internal recommendations swc 2011-12 · identification of hazards, risk register, job safety...

DRILLING RIG

CH-5 DRILLING RIG (LOC: DGM)

1. More persons to be attended MVT, First aid , and Fire fighting training

2. BOP pressure test/Accumulator Drill records to be maintained properly

3. Industrial hygiene survey (noise, illumination, vibration) to be carried out at regular intervals.

4. Checklist for daily inspection of equipments to be made available

5. Minutes of Pit Level Meetings to be recorded properly

6. Mock Fire drill to be carried out in odd hours

7. Proper visitor’s entry procedure to be introduced.

8. Smoking hut to be made available at well site

CH-2 DRILLING RIG (LOC: BGO)

1. Hydraulic testing of air vessels to be done in every three years

2. More persons to be attended MVT, First aid , and Firefighting training

3. Industrial hygiene survey ( noise , illumination, vibration)to be carried out at regular interval

4. Remedial action to be taken for reported near misses.

5. Tone mileage record of casing line is to be maintained properly


7. Pit level monitor should be made operational

8. Remote panel of BOP control unit is not working

9. Identification of hazards, Risk Register, Job safety analysis etc. to be made available

10. Form –B to be maintained properly

11. MSDS to be displayed near chemical loading point

S-7, DRILLING RIG (LOC: HSY)

1. More persons to be attended MVT, First aid, and Fire fighting training

2. ETP is not available

3. Industrial hygiene survey (noise, illumination, vibration) to be carried out at regular interval.

4. Risk Register to be maintained


6. Form-B to be maintained properly

7. Cold & Hot work permit to be filled up with proper item checklist

8. Proper visitor’s entry procedure to be introduced

CH-6 DRILLING RIG LOC: DRA

1. Daily, Weekly, Fortnightly records of inspection for Engines, pumps to be maintained.

2. More persons to be attended in MVT, First aid , and Firefighting training

3. Landing Pad with sandbag should be made available for safe landing with EED

4. Floor-o -matic should be made working


6. Oil trap should be provided to trap the spilled oil

7. Safety valve drain line should be anchored

8. ETP should be used to treat drilling wastes to reduce fresh water generation

9. Railing should be provided on water tanks

10. Housekeeping should be improved to reduce spillage of mud and lub oil

11. Cold & Hot work permit should be properly filled up

12. More display/ posters for safety awareness is highly recommended

13. Industrial hygiene survey (noise, illumination, vibration) to be carried out at regular interval

14. Date of commissioning, name of Installation Manager, Ambulance & Fire call numbers etc. to

be properly displayed

15. Gas detector to be made available at well site

CH-1 DRILLING RIG LOC: HVI




4. Hydraulic testing of air vessels to be done in every three years

5. BOP drill/Trip Drill records to be maintained as per OISD


7. Identification of hazards, Risk Register, Job safety analysis etc. to be made available

8. Area lighting near diesel storage tank should be adequate


S-5 DRILLING RIG LOC:CR


2. Shifting records of casing line to be maintained

3. Pit level meeting to be conducted in every month

4. Near misses to be reported and remedial action to be taken for reported near misses.

5. Pit level indicator to be made available at well site

6. Portable gas detector is not available at site

7. MSDS not displayed near chemical loading point

8. Industrial hygiene survey ( noise , illumination, vibration)to be carried out at regular interval.

9. General plinth condition near cellar is very poor

10. Smoking hut should be made available


S-4, DRILLING RIG( LOC:MSD)

1. Pit level Monitor Display at IM's Cabin to be made operational

2. More near misses to be reported and remedial action to be taken for reported near misses.


4. Spillage trap around fuel tank to be raised as per OISD recommendation

CH-3 DRILLING RIG (LOC: AMG-2)

1. Weekly, Fortnightly records of inspection for Engines, pumps to be maintained





6. BOP drill/Trip Drill records to be maintained as per OISD

7. Emergency Light inside the PCR not working

8. Fire extinguishers to be refilled periodically

9. Earthing of PCR & HSD tank to be replaced by proper GI strip

10. Mud Agitator motor earthing to be replaced

11. Laying of Electrical line near HSD tank to be properly protected

12. Clip attached to the end of the earthing cable HSD tank is out of order

13. Housekeeping of decanting pump should be improved to avoid spillage of diesel

14. Stacking of plastic containers in storage tanks should be avoided

15. High pressure delivery hose and pipes should be properly anchored

16. SRV and air vessel should be tested on regular intervals and test records should be maintained

17. Hot & Cold work permits should be maintained properly

18. MSDS not displayed near chemical loading point

19. Tel. Nos. in the display board to be updated



S-3 DRILLING RIG (LOC:HWN-H)






6. Pit level indicator to be made available at well site

7. Civil Contractor's labourer are working without PPE



10. Flammable containers should not be stored on the mud tanks

11. Walkways should be free from any material storage

12. LDO flow line should be made metallic

13. GI strip to be used for earthing of diesel tank



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WORKOVER RIG

BHEL IR-A

( Water Disposal Well)

1. Fire tender pump along with water storage tank should be incorporated with the out fit to

meet any emergency situation

2. More persons to be attended MVT, First aid , and Fire fighting training

3. Work permit (Hot and Cold) to be maintained properly



6. Gas detector to be made available

7. Vibrator hose to be properly clamped

8. Tray cover over BOP line to be made available

9. Pit level meeting to be conducted in every month and of minutes to be recorded

10. Fire Alarm to be made operative

BHEL IR-C WORKOVER RIG


2. More near misses to be reported and remedial action to be taken for reported near misses

3. Signboard –date of commissioning, no of wells service etc to be displayed at site

4. Fire mock drill to be carried out at regular interval

5. Engine shut off valve at Driller’s console to be made functioning





8. Illumination should be proper

9. Proper anchoring of bleed line and safety valve drain line

10. Spillage of oil and water should be arrested to provide safe working condition

11. Industrial hygiene survey ( noise , illumination, vibration) to be carried out at regular

interval

12. Casing line last change date is not available

13. Hot and cold work permits are not maintained


15. Inadequate area lighting

16. Proper maintenance of Register at site as prescribed in form E,J,B,&G to be practiced

RG-B WORKOVER RIG

1. Trip drill record should be maintained in the new format

2. Maintenance of register at site as prescribed in form E, J, B & G to be maintained



5. Signboard –date of commissioning, no of wells service etc to be displayed at site

6. Mock drill to be carried out at regular interval

7. Work permits (Hot and Cold) to be issued during relevant well operation & maintained

properly.

8. Industrial hygiene survey ( noise , illumination, vibration)to be carried out at regular

interval.

9. Record of inspection of rig engines and maintenance record to be maintained properly.

10. Fire tank to be placed as near to the approach road

11. SRV and bleed drain line to be anchored

12. Rubber Mat to be made available at Generator Hut

13. More persons to be attended MVT & First Aid Training

14. No gate at the entry


RG-E WORKOVER RIG

1. Gas detector to be made available at site

2. Maintenance of register at site as prescribed in form E, J, B & G to be maintained


4. Near misses to be reported and remedial action to be taken for reported near misses

5. Signboard –date of commissioning, no. of wells service etc to be displayed at site

6. Fire mock drill to be carried out at regular interval

7. Work permit (Hot and Cold) to be issued during relevant well operation



9. Industrial hygiene survey ( noise , illumination, vibration)to be carried out at regular

interval



CH-4 WORKOVER RIG



3. Identification of hazards, Risk register, Job safety analysis etc. to be made available at well

site

4. GI Strip to be used for earthing of Engine

5. Engine exhaust should be legged

6. Pump bleed and SRV drain line should be anchored

7. Hot & Cold permit validity date & time should be recorded and issuer & receiver should

sign

8. Relevant items in the Hot & Cold work permit should be checked

9. Standard Form-B Register to be used for recording relevant data

10. Commissioning reports to be filled up and recorded properly

11. Fire Mock drill to be carried out in odd hours

RG A WORKOVER RIG

1. Proper anchoring, greasing & coiling of Guy rope is highly recommended

2. Guy rope fixing is not proper

3. Exhaust manifold of Well servicing pump to be legged

4. Well servicing pump bleed and SRV drain line to be anchored

5. BOP control unit to be placed in safe zone

6. Slanting of Emergency escape rout should be more and landing area to be more safe

7. Engine shut off valve to be made working

8. Pneumatic valve to be made working

9. Form-B to be filled up properly

10. Training Register to be maintained properly

11. Fire alarm system to be made available

12. More safety signboard to be displayed


14. Near miss to be reported and remedial action to be taken for reported near miss

15. Fire tender pump along with water storage tank should be incorporated with the out fit to meet

any emergency situation

16. Industrial hygiene survey ( noise , illumination, vibration) to be carried out at regular interval


18. Tool box meeting to be conducted regularly



KREMCO WORKOVER RIG



3. Signboard –date of commissioning, no of wells service etc to be displayed at site.



any emergency situation.





RG-C ,WORKOVER RIG (KLN-16)


2. Record of inspection of rig engines and maintenance record to be maintained properly

3. Signboard –date of commissioning , no of wells service etc to be displayed at site


5. Maintenance of Register at site as prescribed in form E & G to be made available

6. More persons to be attended MVT, First Aid & Fire Fighting Training






11. Gas detector to be made available at well site

12. Proper drainage system to be made available

13. BOP drill should be carried out regularly

14. Casing line records should be maintained

15. More safety signboards should be displayed


CH-3 WORKOVER RIG (Chabuwa- 16)


2. More near miss to be reported and remedial action to be taken for reported near miss.

3. Identification of hazards, Risk register, Job safety analysis etc. to be made available at well site


5. Fire Mock drill should be carried out once in a month & record to be maintained properly

6. Form-B to be introduced

7. Fire tender register to be maintained

8. Hot & Cold work permit closing date & time, validity date & time to be recorded properly

9. Fire alarm system to be made operative

10. GI Strips to be used for earthing

11. Display boards to be properly written

12. First Aid Box to be filled up in regular intervals. Expiry date of medicines to be regularly

monitored

SKYTOP –B WORKOVER RIG



3. Identification of hazards, Risk register, Job safety analysis etc. to be made available to well site


5. Hot and cold work permit should be filled up properly and should be signed by the

issuer and receiver. Job closing should be recorded with signature of issuer and

receiver.


7. BOP drill records should not be kept in loose sheet

8. Electrical Record should be available at site

9. Daily Tool Box Talk file to be maintained

10. Eye wash station to be made available

11. MSDS display to be made available near chemical loading point

12. Fire Mock drill file to be introduced

13. Pit level meeting minutes to be recorded in file

14. Outfit engine housekeeping is very poor. Spillage of oil should be stopped

15. Severe corrosion of high pressure fittings. Need immediate replacement to avoid accident.

Regular visual inspection of high pressure lines and fittings need to be carried out.

16. Severe puncture of exhaust muffler of outfit Engine-need immediate repair/replacement. It is a

fire hazard.

17. Fire Alarm system to be made available

18. Gas testing record of nearby well to be maintained

19. Training Record Register to be maintained properly

20. First Aid Box to be properly filled up

21. Rubber in Engine hut to be made available

22. Landing of emergency escape device should be improved

23. Fire pump not available


CARDWELL- C WORKOVER RIG

1. More near misses to be reported and remedial action to be taken for reported near miss

2. Safety display is highly recommended

3. Training Register to be introduced

4. Tool Box Talk file to be maintained

5. Industrial hygiene survey (noise , illumination, vibration) to be carried out at regular interval



7. Identification of hazards, Risk register, Job safety analysis etc. to be made available at well site

8. Punctured exhaust manifold of the outfit Engine - need to be repaired/replaced. It is a fire

hazard.


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GAS COMPRESSOR STATIONS

USHAPUR GCS

.

1. Lube oil leakage, Water leakage in Gas Compressor Shed and Air Compressor House

needs to be attended seriously.

2. Proper guards to be provided in running equipments.

3. Painting of vessels, Pipe lines, Compressors to be carried out.

4. Signboards/Display boards needs updated and repainted.

5. Surrounding areas need to be cleaned. Tree branches need to be pruned. Dry twigs

need to be removed.

6. Floor of Compressor sheds to be cleaned.

7. The house keeping is very poor (specially in Compressor area), to be improved Safety

related discussion should be organized periodically by IM at the site.

GCS # 1

1. Leakage of Lube Oil and water at Compressor House to be attended.

2. The outer layer of armored cable is not fitted with the cable gland at FLP Switch in side

the Compressor Shed.

3. The location of both Plan Layout Diagram & Electrical Single Line Diagram is not proper.

It should be located at the entrance to GCS plant.

4. The wooden boundary of Plan Layout Diagram Display Board is in broken condition and

the Electrical Single Line Diagram Display board is found cracked. Need to be remade.

5. Open holes in LPB instrumentation panel to be closed.

6. The house keeping is very poor, to be improved.


8. Signboards/Display boards needs updated and repainted.

9. Surrounding areas need to be cleaned.


11. GCS is having a separate boundary; hence separate drenching system shall be in place.

GCS # 8

1. Insulator of Exhaust Manifold of LPB#2 is found worn out. Need to be repaired.

2. Leakage of Lube Oil and water at Compressor House to be attended.

3. Surrounding areas need to be cleaned. Tree branches need to be pruned. Dry twigs

need to be removed.



6. The MS pipe armouring electrical cable is fitted loose with the ground. Need to be fixed.

7. The outer layer of armoured cable is not fitted with the cable gland at FLP Junction Box

in side Compressor Shed.

8. The FLP Switchgear Box near GL#2 is fastened loose with GI wire at one corner and

other corner is not fitted with body of Compressor Shed column and kept free. Proper

size of nut bolts to be fitted at both the holes of the top side of the box.

9. GCS is having a separate boundary; hence separate drenching system shall be in place.

GCS # 2

1. Fan Belt guards are not found in moving parts.

2. Unused Pneumatic pipe is hanging outside the instrumentation panel.

3. Cable termination at the Junction Box near GI#3 is not proper.

4. Data of HOT Crane Inspection is not displayed.

5. RCC ring of Earth pit found in broken state. Need to be replaced.

6. Lube oil and water leakage observed in compressor engines.

7. At the top of one of SRV found to be nested. To be removed the same.

8. Minor leakage of Glycol observed in the Reboiler unit.

9. There is no provision of Remote Ignition System.

10. Lighting cable height from ground is lower and easily accessible by hand. To be raised to

a safe height.

11. General knowledge regarding safety of working personnel observed to be poor.

GCS # 6

1. RCC rings of earth pit to be covered.

2. Speed Control Knob is found missing at GI#1 Pneumatic Control Panel.

3. Leakage of lube oil on the floor of GI#2 to be attended.

4. Oil spillage on the rubber mat inside Air Compressor House. To be attended and

cleaned.


6. Lube oil and water leakage observed in the engines at Compressors Shed and

Compressor House.

GCS #7


2. Lube oil and water leakage observed in the engines at Compressors Shed and

Compressor House.

Langkashi GCS

1. Water leakage found at GL Compressors. Prevention for stopping water leakage shall

have to be taken immediately.

2. Heavy water corrosion observed in all the compressors.

3. Thickness measurement of Reboiler Chimney shall have to be carried out and action

may be taken for replacement, if required.


5. Cover of holes at GL No.2 Pneumatic Control Panel found broken.

6. Tap of water drain line not working. Water is found leaking at LPB No.3.

7. Lube oil spillage at the floor of Engine inside Compressor Shed.

8. Identification of Engines/Pumps of LPB and GL is not prominent.

9. Waste materials are stored at the backside of Motor Control Centre at GLYCOL Plant.

Kathalguri GCS

1. No name plate of Engines/Pumps inside Compressor shade.

2. Nomenclature wrongly inscribed as GS#2 in place of GL#2.

3. The flexible conduit for the cable of Pressure Switch of Air Compressor is damaged at

several places of the circuit. Need replacement.

4. Rubber mat in front of Compressor Control Electrical Panel is found worn out.

5. Earth pit at Reboiler Plant is not covered.

6. Instrumentation circuit cables in bunches are hanging at one end with naked wires in

front of pneumatic control panel.

7. Insulator jacket surrounding one pipe of Reboiler Plant found in open/damaged state.

8. The foundation bolts of motor for Glycol Reboiler Pump #1 found loose.

9. GCS is having a separate boundary (instead of common drenching with OCS); hence

separate drenching system shall be in place.

10. Leakage of Lube Oil at Compressor House to be attended.

11. Working people are not convergent with the safety concept like Mock Drill, Job Specific

Tool Box Meeting and Near miss Incident Reporting. Installation Manager to educate

these employees and organize safety related discussion periodically at site.

12. Sump of old GCS area is located nearer to the boundary wall. Action may be initiated to

relocate the same.

Nagajan GCS

1. Working people are convergent with the safety concept like Mock Drill, Job Specific Tool

Box Meeting, and Nearmiss Incident Reporting.

2. House keeping in Compressor Shed area and Air Compressor Shed area maintained

properly.

3. Drainage space for lube oil leakage, water leakage etc. in the Compressor Shed is

sufficiently maintained for proper drainage.

4. Heat Resistant Jackets of GL#1 & GL#2 are found in broken state, need repairing.

5. Markings of Earth Pits Covers are faded. Need painting in earth pit covers.

6. Electrical Junction Box near GL#1 is found loose. It is fitted with only one bolt at one

corner.

7. Earthing wire near 25 kVA lighting Transformer is found lying disconnected.

8. Indication bulb & cover (inscribed as “50% Load”) is found missing at Pneumatic Control

Panel for Gas Compressor.

Jaipur GCS

1. Rubber mats are worn out. To be replaced.

2. Ammeter Selector Switch Knob at 200A CFS at Compressor House is missing.

3. Painting at CFS Panel required.

4. A hole for Spare Indication Lamp at GB#2 (Gas Booster) Control Panel needs to be

covered.

5. Heat Insulation Jacket at GB#2 is found to be worn out. Need repairing.

6. Tachometer/Over speed Gauge is missing at GL#2 Control Panel. Need to be fitted else

hole without it needs to be covered.

7. Flexible Conduits for the control wires at GB#2 Control panel is found damaged. Need

replacement.

8. RCC ring covers for Earth Pits need to be marked.

9. House keeping needs improvement.

10. Water leakage, lube oil leakage found in Air-Compressor area.

11. Guards over moving parts need to be fixed.

12. Remote Ignition System to be incorporated at Reboiler unit.

13. Lots of idle lines are there in Reboiler unit. These are to be removed.

14. Painting of the station including Air Compressor is required.

Shalmari GCS:

1. Spillage of water and lube oil on the floors of engines at Compressor Shed and at

Compressor House. Floor needs repair.

2. General House Keeping is found to be poor.

3. Painting is required at Electrical Panels at Compressor House and Power House.

4. “Auto/Manual” Selector Switch and “Control Supply” Switch is found missing at Air

Compressor Control Panel #2. Either these are to be fitted or holes to be covered.

5. All open holes at the Main CFS Board at Compressor House needs to be covered.

6. Rubber Insulatioin Mats at Power House need to be replaced.

7. An engine at Power House is hunting. Need to be attended.

8. All earthing points at Earth Pit electrodes are to be painted.

9. Earth Pits to be covered. Some Earth Pit RCC Ring covers are found to be broken. Need

replacement.

10. Drainage is blocked.

11. Floor at Glycol Plant is dirty and spilled with water/Glycol.

12. Approach road to be made to Sump Pit and cleared from vegetation.

13. Fire Hydrant Monitors are to be increased to 04 Nos. from existing 01 No.

14. There is no fan belt cover.

15. Spillage of water and lube oil on the floors of engines at Compressor Shed.

16. Heat Insulator Jacket at GB#4 is found in damaged condition. Need repairing.

17. Equipments are not marked prominently in the Compressor Shed.

18. One no. oil-water Sump Pit is to be constructed near Reboiler before draining water.

19. Glycol Delivery line to the Contactor Tower from Reboiler needs to be insulated.

20. Painting of the station including compressors is required.

GCS#4

1. No Layout diagram, Single line diagram and Process Flow diagram.

2. Installation Manger’s name is not displayed.

3. Heat Insulation Jacket at LPB#4 Exhaust Manifold is worn out.

4. Heat Insulation at hot surfaces in compressors & Glycol outlet line required.

5. All electrical danger plates are faded.

6. There is missing Indication Lamp Holder and Lamp on the LPB#3 Pneumatic Control

Panel. Either it is to be fitted with Indication Lamps else holes should be covered.

7. RCC Ring Covers for Earth Pits to be painted and marked. Markings are completely

faded.

8. Electrical Rubber Insulation Mats are worn out. To be replaced.

9. Stringing of Lighting Cable from Air Compressor House to Methanol Pump Shed is found

to have low ground clearance. To be raised to a safe height.

10. Engine floor at Pit Pump Shed is found spilling with diesel.

11. Water leakage is found at one of the Fire Monitor operating valve.

12. Heat Insulating Jacket of Reboiler is to be renewed.

13. Ladder bracket at the top of the Contactor Tower is found to be open. To be bolted.

14. Leakage of lube oil & water observed at compressor and glycol delivery pump at

Reboiler.

15. Painting of compressors, vessels & lines is required.

16. HSD leakage observed in Sump Pump. Oil is seen in suction chamber of oil-water sump

pit.

17. Drain inside the station needs cleaning.

18. Fan belt guard at Aircompressor #1 is missing and needs to be fixed.

19. Floor area needs improvement in Air Compressor House.

GCS#5

1. Extinguisher locating positions are not shown in Layout diagram.

2. There is no display of Emergency Shutdown Switch.

3. Oil & water spillage is found at the Engine floor of LPB#1 & 2.

4. There is spillage of lube oil at engine driven Air Compressor Pump.

5. All Electrical Switchgear ( like Control Panel, Distribution Board, Main Switch Box, Starter

Panel) are needed painting.

6. Fuse Box Cover is in open condition at Water Pump House since there is no locking

screw of the cover.

7. The cover of Electrical Junction Box is not fitted at the Air Compressor House.

8. RCC Ring Covers for Earth Pits to be painted and marked. Markings are completely

faded.

9. Electrical Rubber Insulation Mats are worn out. To be replaced.

10. Unused/abandoned electrical Main Switch along with piece of cable is lying without

connection at Compressor House and near Process Area.

11. Emergency Shut Down Valve display board need to be fixed.

12. Compressor shed floor area observed to be slippery.

13. Water and lube-oil leakage observed in compressors.

14. Lube-oil spillage is observed in compressors.

15. Painting of compressors, vessels & pipes required.

Moran GCS#2

1. Earthing strips and earthing points at all Earth Pits are to be repainted.

2. Cover glass at Booster Suction Logging Meter is found missing.

3. Fuel Pressure line Gauge is found to be rusted. Need replacement.

4. Electrical Control Panel for Air Compressor Motors and all other Electrical CFS Boards

inside the station need to be repainted.

5. There are no coverings at some CFS boxes. Need to be covered.

6. Unused cable is hanging open with naked conductor. Need to be removed or insulated.

7. Foundation bolt at the Pre-Lube Oil Pump Motor is found to be missing at GL#2.

8. Cable Channel at GL#2 is broken. Need to be fabricated.

9. Heat Insulation Jacket at Compressor Shed and Glycol Unit are worn out. Need to be

repaired.

10. Insulation of Glycol delivery line to be provided.

11. Illumination at Compressor Shed and Glycol Plant is not adequate.

12. Remote ignition system to be incorporated at Glycol Plant for safe operation.

13. Display board of Crane Inspection need to be fixed at the entrance of Compressor Shed.

14. Painting of vessels, pipes and compressors are to be done. Surface corrosion/rusting is

observed in most of the lines and at some vessels.

15. Clamping to be done in most of the lines. Supports are available without clamp.

16. Support and Clamping is required in AGCL Off take lines.

17. Lube oil and Water leakage oil is observed in the compressors at Compressor Shed.

18. Drains inside Air Compressor Shed are not clean. Outside drains are observed full of dry

leaves.

19. Lube oil is observed in the Air compressor skid. Poor maintenance is observed at the

floor. The skids need to be cleaned regularly.

20. MSDS for Glycol is not available in the Reboiler shed.

Jorajan GCS

1. There are several open holes at the Pneumatic Control Panels GL#4 and LPB#5.

2. Water leakage at LPB#3.

3. Cable glanding is not proper at Air Compressor #1. It is tapped at the glanding point.

4. Voltmeter S/S at CFS Board Panel is missing at Compressor House.

5. Lighting cables are hanged at low ground clearance. To be raised to a safe height.

6. Under construction floor repairing job at Compressor Shed to be completed urgently.

7. Lube oil-Water leakage at Compressors at Compressor House.

8. Water pump leakage at Air Compressor shed observed.

9. Lube oil leakage observed at Air Compressor No. 2 & 3 at Air Compressor House.

10. Heat insulation repairing of hot surfaces of exhaust required.

11. Compressor skids needs cleaning.

12. Painting of vessels & Compressors should be carried out.

13. Floor repairing of Glycol Shed required.

Digboi GCS

1. House keeping is good.

2. SRV testing record shall be inscribed on the vessels.

3. Reporting of near miss incident report shall be encouraged.

4. Cable Trenches at Air Compressor House and at Power House to be filled up by sand.

5. Abandoned/Unused cables are to be removed.

6. Flexible Cable armour at the Power House Engine to be replaced.

7. Guard of Genset Coupling to be repaired.

8. Cover of Sump Pit to be refabricated. These are now worn out and accident prone.

9. Outgoing nullah of Sump Pit to be cleaned manually.

10. Display boards to be updated.

11. Unused/.abandoned material/equipments are to be removed from the site.

Hapjan GCS

1. Lube oil and water leakage at Engine floor of LPB#3 and LPB#2 Compressors.

2. No Fan belt is observed at LPB#3.

3. Repairing of heat insulation at hot surfaces required.

4. Compressor floor is dirty. Need to be cleaned.

5. Floor area of Compressor Shed and Compressor House need to be repaired.

6. Glycol delivery line needs to be insulated.

7. Lots of jungles are observed in the process plant areas. Need to be cleared.

8. There is no demarcation of Hazardous areas.

9. Unused cable is hanging at Glycol unit.

10. Display of Overhead Crane Inspection is to be hanged at the entrance of Compressor

Shed.

11. Cable trenches at Compressor House to be filled up with sand.

12. Air Compressor House is full of dirty with lots of cobweb.

13. Earth pits are to be covered.

Kathaloni GCS

1. Corroded waterlines in 3 nos. compressors need to be replaced.

2. Lube-oil & water leakage observed.

3. Painting of compressors at Compressor Shed and Compressor House is required.

4. Skids of all compressors need cleaning.

5. Dry vegetation near Reboiler and Pressure Vessels to be removed.

6. Lube-oil observed in outside water drain.

7. Foundation bolts for abandoned Pneumatic Control Panel need to be sheared at ground

level.

8. Exhaust heat insulated jackets are to be repaired at GL#2 & LPB#2.

9. Overhead crane Inspection display should be updated.

10. Cover glass of Logging meter to be fitted. Covers of Logging meter are open. To be kept

at closed position.

11. Wiring for pneumatic control at Air Compressor No.1 to be properly dressed.

12. Working personnel shall be made aware of safety terms.

FIELD GAS GATHERING STATIONS

Kusijan FGGS

1. Good house keeping.

2. CODP Shed floor repairing is required.

3. Remote ignition to be incorporated in the Indirect Heater.

4. Earth pit points to be painted.

5. Waste disposal bin to be constructed with proper colour codes.

Kathalguri FGGS

1. General Housekeeping of the area (other than process area) needs improvement.

2. Glass cover of Flare Meter is found in broken state. Need to be replaced.

3. Clamp at one point of 16 inches inlet Gas Line found to be open.

4. Cable of Pilot Guard is tapped.

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MUD PLANT

Kathalguri Mud Plant

1. All signboards shall be displayed systematically and proper shed for it shall be provided.

2. Salt may be stacked in wooden rack instead of stacking on the floor directly.

3. Electrical Junction Box inside the godown found open without the cover and all naked wires are

tapped.

4. The earth electrode of the Main Switch of the Temporary Security Hut could not be traced.

Shanti Mud Plant

1. The Pucca floor surrounding the storage tanks needs to be renovated.

2. Peripheral drains of the Mud Plants needs to be repaired.

3. Skid of Mud Gunning Pump is completely rusted and beyond use. Needs to be changed

/repaired on urgent basis.

4. Cable with Junction Box is found hanging. Needs to be removed.

5. Earthing Wire and earth electrodes are not found in the vicinity of the Godown Cum Office

building of the plant.

6. Mud Transfer Pump floor is completely corroded and need to be replaced.

7. Solution delivery line & Gunning line need replacement.

8. Pump Suction Line need to be replaced.

9. Storing of Salt in the Godown needs improvement.

Mud Plant #7

1. Water leakage is found at Mud Gunning Pump. Problem to be attended.

2. Pipes are rusted. Needs replacement.

3. Protection in effluent pit is needed to avoid overflowing/spillage of contaminated water to the

nearby areas.

4. Under construction shed over the pump shall be completed as early as possible.

5. Corroded portions in suction & delivery line need to be replaced.

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WORKSHOPS

Electrical Workshop

1. Housekeeping needs to be improved.

2. Overhead Crane needs to be inspected and the same to be displayed.

3. SOP should be available in regional language.

Transport Workshop

1. Alertness towards safety is highly commendable.

2. Lots of safety equipments have been introduced in the shop after reporting near miss incident

3. Benefits of near miss incident reporting and tool box meeting is appreciable.

4. Electrical SLD to be displayed at the entrance of Workshop.

5. SOP should be available in regional language.

6. Battery Charger Procedure shall be in trilingual.

ICE Shop

1. Housekeeping, storing of materials & equipment needs improvement.

2. Closing /Opening valve along with Pressure gauge should be incorporated inside the shop for

the gas inlet line.

3. More awareness to be created for use of PPEs.

4. Insulated Exhaust muffler may be installed for testing of engines directing the exhaust gas away

from the shop.

5. Oil-water trap near washing bay (equipment washing area) need to be constructed to trap Lube

Oil/HSD etc. before releasing the water to the central drain.

6. Transparent sheet may be fitted in front of Washing Room to protect spillage water to the shop

floor.

7. Overhead Crane needs to be inspected and the same to be displayed.

Pit Level Meeting to be organized periodically in the shop floor.

Well Logging Workshop

1. Concern on safety is commendable. Team spirit was observed while HOD was also present

during inspection time.

2. Assembly Point to be marked by display board.

3. Unused/abandoned Electrical Panel and cable to be removed from Cage Hole Workshop.

4. Conditions of electrical switch, cable termination and Electrtical Earthing Connection to be

rechecked thoroughly and appropriate measures to be taken accordingly for safe operation.

5. Worn out Rubber Insulation Mat in front of CFS Board to be replaced

6. Waste bin to be made in suitable location inside the premises.

Central Workshop

1. Good hospitality and introduction.

2. Earth Pit covers to be painted and marked.

3. Industrial Switch Socket and Plug to be replaced with ordinary bakelite switch socket and plug.

4. On site mock drill to be done once in a month.

5. Maintenance Schedule and Maintenance record is to be improved. SAP compatible report

generation may be explored with the help of ERP.

6. Equipment logbook shall be maintained for individual equipment.

7. Near miss incident reporting shall be encouraged.

8. Mines approval for Central Workshop (Earlier General Workshop) not found.

9. Project on adequate lighting should be expedited to improve the inadequate lighting.

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LPG Offtake points

LPG Gas Off Take Point

1. The Pressure Gauge near the inlet valve from LPG Recovery Plant needs to be replaced

(It is rusting and marking scales are not visible due to rusting).

2. The MS pipe armouring SCADA cable found open/ loose at one end increasing the risk of

snapping by accidental hitting through passer by.

3. Tree branches above the inlet valve for the gas inlet pipe from the DIKOM field needs to

be pruned.

4. One of stair case is unsafe since only a loose piece of MS sheet kept in one step.

5. Valves are not tested and periodic greasing is not done for easy opening and closing.

6. Earthings for the Gas Vessels are not provided.

Common Notes:

• Interactive talk/discussions amongst the shift employees of installations may be

organized periodically by each Installation Managers to increase safety awareness.

• The possibility to find out the solution to mitigate the birds’ excretion problem at the

Compressor Shed of GCSs installations may be explored in the departmental level.

OIL COLLECTING STATIONS

JOYPUR OCS

1. Walkway to be fabricated properly.

2. Colour coating of the pipes to be done.

3. Painting of crude oil storage tank to be done.

4. Drenching pump shed floor area to be raised to avoid water logging during rainy season.

5. Old static Fire water scrap tanks to be disposed off at the earliest.

6. Entrance to the Drenching Pump house is inconvenient for easy access.

7. Pit near COPD & Crude oil tanks is full of crude oil to be cleaned.

8. Earthen bundh of Disposal water tank to be improved.

9. Record of MVT and other Training to be maintained properly.

OCS – 8

1. Safety relief valves of COD pumps No. 1 & 2 are due for testing due date(14.09.2011)

2. Both the water disposal tanks are damaged/rusted to be disposed off at the earliest.

3. Crude oil storage tank No. 2 is out of order due to roof leakage to be repaired.


5. Boundary wall of OCS required as per norms.

6. Flow directions in the process piping to be marked with paint.

7. Safety distance of Indirect heater near the main gate to be checked and re-sited if

necessary

OCS – 2

1. To improve the efficiency of COD pump, one no. booster pump is installed near COD pump

shed, to be commissioned at the earliest.

2. Painting of crude oil storage tank, water disposal storage tanks to be done.

3. Open area over the valve outside storage tank bundh needs to be covered from the top.

4. Unused motors lying in front of the formation water pump house to be removed.


6. Gland leak in disposal pump to be repaired.

7. Drinking water facility to be provided.

8. Resiting of V-set antenna to be looked into as it is blocking the display board.

OCS – 1



3. SCADA tower to be painted.

4. Flow directions in the process piping are to be marked with paint.

5. All documents to be maintained in OCS for inspection.

OCS – 6.

1. Safety Relief valve (SRV) test record to be displayed near COD pumps.

2. Installation Manager’s diary to be maintained.

3. Scenario based crisis management plan to be displayed.


5. Formation water disposal and fire water scrap tanks to be disposed off at the earliest.

6. Proper lighting to be re accessed.

USHAPUR OCS :

1. Motors of various capacity (03 Nos.) lying near FWD pumps needs to be send to Electrical

Deptt for health assessment.

2. Safety Relief valve (SRV) test record to be displayed near COD pumps.

3. Training records to be maintained in systematic manner.

4. Crude oil and fire water scrap tanks to be disposed off at the earliest.

5. Tank farm in low lying area needs to be reviewed.

JORAJAN OCS :

1. Two nos. crude oil storage tank of capacity 795kl is leaking , needs to be repaired/replaced.

2. Drinking water facility to be provided.

3. Oil spillage near CODP area to be cleared.

4. CODP SRV test data to be displayed near COD pump

LANGKASHI OCS :

1. 1 No. Fire water monitor to be fitted in consultation with Installation Manager of Langkashi

OCS.

2. FWDP coupling guard is missing from its place.

3. Dismantled FWD pump is kept haphazardly.

4. During mock drill test leakage was observed from drenching pump delivery line in front of

manifold area.

5. Fire contingency plan to be made available at OCS.

6. Communication facility to be improved.

7. Scrap tanks to be disposed off at the earliest.

8. Coupling guard of CODP is missing from its place.

9. CODP SRV test data to be displayed near COD pump

10. Generator area house keeping to be improved

KATHALGURI OCS :

1. COD pump engine side area is slippery and unsafe for working.

2. FWDP coupling guards are missing from its place.

3. SRV test record to be displayed near CODP.

4. ET safety blow line to be properly routed.

5. Manifold area / ET area house keeping needs improvement.

6. Drinking water facility to be provided

TENGAKHAT OCS :

1. Electric siren is out of order.

2. Sound of mechanical siren is quite low.

3. During Fire mock drill test nozzle from monitor came out .It should be repaired/ replaced

FWD pump coupling guards are missing from its place.

4. SRV test record to be displayed near COD pump.

5. Communication with ITF to be reaccessed as drenching pumps to be operated from ITF.

6. Power house is within the OCS. The IM for the power house to be well defined.

7. General house keeping of the installation to be improved.

DIKOM OCS :

1. Engine driven sump/ pit pump belt guard is missing from its place.

2. Coupling guard to be fitted over drenching pumps.

3. Training matrix to be maintained.

4. Fire contingency plan to be updated.

5. ET area house keeping to be improved.

6. Well inspection report to be maintained.

KATHALONI OCS

1. Exhaust spark arrestor and belt guards to be provided in FWDP 4.

OCS 5

1. Drenching pump is at a distant place. Review is required.


NAGAJAN OCS

1. Belt guards over all rotating parts of Engine/ Pumps are to be provided

2. Scrap tanks to be disposed off at the earliest.

3. Coupling guard over Chemical dosing pump is required.

KHARSANG OCS

1. Tool box meeting records to be maintained.

2. Belt guard over sump/ pit pump to be fitted.

3. Boundary wall holes of the Crude oil tank bundhs to be closed.

HAPJAN OCS

1. House keeping to be improved.

2. During Fire mock-drill test drenching pump pressure could not be build up due to low

engine RPM

3. Painting of piping is required.

4. Additional fire extinguishers required in process area.


6. Recharging pump coupling guard is missing from its place.

MAKUM OCS

1. Display board of the main gate area to be updated.

2. Pit level meeting not conducted after September, 2011

3. House keeping in process area need to be improved.

4. Oil spillage in CODP and Tank area is observed to be cleaned..

OCS 4


SHALMARI OCS 1 :

2. Spark arrester in exhaust silences of COD pump to be fitted.

3. Emergency isolation valves to be identified.

4. House keeping in manifold and I/H area to be improved.

5. Remote ignition system to be installed.

6. Coupling guard over recharging pump to be fitted.

7. During Fire mock drill test, it is observed that water spray system in crude oil storage tank no.1

is not working.

SHALMARI OCS-2 :

1. Water leakage through Gen set no 2 radiator causes water spillage on the floor of the Gen-set

house

2. particularly in front of the control panel to be arrested.

3. Pump safety relief valve drain train to be maintained in close circuit.

4. Guard over FWDP coupling to be fitted.

5. During fire mock drill test one monitor is found faulty not developing pressure.

6. Remote ignition system to be installed in ET.


MORAN OCS-1 :

1. Safety relief valve drain train to be maintained in close circuit.

2. Pit safety meeting to be conducted monthly basis.

3. SRV out let lines to be connected to flare.

4. Coupling guard over recharging pump to be fitted.

5. Pressure gauge in flow lines to be installed.

****************************************************************************

EARLY PRODUCTION SET UP

BHOGPARA EPS :

1. Engine oil is spilled in cable trench in Generator House .Oil leakage was also observed from

engine of Gen set No.-1.

2. Radiator leakage was observed for Generator No. 2.

3. Safety relief set pressure date, hydro test pressure date etc. are to be updated and displayed on

the vessels.

4. Fire mock drill with the involvement of Fire Service personnel to be conducted once in a year.

5. Coupling guard of CODP is missing from its place.

HATIALI EPS


2. Process area house keeping to be improved.

3. Approach to crude oil tank to be developed.

4. Boundary wall of OCS required as per norms

5. Electrical siren to be installed.

HJC EPS

1. Oil leakage near CODP area to be cleaned.


DEROI EPS :

1. Gas Engine driven COD pump safety relief valve(SRV) bleed line to be disconnected from Pump

delivery line.

2. Spark arrestor and belt guard in the CODP engine to be fitted.

CHABUA EPS

1. Spark arrestor to be provided in CODP engines.


BHEKULAJAN EPS

1. 1 inch gas line near CODP to be buried.


3. House keeping in an around ET and I/H area to be improved.

4.

BALIJAN EPS

1. General house keeping to be improved.

KHUMCHAI EPS


2. Crude oil to be removed from the pit.

3. Pressure gauge in the flow lines to be installed.

QUICK PRODUCTION SET UP

KUSHIJAN QPS :

1. COD pump engine is in shabby condition needs to be cleaned at regular interval.

2. Belt guard of generator engine (No.1) is in damaged condition to be replaced with new guard.

3. Rubber mat to be provided near Generator control panel.

4. Spark arrester in exhaust silence of gen set No.2 to be fitted.

NKF QPS


2. SRV test records to be displayed near COD pump.

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WATER INJECTION STATIONS

1. Neat and clean Plant Lay out should be displayed near the entrance of boiler shed.

2. Distinct demarcation of working areas should be maintained with proper color code.

3. Floor of pump shed required to be repaired for maintaining smooth surface and water logging is

to be avoided.

4. Water leakage from pump should be prevented through proper maintenance schedule program.

5. Pump guard should be of standard size and proper material.

6. Pump plunger housing must have top cover while running.

7. OIL telephone must be in healthy condition.

8. Drinking water facility should be readily available.

9. Painting and housekeeping are to be improved to keep the equipment in well form.

10. Goggles required to be issued to all work persons.

11. Separate earthing to be connected to the instrument control panel.

12. Siren is to be installed in the shed

13. Sand buckets and extinguishers are to be installed near the shed in one place.

14. Re-insulation of engine exhaust pipes and spark arrestor are required to be undertaken along

with the maintenance job.

15. Height of pump sheds should be like the Moran Water Injection Station.

16. Crane for lifting and installing heavy motor, pumps and engines should be available inside the

shed. It will avoid removing/dismantling of CGI sheets and iron supports during maintenance of

heavy duty equipment.

17. Concept of double storied building for covering pumps, control panel, electrical sub-station,

store room , operator room, and officer’s room may reduce area of infrastructure. It will

facilitate the operator for close monitoring and controlling of process equipment safely.

18. Valve and instrument tagging should be available.

19. All local pressure gauges must be vibration proof type to avoid frequent failure of gauges.

20. Trimming of big and tall trees inside the premises should be undertaken before monsoon

comes.

21. Signboard of authorized personnel should be updated in time.

*************************************************************************************

BOILER BATTERY

DULIAJAN AND MORAN BOILER BATTERY:



3. Floor of boiler battery required to be smooth surface.


5. Pump guard should be of proper standard size and material.

6. Walkway towards shed should be of proper hard standing.





11. Separate earthing is to be connected to the instrument control panel.

12. Siren is to installed in the shed


14. Re-insulation of boiler, steam pipes and valves are required to be undertaken along with the

maintenance job.

15. Additional exit for operator and others should be available in case of fire/disaster.

LOCO TYPE BOILER

1. Fuel control valve may be incorporated to generate optimum steam pressure automatically. It will

avoid delay in manual adjustment of fuel required for immediate steam supply against demand.

2. Interlock for high fuel and steam pressure may be incorporated for safety of boiler.

3. Bi or tri color magnetic indicating water level gauge with alarm may be installed to replace the too old

glass gauge. It will facilitate the operator to maintain the water level easily in dark also.

DIGBOI LOCO TYPE BOILER BATTERY:



3. Cleaning of water reservoir tank should be undertaken periodically.

4. Leakage of steam from pump should be prevented through proper maintenance schedule program.



7. Siren to be installed in the shed



maintenance job.

10. Fuel control valve may be incorporated to generate optimum steam pressure automatically. It will

avoid delay in manual adjustment of fuel required for immediate steam supply against demand.

11. Interlock for high fuel and steam pressure may be incorporated for safety of boiler.

12. Bi or tri color magnetic indicating water level gauge with alarm may be installed to replace the too

old glass gauge. It will facilitate the operator to maintain the water level easily in dark also.

13. Additional exit for operator and others should be available in case of fire/disaster.

14. Pressure gauges are to be calibrated periodically.

FIRE SERVICE STATION

FIRE SRVICE STATION- DULIAJAN

1. Documentations to be improved.

2. Water bowser required for efficient service.

3. Monthly pit level meting to be conducted regularly.

4. Intrinsically safe communication system is required.

5. Satellite base for fire fighting system to be developed in Greater Tengakhat and Makum / Baghjan

area.

6. First aid box in fire tender is not maintained properly.

MORAN Fire Service :

1. Record is not maintained properly due to shortage of main power.

KHARSANG FIRE SERVICE

1. Additional fire tender is required.

2. The station is manned by one operator only in the night shift. Providing additional operator / security

guard to be looked into.

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WATER SUPPLY STATION

Water supply Station, Duliajan

1. Chain cover to be provided for the Bridge Motor.

2. Lift controlling Power Switch and the cable to be insulated properly to avoid short

circuit with the metallic drum.

3. Periodic Calibration of water level meter to be undertaken.

4. Flag for Eye Wash basin.

5. Unused Instrument / equipment to be tagged as “Not In Use” Flag

6. Electrical Panels inside Chemical handling area to be protected from Calcium Carbonate dusts.

7. Ladder hand railings to be in clean condition.

8. Washroom to be in useable condition.

*************************************************************************************

TANK FARMS

1. Weather proof paint is to be used for better condition of crude oil tank .

2. Last and next due dates of tank testing are required to be highlighted on the body of tanks.

3. All earthing materials should be of aluminum strips of proper thickness as per safety guide lines

4. Periodic testing of earthing should be undertaken on regular basis.

5. Floor and inside walls of dykes should be always in healthy condition without any crack.

6. Formation of moss and vegetation over the concrete surface is to be prevented.

7. Drains inside the tank areas are to be maintained as and when required for easy flow of liquied.

8. Motor driven drenching pump is required to be used in addition to DG pump

9. Quality and quantity of hydrant is to be maintained on priority basis.

10. Water leakage from pump gland is to be prevented




14. Pump guard should be of standard size and proper material.


16. Proper and standard contact and non-contact type tank level gauging system must be available

17. DGMS approved portable explosimeter must be used while undertaking gas testing in the tank

areas.

*************************************************************************************

BOWSER UNLOADING STATIONS



3. Floor of boiler battery required to be repaired for maintaining smooth surface.


5. Pump guard should be of proper standard size and material.

6. Walkway towards shed should be of proper hard standing.





11. Electrical earthing is to be connected to the instrument control panel.




15. maintenance job

16. Extinguishers of tankers to be checked as per statutory guide lines/norms. Date of re-filling of

17. dry chemical powder and next inspection date to be marked on the body of the extinguisher.

18. The above to be checked at the entry of gate by company’s authorized personnel.

19. Dry and clean earthing conductor with non sparking cap is to be installed separately so as to

20. ensuring proper earthing of truck during unloading operation.

21. Battery connection of truck must be in isolated condition before unloading operation . It is to be

22. ensured by an authorized personnel.

23. Spark arrestor must be in healthy condition and it is to be ensured by an authorized personnel.

24. Special arrangement for safe rescue of breakdown truck should be available inside the installation.

***************************************************************************************

LPG PLANT

1. Extinguisher of LPG tanker/cylinder truck to be checked as per statutory guide lines/norms. Date of

re-filling of dry chemical powder and next inspection date to be marked on the body of the

extinguisher. The above to be checked at the entry of gate by company’s authorized personnel.

2. Dry and clean stud type earthing connector with non sparking cap to be installed on the chassis of

the Tankers so as to ensure proper earthing during filling operation of LPG.

3. Battery connection of truck must be in isolated condition before filling operation of LPG. It is to be

ensured by an authorized personnel.

4. Spark arrestor must be in healthy condition and it is to be ensured by an authorized personnel.

5. Special arrangement for safe rescue of breakdown truck should be available inside the LPG Filling

Plant.

6. LPG Purging blower should be in running condition for a few minutes after carousal operation is

stopped.

7. Details of maintenance job in LPG Recovery plant should be recorded in SAP.

8. Important Documents (photo copies at least ) like Licenses, External Audits, Vessel Testing

records/certificates may be kept in a Single file for easy verification/confirmation,/ renewal.

9. Dumping of items like paper boxes, Register books etc. behind Panels of the

Control Room should not be allowed.

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POWER STATION

MORAN POWER STATION

1. Earthing system needs enhancements

2. Ultrasonic Pest Controllers may be installed in few locations to discourage entry of

rodents, birds etc. to the Turbine Hall. These Controllers to be switched off when

work is carried out nearby.

3. More Safety signboards to be displayed outside Turbine Hall.

4. More effort needed for Green Belt development.

5. Few more Electric Shock Treatment Charts may be displayed.

DULIAJAN POWER STATION

1. Earthing system needs enhancements

2. Ultrasonic Pest Controllers may be installed in few locations to discourage entry

of rodents, birds etc. to the Turbine Hall. These Controllers to be switched off

when work is carried out nearby.

3. More Safety signboards to be displayed outside Turbine Hall.

4. More effort needed for Green Belt development.

5. Barricades for new GT site need strengthening.

6. Few more Electric Shock Treatment Charts may be displayed.

***********************************************************************************

MATERIALS GODOWN

1.Hazard identification is to be carried out as per the nature of material.

2. Extinguisher of chemical powder and CO2 should be available in the godown

3. Bamboo ceiling is to be replaced with standard material as per safety guide lines.

4. Smoke detector may be incorporated wherever possible to avoid fire disaster.

5. Pressure of CO2 cylinder contained in water type extinguisher is to be maintained to optimum level

and it is to be ensured by concerned deptt.

6.Fire fighting training to be imparted to all persons involved in handling of materials inside the

godowns.

7. All liquid chemical containers are to be stored safely so to avoid leakage from the container.

Concrete dyke may be used for such material.

************************************************************************************