valves V4.1 and V4.2, followed by valve V4.5. Removed the LOTOTO

Switch the system back to automatic mode from the HMI. Carefully check the vacuum pressure and inspect for any leaks. Finally, verify that all parameters displayed in the HMI are within the required limits. These checks confirm that the system is stable, secure, and ready for safe recommissioning.".

[Audio] Thank you for watching — Work Safe, Stay Safe.".