Amended edition, August 1999 Amended Editi on, August 2007
Specific Practices for Instal lation and Maintenance of Rotary Equipment
Prepared by Functional Committee
OIL INDUSTRY SAFETY DIRECTORATE 7 th FLOOR, NEW DELHI HOUSE 27, BARAKHAMBA ROAD NEW DELHI-110 001
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NOTE
OISD publications are prepared for use in the oil and gas industry under Ministry of Petroleum and Natural Gas. These are the property of Ministry of Petroleum and Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.
These documents are intended only to supplement and not to replace the prevailing statutory requirements.
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FOREWORD
The oil industry in India is 100 years old. As such a variety of practices have been in vogue because of collaboration/association with different foreign companies and governments. Standardisation in design philosophies and operating and maintenance practices at a national level were hardly in existence. This, coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need of the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.
With this in view, the then Ministry of Petroleum & Natural Gas in 1986, constituted a State Council assisted by Oil Industry Safety Directorate (OISD) staffed from within the industry, in formulating and implementing a series of self- regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly, OISD constituted a number of Functional Committees of experts nominated from the industry to draw up standards and guidelines on various subjects.
The present document on " Specific Practices for Installation and Maintenance of Rotary Equipment " was prepared by Functional Committee constituted for total review of OISD standards on Rotary Equipment.
This document is based on the accumulated knowledge and experience of Industry members various manuals, national and international codes of practices. This document is meant to be used as a supplement and not as a replacement for existing codes, standards and manufacturers' recommendations. It is hoped that provision of this document if implemented objectively may go a long way to improve safety and reduce accident in the oil and gas industry. Suggestions for amendments, if any, to this document should be addressed to:
This document in no way supersedes the statutory regulations of CCE, Factory Inspectorate, or any other statutory body which shall be followed as applicable.
Suggestions for amendments to this document should be addressed to
The Coordinator, Oil Industry Safety Di rectorate, 7 th Floor, New Delhi House 27, Barakhamba Road New Delhi 110 001 (iv)
LIST OF FUNCTIONAL COMMITTEE MEMBERS
S.N Name Organisation Position in Committee 01 Mr. D.K. Puri Reliance Industries Limited Leader 02 Mr. S.K. Chatterjee Hindustan Petroleum Corporation Limited Member 03 Mr. P. Veerabhadra Rao Hindustan Petroleum Corporation Limited Member 04 Mr. T.V. Venkateswaran Reliance Industries Limited Member 05 Mr. A.K. Dash Indian Oil Corporation Limited Member 06 Mr. Deepak Prabhakar Mangalore Refinery and Petrochemicals Ltd. Member 07 Mr. R.C. Agarwal Bharat Petroleum Corporation Limited Member 08 Mr. K Ravi Kochi Refineries Limited Member 09 Mr. Shamsher Singh Oil Industry Safety Directorate Member Coordinator
Specific Practices for Instal lation and Maintenance of Rotary Equipment
1 INTRODUCTION
The proper upkeep and maintenance plays an important role in trouble free, safe operation of rotating equipment in the hydrocarbon industry. Sound procedures & practices for installation and maintenance are required to ensure safety and integrity of the equipment. These recommended practices should be helpful in forming systems & procedures. This document covers Rotating Equipment such as Pumps, Blowers, Fans, Steam Turbines, Gas Turbines, Compressors, Motors, Generators, Expanders, Gearboxes and Engines installed in hydrocarbon industry.
2 SCOPE The following specific maintenance practices for rotating equipment are covered in these recommended practices; a) Equipment Protection & Change Management System b) Lubricant and lubrication System c) Safe Commissioning Practices d) Root Cause Failure Analysis e) Safe Utilization of Lifting Tools and Tackles f) History Recording 3 DEFINITIONS 3.1 Equipment An asset & its associated parts /auxiliaries which are essential to achieve organizations business goal and requires strategic operational & maintenance attention from time to time and to keep it in a state of delivering desired service. 3.2 Protection The device or integrated system to prevent an equipment or group of equipment from undergoing potential failure or unsafe conditions. 3.3 Li fti ng Tool s & Tackles The devices & systems like Slings, Chain Blocks, Winches, Shackles, EOT, HOT and Cranes etc that are required to lift, carry, load & unload, support, install, and remove different equipment in course of various maintenance & operational activities. 3.4 Change Management Mechanism to control and manage changes to operating conditions, protection systems and mechanical systems of equipment that affect safe operation of the equipment. 3.5 Documentation A system to keep information in systematic manner, which is retrievable whenever required. (1) 3.6 Potential Ri sk The degree of probability for occurrence. 3.7 Root Cause Fai lure Anal ysis A data based analytical approach to identify the basic cause/s of failure 3.8 Commissioning Process of releasing an asset for normal operation. 3.9 Manufacturers Report/ Record Book (MRB) The documentation supplied by the manufacturer along with the equipment. 4.0 EQUIPMENT PROTECTION AND CHANGE MANAGEMENT
4.1 The equipment protections considered for safe operation include but not limited to critical parameters like vibration, bearing temperatures, axial displacement, motor winding temperatures, lube oil pressure/ temperatures, cooling water temperatures, and process parameters as applicable. 4.2 Records of equipment protection systems shall be maintained as per OISD 124. 4.3 Alarm and danger values for the above parameters shall be part of the record. 4.4 Procedures shall be in place to control changes to these protection systems. Procedures shall include authorizations required for carrying out these changes. Records of such changes shall be maintained. 4.5 The record of such changes should be in specific format mentioning, but not limited to the following: a) The details of equipment/ tags being considered for change b) The proposed nature of change c) The reasons for the change d) The potential risk involved in proposed change e) The time span of change (duration) f) The precautions to be taken for incorporation of change g) The precautions to be taken during operation and after implementation of change h) Define functional responsibility and authorization for implementation i) Feedback to initiator on incorporation of change j) Incorporation of change in as built drawing/ data sheet/ P&IDs/ Eqpt. Drawing and other relevant records. k) Information of changes implemented to concerned authorities A sample procedure & format is attached as Appendix-1 for reference. 4.6 Change management procedures shall include modifications to critical components like Seals, Bearings, Couplings, Shafts, Impellers and Lubricants. 5 LUBRICANT AND LUBRICATION SYSTEMS
5.1 Systems and procedures shall be in place to ensure the following;
a) Selection of correct lubricant in line with OEM recommendation/ National & International standards/Standard Engineering Practices. b) Adequacy of protections against lubrication failure. c) Lube oil condition monitoring as per OISD-RP-124. d) Replenishment/ replacement of lubricant. e) No mix up of lubricant grades/ brands during replenishment. 5.2 Make-up of lubricant shall be done ensuring that proper grade of lubricant in recommended quantity is applied. 5.3 Recommended grade of lubricant shall be displayed prominently on or near the equipment. 5.4 Procedure for proper storage and identification of lubricants should be followed. A recommended procedure for storage is given in appendix-II. 5.5 Procedure for identification of sampling points and sampling of lube oil should also be established to ensure proper collection and identification of samples. (3) 6 SAFE COMMISSIONING PRACTICES
6.1 Procedures should be in place to ensure proper installation and safe commissioning of rotating equipment as per specific practices mentioned in the relevant OISD standards and OEM guidelines. 6.2 Procedure shall cover the following: a) Checks for completeness of all systems and subsystems including fire protection systems as per OISD-STD-116 and OISD-STD-117 b) Adequacy of space around equipment for safe movement c) Availability of operating procedures including startup and normal/ emergency shutdowns d) Checks for functioning of interlocks and configuration of set-points of all protections like alarms and trips e) Identification of equipment specific hazards and steps taken to mitigate and to create awareness about hazards to all concerned. f) Training of manpower deployed g) Use of personal protective equipment h) Availability of commissioning spares and their replenishment. 6.3 Records of base data and specific problems faced during the commissioning shall be maintained.
7 ROOT CAUSE FAILURE ANALYSIS
7.1 System shall be established to carry out root cause analysis for failures that have impact on safety and environment. 7.2 The analysis should identify the cause of the failure and recommend corrective and preventive measures to prevent failure from recurring. A sample failure analysis report is attached in Appendix-III. 7.3 Root cause failure analysis should be based on the following broad steps; a) Data collection, observation and organization of data b) Sequence of events leading to failure c) Identification of probable causes d) Analysis of probable causes and identification of most probable cause e) Recommendation of corrective measures to prevent recurrence f) Implementation of corrective action and preventive action in a time bound manner 7.4 Cause of failure shall be categorized broadly as below: a) Process failure b) Component failure c) Design failures d) Human failure e) Failure of systems and procedures The action taken record on the recommendations shall be maintained.
8 SAFE UTILIZATION OF LIFTING TOOLS AND TACKLES 8.1 To ensure safe utilization of lifting tools & tackles, periodic inspection and testing as per applicable statutory rules and regulations applicable shall be carried out. 8.2 Each lifting tool & tackle shall have unique identification and shall display the safe working load, testing date and next due date for testing. 8.3 Records shall be maintained for verification
9 EQUIPMENT DOCUMENTATION 9.1 Proper documentation system shall be available to ensure safe operation of rotating equipment. 9.2 Documentation shall include the following a) Data sheets (4) b) Performance curves c) Cross sectional & constructional drawings and relevant P&ID d) O&M manuals and MRBs e) Commissioning data f) Maintenance History g) Break down/ failure analysis reports h) Change management procedures and records 9.3 Records/ documents should be maintained either in soft/ computerized or in hard/ paper form.
10. REFERENCES This document refers to the following standards/documents: a) OISD STD - 105, 116, 117, 119, 120, 121, 123, 124 & 125 b) API STD - 614 c) API RP - 686 d) Relevant API standards for specific equipments
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Appendix I
Sampl e Record for Alarm/ Trip Changes
Date: Request No.:
Plant Eqpt. Tag no. Description Probe Tag. No. Existing Setting Proposed Setting Reason for Change
Remarks
Initiated by:
Approved by:
Change Implemented: Date & Time
(Note: Authority for Initiating, Approving and implementing these changes shall be spelt out clearly)
(6) Appendix II
SAMPLE PROCEDURE FOR STORAGE OF LUBRICANTS
1. There shall be no direct contact between the drum and the ground, if storage is for period greater than 3 months. 2. Long term storage of lube oil shall be in covered area. 3. Containment facility shall be provided in Drum Storage Areas. 4. Drums in long-term storage shall be positioned horizontally. (Grease drums shall be stored Vertically) 5. The nozzles on the drum shall be kept at 9 and 3 Oclock positions. 6. Areas where short-term storage of Drums is done shall not have more than 5 drums. 7. For drums provided with valve and nozzle, a tray shall be provided underneath the valve. The tray shall periodically be drained to Used Lube Oil Drum or to OWS 8. A First In First Out policy for lubricant usage shall be used. 9. Shelf life of lubricants shall be mentioned