operation and maintenance guidelines for gas processing units · 2020-01-29 · rev-03: january 7,...

Rev-3: January 7, 2020

Operation and Maintenance

Guidelines for Gas Processing Units

GAIL (India) Limited (A Government of India Undertaking – A Maharatna Company)

Rev-03: January 7, 2020 of 19

Operation & Maintenance Guidelines for Gas Processing Units

Table of Contents 1.0 INTRODUCTION .......................................................................................................................................... 3

1.1 GENERAL ............................................................................................................................................................... 3 1.2 STANDARD OPERATING AND MAINTENANCE PROCEDURES (SOPS / SMPS) ....................................................................... 3 1.3 CRITICAL EQUIPMENT ............................................................................................................................................... 4 1.4 PREVENTIVE & PREDICTIVE MAINTENANCE .................................................................................................................. 4 1.5 STATUTORY PERMISSIONS ......................................................................................................................................... 5 1.6 TECHNOLOGY UPGRADATION .................................................................................................................................... 5

2.0 SAFETY & SECURITY .................................................................................................................................... 6 2.1 SAFETY .................................................................................................................................................................. 6 2.2 PRESSURE SAFETY VALVES ......................................................................................................................................... 7 2.3 SECURITY AND RISK MANAGEMENT OF OPERATIONAL TECHNOLOGY SYSTEMS .................................................................... 8

3.0 OPERATIONS ............................................................................................................................................... 8 3.1 GENERAL ............................................................................................................................................................... 8 3.2 ALARM MANAGEMENT ............................................................................................................................................ 9 3.3 ENERGY EFFICIENCY MONITORING AND CONTROL........................................................................................................ 10

4.0 MONITORING & MAINTENANCE OF GAS PROCESSING UNITS (GPUS) ....................................................... 10 4.1 GENERAL ............................................................................................................................................................. 10 4.2 ASSET INTEGRITY MANAGEMENT SYSTEM .................................................................................................................. 11

4.2.1 General ..................................................................................................................................................... 11 4.2.2 Major Maintenance / Overhauling: .......................................................................................................... 11 4.2.3 Inspection/Maintenance of Piping Systems ............................................................................................. 11 4.2.4 Gas Fired Heater /Columns / Heat Exchangers / Cooling Towers / Pressure Vessels ............................... 11 4.2.5 Annual Turn-Around ................................................................................................................................. 12

4.3 TEST AND MEASURING INSTRUMENTS ....................................................................................................................... 12 4.4 METERING ........................................................................................................................................................... 13 4.5 ELECTRICAL SYSTEM ............................................................................................................................................... 13

5.0 SPARES PHILOSOPHY ................................................................................................................................ 14 5.1 GENERAL ............................................................................................................................................................. 14 5.2 INSURANCE SPARES: .............................................................................................................................................. 15 5.3 SPARES FOR RUNNING MAINTENANCE:...................................................................................................................... 15 5.4 CONSUMABLE ITEMS: ............................................................................................................................................. 16 5.5 SPARES FOR OVERHAULING / MAJOR MAINTENANCE / ZERO HOUR REPAIRS: ................................................................... 16

6.0 AUDIT AND MANAGEMENT OF CHANGE ................................................................................................... 16 6.1 AUDIT ................................................................................................................................................................. 16

6.1.1 General ..................................................................................................................................................... 16 6.2 MANAGEMENT OF CHANGE .................................................................................................................................... 17 6.3 AMENDMENT & DEVIATION .................................................................................................................................... 17 6.4 PERIODICITY OF REVIEW OF OPERATION AND MAINTENANCE GUIDELINES ........................................................................ 17

7.0 EXPLANATORY NOTES ............................................................................................................................... 18 8.0 RESPONSIBILITY MATRIX ........................................................................................................................... 18



1.0 Introduction

1.1 General

(a) The provisions contained in this guideline shall be considered as minimum requirement for safe and efficient operation of assets, promote consistency, uniformity and highest quality practices in operation & maintenance. Any additional activity required for maintaining integrity and / or system improvement may be carried out as per specific requirements. Through the provisions of the guideline, it is endeavoured to inculcate behavioural aptitude in O&M personnel focusing on safety first, proactive & positive approach, team work and diligence.

(b) All process plants shall establish, document, implement and maintain an Integrated Quality Management System (IQMS) which encompasses Quality Management System (QMS), Environment Management System (EMS) and Occupational Health and Safety Assessment Series (OHSAS). All the units shall ensure certification/recertification as per latest relevant version from reputed certifying agency. Maintenance workshop / meet for experience sharing will be arranged at least once in a year to disseminate the maintenance experience, innovative initiatives, adoption of latest technologies, etc. The same shall be compiled and shared widely amongst employees through e -platforms such as intranet, email etc.

(c) IQMS shall be implemented in all the new plants / systems within minimum possible time after their commissioning but not later than one year from start of operation. To ensure uniformity and consistency across installations of similar nature, effort shall be made to keep similar frequencies for monitoring & maintenance activities in the IQMS unless some specific requirement exists.

(d) With a focus towards safety and integrity of assets of Gas Processing Units (GPUs), there shall be a Central Integrity Management Group for GPUs (GPU CIMG) at Vijaipur, and Regional Integrity Management Group for GPUs (RIMG GPU) at other GPU locations. GPU CIMG shall coordinate with respective GPU RIMGs for Asset Integrity Management across all the GPUs. The core function of the Integrity Management Group shall be identification and effective management of all concern that have the potential to impact integrity of assets.

(e) Whenever a new system/ GPU are commissioned by project department, the base line data, such as machine performance test run data, vibration data etc. of commissioning stage shall be handed over by project department at the time of handing over for O&M.

1.2 Standard Operating and Maintenance Procedures (SOPs / SMPs)

All the departments shall prepare Component based SOP/SWP to address all components and aspects of operating & maintenance of plants which may be part of IQMS:

(a) The SOPs & SWP shall be prepared by a team of concerned maintenance/ operation group after due consideration of manual, OEM recommendations, experience & if required advice taken from expert.

(b) Apart from operation/maintenance aspects, the SOP/SWP shall take care of the safety aspect of environment, man, and machine.

(c) The draft SOPs / SWPs shall be forwarded to respective GPU RIMG (Regional Integrity Management Group). GPU RIMG shall put-up the same to CGM / OIC for approval after getting the same vetted by GPU CIMG (Central Integrity Management Group) at Vijaipur for uniformity across GAIL.

(d) The SOPs/SWPs shall be circulated among all the personnel and shall be made available in soft form in Intranet for the access by all.

(e) SOPs/SWPs shall be adhered to, in carrying out Operation and Maintenance activities and a confirmation shall be taken by the respective OIC / RIMG every year from the all the concerned employees regarding adherence of SOPs/SWPs during all operation and maintenance activities.



1.3 Critical Equipment

(a) All the critical equipment of GPU’s shall be maintained in such a way that they can be operated instantly at any given point of time including standby equipment.

(b) List of all critical equipment / components / instruments / spares shall be declared by all the Departments / Stations, along with its OEM / OEM approved vendors with the approval of respective OIC / CGM. The list shall be reviewed by OIC / CGM every year for any revision based on experience gained and / or any modification in system during the preceding years and shall be part of IQMS.

(c) Any equipment / component / instrument / spares shall be considered critical if it is custom made/ have long lead times from ordering to delivery/ outage of the same directly disrupts the intended objective of the station (i.e., throughput, production etc.)/ direct impact on safety, environment and its frequency of failure. Such an equipment / component / instrument / spares meeting the above criterion shall be considered critical even when standby equipment is provided since availability of standby equipment also has to be ensured.

1.4 Preventive & Predictive Maintenance

(a) All machines, big or small, shall be covered under preventive / predictive / condition monitored maintenance programme and all such machines to be mapped in respective database & applications. The preventive / predictive / condition monitored technique shall be selected depending upon criticality of the machine and shall be incorporated in the maintenance manual. The frequency of maintenance shall be based on past experience, vendor recommendations and national / international codes & standards.

(b) All the entries in respective database & applications shall be ensured while carrying out the maintenance activities i.e. maintenance planning to generating order / PR to completion of job, OIC / CGM / network in charge / Department Head should ensure compliance every month.

(c) All preventive maintenance activities shall be carried out in accordance with good engineering practices, vendor instructions & checklists / datasheets, as applicable, at prescribed frequency / interval. However, specialised maintenance activities shall preferably be carried out under OEM supervision / through OEM where in-house expertise is not available e. g. rotary & static equipment, critical systems, UPS, VSD, Circuit breakers, Battery chargers etc.

(d) Predictive / Condition Based Maintenance: Since rotating equipment is more prone to wear and tear it is imperative to adopt equipment specific predictive / condition-based monitoring programme. If running of such turbo-machinery beyond recommended Time between Overhaul is necessitated, the same shall be done in consultation with the OEM. On line / off line predictive maintenance shall be part of the maintenance programme which shall include but not limited to following techniques.

(1) Boroscopic Inspection of Turbines: Boroscopic inspection shall be part of predictive maintenance practices of gas turbines / other rotary machines where ports / provisions for such inspection exist and shall be carried out at least once in six month or at the best possible interval in case machine is run continuously beyond six months. Records shall be maintained and analysed periodically to assess the deterioration of turbine internals with time and for any other condition that requires attention.

(2) Lube Oil Analysis: Oil samples from equipment shall be collected at least once in a year from major rotating equipment and sent to reputed laboratories for analysis of various properties as well as for detection of presence of various metals. Based on such analyses, corrective action may be decided.

(3) Vibration Analysis: Online / off line vibration monitoring shall be part of maintenance programme. Online vibration monitoring shall be adopted for critical / major equipment like gas turbines, compressors, major pumps etc. For non-critical / other rotating equipment off-line vibration monitoring may be carried out at regular intervals. Remedial measures required to maintain the health of the equipment shall be taken immediately based upon such analyses / diagnoses.



(e) General Housekeeping of plant / station shall be maintained under excellent condition keeping the safety aspects in mind.

(f) As a general practice painting of plant machinery / piping / structures / building / offices shall be carried out once in three years. However, if condition of painting is found satisfactory, the periodicity may be increased after reviewing the condition of painting. For corrosive environment, higher frequency and special type of painting / coating will be required and the same may be decided by concerned OIC / CGM / GM of the unit.

(g) All the important structures like foundation of motors, turbines, generators, building etc. shall be checked every year visually and shall be checked once in five years or after every extension, alteration, repairs, addition or machinery, plants etc. through competent agency to ensure their structural integrity.

(h) All the drainage of plants and buildings shall be cleaned before start of monsoon every year.

1.5 Statutory Permissions

(a) OIC / CGM / In-charge of unit shall ensure that all required clearances / permissions for operating the facilities are in place. Clearances / permissions obtained during the construction phase shall be taken over from the construction / project group and their continued validity ensured. Details like date of inspection, next renewal date, capacity, license etc. shall be displayed nearby respective equipment in the field, wherever applicable. A list of all required licenses / permits / clearances shall be maintained with the office of the OIC / CGM / Station-in-Charge with details of validity, file references, contact details of authorities concerned etc. to enable advance action for renewals if required and maintaining validity of such documents.

(b) Statutory inspections and permissions required to be complied may include the following:

(1) Central / State Pollution Control Board clearances (2) Environment Act (3) Petroleum and Explosive Safety Organization (PESO) (4) State & Central Electricity Authority Permissions & subsequent periodical inspection as per

prevailing Electricity Act (5) Boiler Inspector (6) Factory License / State Factories Act (7) Weights & Measures (8) Any other requirement of State/Central Government Body

The details like date of inspection, next renewal date, capacity, license etc. shall be displayed nearby respective equipment in the field, wherever applicable.

(c) The requirements of applicable code for inspection of equipment (Columns / Process Vessels / Storage Vessels / Electrical Equipment / Weights & Measures / Boilers / PSV / Lifting tools & Tackles / etc.) shall be complied without any exception.

(d) Inspection of such equipment requiring periodical statutory inspection shall be completed at the required frequency as per the applicable code. In case no stand by equipment is available, such inspection shall be scheduled during the available opportunity / annual shutdowns in advance.

(e) For equipment where required inspection as per code is not feasible for whatsoever reason, an alternative method (such as external inspection / thickness measurements etc.) that can be agreeable to the concerned statutory body / agency may be adopted.

(f) Effluent streams of Gas Process Units shall be monitored on a continuous basis in order that applicable statutory norms are satisfied as well as to draw forewarnings of specific equipment / plant mal-operation and signs of impending break down.

1.6 Technology Upgradation



(a) All systems like Monitoring and Control systems, Electrical, Mechanical, instrumentation, metering skids etc. shall be reviewed for technical obsolescence at least after 10 years of its installation and every two year thereafter.

(b) GPU CIMG at Vijaipur and RIMGs at other GPUs shall interact with vendors, sites etc. time to time for any new Technologies and with regard to its applicability for GAIL’s operations and maintenance which can improve the efficiencies and quality. Based on merit of technology, the same shall be presented for management approval by GPU CIMG. In such cases Management of Change procedure shall be duly followed.

(c) As and when new technology or better / efficient equipment become available, the same may be reviewed for replacement of older systems based on suitability and techno-economic advantages irrespective of frequency mentioned above.

(d) System PC like desktop, monitor, Printer and other IT accessories which are essential part of any DCS / PLC laptop used for configuration of flow computers or instrumentation systems are to be replaced after review done by respective site based on OEM feedback / site experience / condition of PC, Laptop etc. As minimum, such review is to be done at the end of 4 years of commissioning and subsequent review is to be done every year. Software of DCS / Plant system, Laptops used as configurators may be upgraded on case to case basis based on vendor system requirements & benefits envisaged for system upgradation.

(e) Technological obsolescence of the supporting monitoring / control systems / tools like Distributed Control System (DCS) / VFDs / UPS / Switch Gears / Battery chargers & protective relays / Vibration Monitoring Systems / Fire and Gas detection systems / measuring instruments etc. which may affect the proper monitoring of the machine should also be reviewed as per the frequency mentioned above.

2.0 Safety & Security

2.1 Safety

(a) GAIL fosters highest level of safety in all its activities. All the maintenance procedures shall invariably incorporate specific safety precautions to be followed during various activities. “Health, Safety and Environment Management System Manual” should also be referred while carrying out the maintenance activities.

(b) All GPUs shall designate a Risk officer. All the modifications shall be carried out following management of change procedure.

(c) Subsequent to commissioning of Plants, QRA and HAZOP shall be carried out at regular intervals as per stipulations of prevailing statutes such as OISD etc.

(d) No maintenance job shall be executed without ensuring proper safety. Guidelines for work permit system and /or safety check list issued by Corporate O&M / HSE department shall be adopted to ensure that all activities are performed under due authorization and safety measures.

(e) In addition, hot work, work at height, vessel entry etc., shall be undertaken after complying with required safety measure suggested by Fire & Safety department and under the supervision of Fire & safety department representative for completion of the required jobs safely.

(f) Safety devices:

LEL / UV/ Thermal/ Infrared/ smoke detectors shall be checked for their operation at least half yearly through simulating their operation and healthiness shall be ensured by taking corrective actions based on simulation results. LEL / UV/ Thermal/ Infrared/ smoke detectors installed in continuous running machine shall be checked during turn around. The healthiness of the detectors shall be monitored for any drift, and necessary corrective action shall be taken.



(g) Monthly status of all installed safety devices – relief valves, rupture devices, switches, LEL / UV/ Thermal/ Infrared/ smoke detectors, interlocks, fire extinguishing agent release system to be updated and a consolidated report to be prepared at each station and an exception report shall be sent to Corporate O&M with reasons for exception and action plan for restoration.

(h) Electrical earthing system shall be constructed and maintained in accordance with IS: 3043 / OISD137 / OISD147 at all the installations of GAIL to ensure safety to plant machinery and personnel. Testing of earth pit shall be carried out at least twice in a year (once in dry season) and appropriate action shall be taken to maintain the pit resistance within the specified values as per relevant codes / standards.

(i) Routine and diligent use of Safety Appliances, Non-Sparking Tools in Hydrocarbon areas, etc. shall be adopted while carrying out maintenance jobs.

(j) Testing and Calibration of all the safety devices (such as critical pressure / temperature indicating devices, lifting and hoisting devices, tools and tackles, Electrical Overhead Cranes, etc.) shall be carried out regularly without exception as per statutory requirements.

(k) All the tools and tackles used for maintenance activities by respective department shall be maintained for safe use & inspected at least once in six months to ensure their integrity. This shall be made part of IQMS system also.

(l) All efforts shall be made to keep environment green and clean during maintenance. Waste / hazardous material generated during maintenance activities shall be disposed-off at designated places only.

2.2 Pressure Safety Valves

(a) Pressure Relieving Devices are installed on process equipment, pressure vessels, piping, and tanks to relieve excess pressure resulting from operational upsets and other causes. Malfunctioning of these devices could lead to devastating and disastrous conditions. Inspection, Maintenance and Calibration of these devices therefore assume critical proportions. Isolation valves of PSVs shall be kept open under normal operating condition.

(b) Guidelines for frequency for calibration / checking of Pressure Relief / TRV / Safety Devices are given as under:

Application Frequency

Gas Processing Units

Equipment / Pressure Vessels Not covered under SMPV rules

Corrosive Service Every Turn-around but not later than 2 years

Non-Corrosive Service Every Turn-around but not later than 4 years

(b) Equipment / Pressure Vessels covered under SMPV rules

At least once every year or according to SMPV rules

(c) Calibration Methodology: Further, following shall be ensured while carrying out the calibration:

(1) For outsourcing the calibration of PSVs, the contractor shall fulfil the following minimum criteria:

(i) Agency / authorized representative must be certified by CCOE for testing and calibration of PSV for Equipment / Pressure Vessels covered under SMPV rules.

(ii) Test bench shall be hydro-tested as per frequency defined in SMPV rules. (iii) Third party certification / inspection / calibration of test benches and accessories like pipe,

flexible hose, pressure gauges etc. shall be submitted by the contractor. (iv) Contractor must fulfil the experience and other criteria as per C&P procedure of GAIL.



(v) Persons involved in testing must wear proper PPE & toughened glass shield during calibration.

(2) For in-house calibration following minimum shall be ensured:

(i) Test bench shall be hydro tested as per frequency defined in SMPV rules. (ii) Third party certification / inspection / calibration of test benches and accessories like pipe,

flexible hose, and pressure gauges shall be maintained. (iii) Persons involved in testing must wear proper PPE & toughened glass shield during calibration. (iv) Process / Operation department shall witness the calibration and sign the calibration report

jointly.

2.3 Security and Risk Management of Operational Technology Systems

(a) Effective governance and management of the Operational Technology (OT) environment at GAIL is essential to maximize the value that can be delivered to GAIL and its stakeholders. Given the strategic importance of OT systems and GAIL’s endeavour to ‘Think Digital, Be Digital’, a structured approach to develop and maintain the OT operating environment, this requires the management commitment and guidance for establishing streamlined and robust OT processes, practices and structures to ensure effective OT management by way of:

Achieving operational excellence through effective and efficient utilization of OT Systems

Managing risks

Complying with applicable laws, regulations and contractual agreements

(b) OT Systems in GAIL consist of DCS / PLC system in process plants, compressor stations, Pipelines and all digital systems like Advance Software Applications for Pipeline Integrity Management System, Pipeline Intrusion Detection System, Smart meters, SCADA Systems etc. For the effective security from the emerging threats and existing vulnerabilities of the operational environment, the security of the Operational Technology (OT) Systems requires critical care. Thus following are to be adopted:

(1) Remote access of OT Systems for maintenance or incident management should be done via secured mechanism.

(2) Asset listing of OT Inventory should be done (that includes details like Asset name, Patch upgrade records, Licence, Critical/Non-Critical, identification of trusted devices, maintenance activity etc.)

(3) Procedure shall be established for maintaining and upgrading of Architecture Drawings of OT Systems.

(4) To increase the host security of OT Networks,

(i) Create separate account with lower privileges for user to perform day to day activities. Administrator privileges should be restricted to limited users only.

(ii) Configuration and maintenance machines for OT Systems (i.e. Laptops) should not be connected to internet and kept under lock and key when not in use

(iii) Disable all USB Ports and CD/DVD ROM access for OT Systems to restrict external media usage.

(5) Personnel involved in the O&M of OT Systems should be given awareness training on the Security and Risks Management of OT Systems.

(c) Classification of OT Systems and Data as per importance and criticality, Network segregation within the OT Systems of the compressor / booster stations and Pipelines, taking into account the criticality of Systems & Data and implementation of OT Security shall be done as per Corporate Guidelines.

3.0 Operations

3.1 General

(a) A Comprehensive Operation Manual for GPU covering written procedures for conducting operations and for emergency response shall be prepared with due approval of OIC / CGM concerned / In-charge of unit within the Integrated Quality Management System (IQMS) of the



concerned network / facility. The manual shall be scrupulously adhered to and shall be reviewed and updated every year.

(b) The Operation manual shall include but not limited to following procedures to ensure safety during operations and maintenance:

(1) Normal Conditions

(i) Standard Operating Procedures (SOPs) for all plant operation activities. (ii) Monitoring, sample testing and controlling of quality of Natural Gas / LPG at GPUs such as

moisture / hydrocarbon dew point, total sulphur, H2S etc. (iii) Maintaining records related to construction & operations such as statutory / other

permissions, P&ID, maps, operating history, incident reports etc. (iv) Start-up and shutdown of plants in a manner designed to assure operation within the limits

prescribed for operation. (v) Procedure for isolating and purging of various systems of GPUs, as applicable before handing

over for maintenance and after taking over for service. (vi) Periodically reviewing the effectiveness and adequacy of the procedures followed for normal

operation and amendment of the procedures for continual improvement. (vii) Periodic inspection and testing of pressure limiting equipment, sectionalising / critical / safety

valves and devices to determine that they are in safe operating condition. (viii) Control Room Management / Shift Management procedures for smooth operation of pipeline

/ Compressor / Booster stations and implementation as applicable.

(2) Abnormal Condition: Procedures, when operating design limits have been exceeded, such as Responding to and correcting the cause of:

(i) Unintended shutdowns such as closure of valves etc. (ii) Increase or decrease in process parameters (such as pressure or flow rate or temperature etc.)

outside normal operating limits. (iii) Loss of communications. (iv) Actuation of any safety device due to abnormal condition / situation. (v) Any other anticipated malfunction of a component, deviation from normal operation, or

personnel error, which may result in a hazard to persons or property. (vi) Handling and reporting for any abnormal operation / condition. (vii) Emergency response as per Emergency Response and Disaster Management Plan. (viii) Total power loss.

(c) The control rooms of GPUs shall be manned round the clock with manpower of adequate level, qualification and experience.

(d) All the Gas Processing Plants shall be equipped with state of art DCS facility for remote monitoring and control of operational parameters and critical operations including quick response to failures/emergencies.

(e) All the interlocks of Machine / equipment shall always be kept in healthy condition and should not be bypassed but for extremely exceptional conditions which need to be duly certified and authorized by the Operations-in-Charge of the plant. Such exception shall be brought to the notice of OIC / CGM and efforts taken for expeditious restoration of system to conditions that do not require such by-passing. However, if any interlock is not restored within 7 working days then approval of OIC / CGM shall be taken with proper justification.

3.2 Alarm Management

An alarm management system shall be established to review and analysis of all the alarm / abnormal operating conditions / events.

(a) DCS/HMI shall be equipped for indicating, storing and trending of alarms.



(b) Annunciator / Buzzer of Alarm shall always be ON in GPU control rooms.

(c) All generated alarms shall be segregated to two major categories through alarm management system:

(1) Process alarm (2) System Alarm

(d) Review of Process alarm shall be done by operation department by the shift In- charges in every shift. Review of System Alarm shall be done by Instrument department on daily basis. After review, alarms shall be categorized as:

(1) Critical alarms that can affect the safety and operation of plant. (2) Non critical alarm / status information which may not hamper the operation and safety (3) False alarms

(e) All critical Process alarms and System alarms shall be analyzed to ensure that the accurate and corrective action is taken by concerned departments on daily basis by sectional head. The False alarms shall be rectified within 3 days of occurrence by the concerned department in coordination with Operation.

(f) Yearly review of following should be done by CGM / OIC.

(1) Review of the correct safety-related alarm set-point values and alarm descriptions. (2) Review of alarm management plan to determine the effectiveness of the plan. (3) Review content and volume of alarms and followed for corrective action to avoid the

escalation of alarm / event to breakdown / trip.

(g) An exception report shall be generated by Sectional head of concerned plants on all the faulty field signals and critical alarms and the report shall be sent to concern HOD on weekly basis.

(h) Fortnightly report of critical alarms and faulty signals older than 15 days shall be sent by the HODs to respective GM/CGM.

(i) The critical alarms and faulty signals older than 30 days shall be reported to OIC.

(j) The critical alarms and faulty signals older than 45 days shall be reported by Corporate O&M to Director (Projects).

3.3 Energy Efficiency Monitoring and Control

(a) Operation department shall identify the major equipment and system for performance monitoring.

(b) The performance of major equipment and system shall be monitored for energy / specific energy efficiency and compared with designed data / benchmark at least once in quarter followed by suitable action to keep the performance within targets and made part of IQMS system.

(c) To improve the energy efficiencies in process and operations, all major installation such as compressor stations / booster stations shall endeavour to implement latest applicable energy audit standards certification e.g. ISO 50001.

4.0 Monitoring & Maintenance of Gas Processing Units (GPUs)

4.1 General

(a) A comprehensive maintenance manual covering guidelines, procedures and practices shall be prepared by respective GPU’s within the ambit of IQMS. An annual composite preventive maintenance schedule/manual covering all the critical as well as non-critical equipment shall be established with the approval of OIC/CGM. In case of any deviation in actual execution of maintenance actions as per the schedule, same shall be only with the approval of respective OIC / CGM with due justification and catch-up / alternate plan.



(b) Monitoring and Maintenance of equipment and machinery should be carried out as per OEM guidelines and best industry practices with an objective to minimize unplanned stoppage of plant. For this purpose, planned stoppage of plant should be considered for completion covering all accumulated jobs requiring plant shutdown and should be taken up in a planned manner in the shortest possible duration. Data on plant outage should be maintained to enable critical analysis of health of equipment and machinery and effectiveness of maintenance frequency and practices. Unplanned stoppages should be analyzed in three distinct categories viz., a) Internal reasons such as breakdown of equipment / machinery, failure of internal power systems, alarm condition of process parameters / any other unsafe condition requiring urgent intervention b) External Reasons such as External (Grid) power failure, stoppage of gas supply due to interruption at supplier’s end or receipt of off-spec gas, availability of gas of required quality and / or quantity and c) Force Majeure conditions.

(c) On commencement of each calendar year, all the OIC / CGMs shall prepare their Maintenance Plan / Work plan covering important jobs along with major milestones and completion targets. The same shall be presented during O&M meets along with its progress / status.

4.2 Asset Integrity Management System

4.2.1 General (a) Strategies to audit, identify, monitor, control, and demonstrate improvement on each concern shall

be prepared, disseminated and maintained with an objective of Zero incidents.

(b) The health of all the equipment/systems shall be continuously monitored by all GPUs & compliance of all requirements, for smooth operation, shall be ensured. A report shall be furnished by OICs, on annual basis to concerned ED and ED (O&M)-CO, as per format circulated by CO-O&M for apprising the top management.

(c) Liquid hydrocarbons inventory shall be evacuated from storages, to the extent possible, during plant shutdowns and statutory inspection etc.

4.2.2 Major Maintenance / Overhauling: (a) Major maintenance / overhauling of notified / declared critical equipment shall be carried out at

OEM / OEM authorized workshop or at site, if feasible, under the supervision of OEM representative.

(b) A long-term equipment inspection / overhaul schedule shall be in place such that major maintenance activities can be undertaken within the recommended run-hours band at the available annual turnaround / shutdown maintenance of plants. Meticulous planning for spares and services support may be called for in successful completion of such major maintenance jobs.

4.2.3 Inspection/Maintenance of Piping Systems (a) External inspection of above ground process and offsite piping systems and vessels shall be carried

out at least once in a year to find out any wear & tear, corrosion etc. at support, pipe bends, high velocity area & condition of painting/coating etc.

(b) Thickness measurement survey of above ground pipeline, piping and vessels such as scrubbers, knock-out drums, etc., shall be done at least once in a year with particular attention to potential corrosion areas such as 5 - 7 o’ clock position on piping, vessel bottoms / drains etc. The measured thickness of piping / vessels shall be assessed for continuation in service. Based on the survey report suitable action shall be taken to establish the integrity of piping.

4.2.4 Gas Fired Heater /Columns / Heat Exchangers / Cooling Towers / Pressure Vessels (a) Performance of the various equipment’s like Gas Fired Heater/ Fractionating Columns / Heat

Exchangers / Dryers / Cooling Tower / Air & Nitrogen Plant etc. shall be monitored by means of direct and indirect measurements, to assess the serviceability and condition of internals of the equipment(s) such as Trays & Internals in Fractionating Column, Tube Bundles of Exchangers etc.



(b) All the sites should incorporate the periodical (at least once in a quarter) performance/efficiency monitoring of major equipment in IQMS with thresholds for corrective active action. Analysis of such performance indicators shall be utilised to build job lists that need to be attended during the next annual turn-around / shutdown maintenance, with due care to requisition required materials and services thereof in time.

4.2.5 Annual Turn-Around (a) Annual Turn Around of processing plants shall be planned with the approval of concerned Director

to attend various preventive and condition based inspection, repair, maintenance and modification jobs in addition to major maintenance / overhaul of critical equipment / systems. Various material and services mobilisation shall be planned and arranged well in advance.

(b) List of accumulated jobs shall be deliberated inter-departmentally at the plant with due attention for critical path jobs, for sequencing of operations and optimization of shut down duration to the bare minimum required.

(c) As maintenance activities are carried out round the clock, due care and attention may be accorded to details such as manpower rotation, job review by shutdown co-ordinator(s) at the start/end of shifts, pre-job safety meetings etc.

(d) Utmost safety precautions and practices shall be applied prior to and during every activity. Electrical lock-outs of machinery, closed-locking of valves, positive blinding and inertization of process pipelines, running fire hoses, welding booths, personnel protective wear and such other safety measures as may be required shall be scrupulously undertaken.

(e) A Standard Task List (prepared by concerned GPU RIMG in consultation with GPU CIMG) to be followed during Annual Turnaround to be maintained at each GPU by concerned GPU CIMG / RIMGs. The same shall be followed during each Annual Turnaround.

4.3 Test and Measuring Instruments

(a) A consolidated list of instruments including test software, if any, shall be established, segregated into ‘Instruments’ and ‘Masters’. History sheets of the master / instruments shall be maintained.

(b) All Test & measuring instruments shall be calibrated traceable to national / international standards.

(c) All product quality control instruments shall be calibrated with standard test and measuring instruments to generate required confidence on manufactured product quality.

(d) All field and master instruments as identified above shall have a unique identification number (tag number).

(e) The identification and status of calibration of test equipment covered under list of master & instruments shall be indicated on the instrument in the form of stickers / tag indicating the instrument name, tag number, calibration date, calibration due date etc.

(f) Upkeep of master instruments shall be ensured with regard to safety, accuracy and repeatability. Master instruments shall be calibrated traceable to National / International standards through an unbroken chain.

(g) Deviations from approved Calibration and Maintenance periodicities and procedure shall be only with the approval of OIC / CGM concerned.

(h) Testing and Calibration of all the safety devices (such as critical pressure / temperature indicating devices, lifting and hoisting devices, tools and tackles, Electrical Overhead Cranes, etc.) shall be carried out regularly without exception as per statutory requirements.

(i) Dead weight testers shall be calibrated at least once in three years from laboratory accredited to ISO / IEC 17025 and test certificates shall be readily available for reference. Calibration shall be carried out using cross float method.

(j) Following calibration frequencies to be maintained



Road Weigh–bridge System calibration Quarterly

Rail Weigh–bridge System calibration Half yearly

Product mass flow meter calibration Once in 02 years

Different level password protection to be ensured in Weighbridge systems for overriding the alarms for tare weight difference, less filling, etc.

4.4 Metering

(a) Primary metering devices shall be installed for Plant Mass balancing, Energy balancing and Product declaration with adequate accuracy.

(b) Inspection / validation of metering element such as orifice plates, upstream/downstream meter tubes etc. for steam service, other corrosive service shall be carried out at least once in two years.

(c) Turbine meters shall be proved at least once in two years from GAIL’s facility or a reputed calibration agency certified by national/ international accreditation bodies. Servicing of Turbine meters shall also be carried out along with proving. The K-factor & linearization curve shall be fed correctly in the flow computers immediately after calibration.

(d) Mass Flow meters used in Custody transfer application shall be proved at least once in 1 year from a reputed calibration agency certified by national/ international accreditation bodies.

(e) Mass Flow meters used in Non-Custody transfer application shall be proved at least once in 5 years from a reputed calibration agency certified by national/ international accreditation bodies.

(f) Validation of Flare meter shall be done at least once in two years.

(g) Proper care shall be taken during removal, transportation & reinstallation of turbine/ ultrasonic meters during calibration.

4.5 Electrical System

(a) Criteria for Electrical Power Requirement and Battery Bank back-up hours: Battery banks shall be provided as indicated below:

Minimum Battery Bank back-up during design (New Projects)

Minimum Battery Bank back-up during Service

12 hrs. 8 hrs.

Note:

1. The capacity test and boost charging of all battery banks of Ni-CAD & Flooded Lead Acid type cells shall be carried out every year except for field mounted equipment to ensure the desired back up hours as above. For SMF/VRLA Battery banks, it should be performed every two years. For new Battery Bank, annual capacity testing may not be required for the initial two years of operation.

2. Use of sealed maintenance free (SMF)/ VRLA batteries shall be avoided in upcoming projects/during in service replacements wherever technically feasible.

3. While planning for Battery bank replacements by a type other than originally installed, boost charging requirements should be taken care for its compatibility with existing Charger/UPS.

4. Assessment of Battery Banks performance shall be taken up based on the capacity tests as per above requirements and accordingly replacement action should be taken up on case to case basis.

5. For smaller Battery banks consisting of 12 Volt Batteries (e.g. Field mounted equipment, Diesel Engine starters etc.), capacity test may not be required. Hence they should be replaced at every two years of their installation or as recommended by OEM or based on the service performance whichever is earlier.



(b) Condition monitoring of the Switchyard equipment’s like Current Transformers (66 KV & above), Power Transformers, Lightning Arresters shall be performed at an interval of 3 years or as recommended by OEM whichever is earlier, to check the Tan Delta, Polarization Index (PI), Insulation / Electrical Resistance etc. and further steps of maintenance /replacement to be taken based on historical trending to avoid any catastrophic failure of equipment. Operational performance of Switchyard Isolators shall be ensured with all interlocks. Above exercise shall be taken during planned shutdown, ensuring all safety measures for electrical isolation of the equipment to be inspected.

(c) Condition monitoring of all other critical rotating equipment like HT alternators, HT Motors, Transformers may be carried out at an interval of at least 5 years or as recommended by OEM, whichever is earlier and based on this, action for major overhauling should be taken. Other than the above, Run-Hour based major overhauling of Rotating Electrical equipment shall be also performed as per OEM recommendation.

(d) Other than the regular preventive maintenance of HT / LT Circuit breakers, their major overhauling shall be carried out during shutdowns from its OEM / Experienced service provider / In-house expertise at an interval of 5 years or as recommended by OEM whichever is earlier Or as whenever required based on the condition assessment. It’s Contact Resistance with Close / Trip / Close-Open time of Circuit Breakers (for 6.6KV and above) to be recorded at regular intervals and further required maintenance actions should be taken.

(e) Electro-mechanical relays shall be tested yearly. However, Numerical Relays to be tested at least once in three years. Also, it should be ensured that their settings are restored as per relay co-ordination chart before taking into operation.

(f) Protection / Operational Interlocks of the HT / LT panels, DEG set, Switchyard equipment shall be checked annually during the shutdown of the plant or during the available opportunity and all steps should be taken to ensure the healthiness of their functioning. Bus-Bar tightening of all HT / LT switch gear panels to be carried out during the shutdown.

(g) Transformer (TR) oil in service shall be tested as per IS: 1866 every year and Dissolved Gas Analysis (DGA) at every two years, to know the deteriorations and contaminations in Oil. New TR oil may be added as make up only and not to exceed 10 % of the in-service quantity, otherwise whole oil to be replaced with new one. Insulation resistance and Polarization Index of HV Cables connected with Electrical Equipment to be recorded every year for historical trending.

(h) General Illumination level of the unit to be recorded half yearly and to be maintained as per OISD / BIS requirement.

(i) Lightning protection shall be provided in accordance with IS/IEC-62305.

5.0 Spares Philosophy

5.1 General

(a) Spares are critical for proper upkeep of equipment and machinery. However, in order to keep the inventory and maintenance costs to a minimum, procurement of spares shall be optimized to meet the requirement without build-up of inventory to unwanted levels.

(b) The spares availability vis-à-vis requirement shall be reviewed by each Maintenance Base / plant at least every year followed by procurement action for short fall quantities to ensure the timely availability of spares. As a minimum requirement the following shall be followed: (1) Review of spares requirement by the month of January. (2) Consolidation and finalization of spares requirement by regional headquarter by the month of

February. (3) Administrative approval and financial concurrence by mid of the month of March. (4) Placement of Indent to C&P department by the end of the month of March.



(5) Procurement for critical / insurance item immediately after its consumption for replenishment as required.

(c) Inventory in GAIL can be classified in to following categories depending upon its usage, procurement procedure, criticality etc.: (1) Insurance Spares (2) Spare for running maintenance (3) Spares for Overhauling / Major Maintenance (4) Consumables

(d) All procurement shall be carried out by considering the followings: (1) Consumption rate of the item (2) Existing stock (3) Spare parts ordered / in transit (4) Processing time and lead time for procurement

(e) The use of critical spares / components should normally be avoided beyond their recommended service life, however, if condition of spare is found to be satisfactory for reuse till next inspection / maintenance, same may be reused based on assessment of the condition of spare / component, in consultation with OEM, if required.

(f) Non-moving and disposable inventory shall be reviewed every year followed by suitable action as per C&P guidelines.

(g) Any spares / consumable items drawn by user groups for emergency use etc. shall be properly documented, stored and maintained in such a way which allows for easy retrieval and proper records.

5.2 Insurance Spares:

(a) Declaration of critical components / spares shall be governed by applicable accounting standards and company policy / procedures notified from time to time. List of all such insurance items / spares shall be maintained by each site, which shall be updated every year. On consumption of these spares, necessary steps shall be taken to replenish the stock and accord requisite accounting treatment.

(b) Purchase of Insurance items is done after comparing the cost of loss of production in the absence of the item, considering the production / throughput loss. The cost of production loss in such cases will be multiplied by the probability of failure of the stand by machine. When there are identical machines in the plant / system with standby machines, Insurance items are purchased for group of machines (including similar machines spread across various sites).

5.3 Spares for Running Maintenance:

(a) Spares of Proprietary Nature: Since the specification / source of procurement of these items is fixed / limited, they shall be procured for annual requirement considering available stock every year. However, in exceptional cases, if lead time of spares is 6 months or more, two years’ requirement may be procured.

(b) Spares / consumables having critical application shall also be purchased from OEM, OEM of packaged equipment or OEM approved vendors to ensure the reliability of system though same may be available from other sources [e.g. Air filter required for feed gas intake system for Gas turbines].

(c) However, for spares / consumables used for non-critical application, efforts can be made to source the same from reputed vendors having proven track records and requisite experience in the same field [e.g. filters for gas turbine enclosure etc.]

(d) Other Spares: Spares / components having multiple vendors shall be procured after assessing annual requirement and available quantity in stock every year through competitive bidding.



However, if spares of different makes are not suitable due to their mounting/dimensional problem same shall be procured through OEM / OEM approved vendors.

5.4 Consumable Items:

(a) Consumable are normally required on regular basis for smooth operation and maintenance. Procurement of common items may be carried out centrally by designated department, at site.

(b) Continuous review shall be adopted for procurement of consumables. Maximum, minimum, safety stock and reordering level shall be established for each item. Procurement then, shall be for Economic Order Quantity (EOQ) with due consideration for procurement lead time. Consumables having definite shelf life shall be consumed on ‘first-in-first-out’ principle.

5.5 Spares for Overhauling / Major Maintenance / Zero Hour Repairs:

(a) Equipment Overhauled at OEM / Authorized Maintenance Centres (AMC): For these equipment / machineries, no spares are required to be stocked for overhauling purposes. Spares required for overhauling should be purchased / ordered along with overhauling job from AMC / OEM. Specific strategy for any long lead item among such overhauls shall be decided on a case to basis by the OIC / CGM / In-charge of unit.

(b) Equipment Overhauled at Site under Vendor Supervision: The spares required for overhauling of these machines need not be stocked at site as overhauling become due at every 5/6 years interval. They should be procured sufficiently well in advance, keeping the lead time and processing time in consideration, so that they will be available at site before commencement of overhauling. The list of unused spares after overhauling should be circulated to all sites having similar machines. However, for such machines, at least one set of critical components may be kept as insurance spare.

(c) For the critical equipment of GPU such as Feed Gas Compressor, Lean Gas Compressor, Expander Compressor, HT motors & drives, Control valves, safety instrumentation and control systems and other equipment directly effecting plant production, special attention shall be given for Spare parts inventory and equipment upkeep, as the breakdown of these equipment can directly affect the production of the plant.

(d) For critical equipment / components, exercise for developing substitute spares / suppliers is not recommended as any failure owing to the same may far outweigh the expected benefits. This shall also be applicable for refurbishment of critical spares / components.

(e) However, for equipment / components not notified as critical, the spares / components can also be sourced / refurbished from reputed vendors having proven track record and requisite experience in the similar field. The process of selection / identification of such alternate source of supply / service needs to be rigorous with due regard to accrued benefit in cost and time without any compromise whatsoever on quality.

(f) The review for indigenization of imported spare may be carried out on yearly basis by a committee for possibility to reduce the dependence on foreign vendors / components and plummeting the lead time and cost of replacement.

6.0 Audit and Management of Change

6.1 Audit

6.1.1 General (a) Various technical and non-technical audits / inspections are being carried out by OISD, PNGRB, CTE,

Internal Audit etc. throughout the year. The majority of these audit recommendations are corrective measures to be taken to improve safety and integrity of system. To ensure timely review and implementation of corrective measures, a systematic monitoring and reporting mechanism shall be put in place which shall include review of Audit report by ED / CGM / OIC concerned and



action plan for compliance within three weeks and regular periodical review at all levels until liquidation.

(b) Pro-active audit (Internal / Self-Check Audit) shall be conducted by multi-disciplinary team on yearly basis to ensure compliance of relevant OISD standards. Multi-Disciplinary audit team will be constituted by respective EDs and audit calendar will be declared at the start of the year. OIC / CGM’s of respective networks / units shall ensure time bound compliance of the recommendations of such audits.

(c) In addition to technical audit by internal audit group, Internal Audit shall be conducted by Multi-Disciplinary, cross location team on yearly basis to ensure compliance of PNGRB regulations / O&M Policy & Guidelines / HSEMS etc. Multi-Disciplinary, cross location audit team will be constituted by Corporate O&M and audit calendar will be declared at the start of the year. OIC / CGM’s of respective networks / units shall ensure time bound compliance of the recommendations of such audits.

(d) Each GPU shall develop a checklist of most common deficiencies pointed out by various auditors for a proactive internal assessment and rectification with an objective to achieve zero audit point status.

6.2 Management of Change

(a) Management of change should be implemented to achieve higher efficiency, improve operability, safety, reliability, improvement of the plant machineries and equipment and to accommodate technical change. The management of changes may be arising due to various reasons like operational flexibility, energy conservation, capacity augmentation, improvement of product specification, yield improvement, compliance with statutory rules and regulations.

(b) However, before implementing any major modification, same shall be reviewed by formulating a cross functional team. The cross functional team should review the modification in totality including safety hazards, quality issues, HAZOP etc. OISD 178 shall be referred for details. The approving authority for these changes shall not be below the level of OIC / CGM.

(c) Management of change shall also include the introduction to personnel, who is new to the process, through training on overview of the process and operating procedures. The training shall include emphasis on the specific safety and health hazards, emergency operations including shutdown, safe work practices applicable to employee’s job task.

6.3 Amendment & Deviation

(a) All the operation & maintenance activities should be carried out in line with above guidelines; deviation(s) if any shall be put up with time limit for approval of the Executive Director concerned along with proper justification. Maximum time period for such deviation(s) shall not exceed one year. In case of continuation of deviation, approval to be taken afresh.

(b) Previous Management communications, related to provisions specifically covered in these guidelines shall stand superseded with effect from the date of issue of this revision.

6.4 Periodicity of review of Operation and Maintenance Guidelines

(a) O&M Guidelines shall be reviewed once a year with the approval of ED (O&M)-CO and if changes / amendments are envisaged, the same shall be put up to Director (Projects) / Director concerned for approval by a committee not below the level of CGM.

(b) Timeline for review of O&M guidelines shall be as following: (1) Exercise for feedbacks / suggestion(s) for changes / amendment(s) from sites: August to October (2) Review by senior level management committee: November to December (3) Approval of the competent authority: January to February



(c) O&M Guidelines shall be reviewed comprehensively after every three years by formulation of CGM level committee.

7.0 Explanatory Notes (a) Equipment / Station Availability: The availability of any equipment / station is the total time for

which equipment is available for operation excluding planned and unplanned down time.

%𝐴𝑣𝑎𝑖𝑙𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = [𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 − (𝑃𝑙𝑎𝑛𝑛𝑒𝑑 & 𝑈𝑛𝑝𝑙𝑎𝑛𝑛𝑒𝑑 𝑑𝑜𝑤𝑛 𝑇𝑖𝑚𝑒)]

𝑇𝑜𝑡𝑎𝑙 𝐻𝑜𝑢𝑟𝑠] × 100

(b) Equipment Reliability: The quality of maintenance should be such that the unplanned downtime should remain as minimum as possible. The reliability of the system is total availability of system including planned maintenance time but excluding the unplanned down time.

%𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = [𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 − (𝑈𝑛𝑝𝑙𝑎𝑛𝑛𝑒𝑑 𝐷𝑜𝑤𝑛 𝑡𝑖𝑚𝑒)]

𝑇𝑜𝑡𝑎𝑙 𝐻𝑜𝑢𝑟𝑠] × 100

(c) Process Efficiency: In addition to various equipment efficiency following may also be monitored:

(1) % of fuel for gas compressed (Energy Terms) = [𝐹𝑢𝑒𝑙 𝑓𝑜𝑟 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛

𝐺𝑎𝑠 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑒𝑑 𝐸𝑛𝑒𝑟𝑔𝑦] × 100

(2) % Operational Efficiency = [𝑃𝑟𝑜𝑑𝑢𝑐𝑡 𝐸𝑛𝑒𝑟𝑔𝑦

𝐸𝑛𝑒𝑟𝑔𝑦 𝐷𝑟𝑎𝑤𝑛 𝑓𝑟𝑜𝑚 𝑝𝑖𝑝𝑒𝑙𝑖𝑛𝑒] × 100

(3) % Handling Efficiency = [𝑆𝑎𝑙𝑒

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛−𝑐ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑖𝑛𝑣𝑒𝑛𝑡𝑜𝑟𝑦] × 100

8.0 Responsibility Matrix

SN Activity Designated Engineer/

Officer HOD OIC

ED (O&M)

1 Overall Implementation of Maintenance Policy & Guidelines Provisions

- - M/R P/C

2 Overall integrity of assets M R/P C

3 Availability of Machines M R P C

4 Plant Availability M R/P C

5 Operating reliability M R/P C

6 Permit system implementation M R/P C -

7 Safety in operation and Maint.* M R P C

8 Availability of accredited ERDMP M R P/C -

9 Hazop and QRA M R/P C -

10 Healthiness of safety devices Such UV/LEL/Thermal /IR etc.

M/R P/C -

11 Healthiness of Earthing System M R P/C -

12 Calibration of Pressure Safety Valve M R P/C -

13 Testing and Calibration of Safety devices M R P/C -

14 Testing of Tools and tackles M/R P C -

15 Review and adherence to SOPs/SWPs M R P/C -

16 Monitoring of gas source parameter and other operating condition, alarms etc.

M/R P C

17 Trip Failure and alarm analysis M R P/C -



18 Energy Efficiency Monitoring and Control M R P C

19 Maintenance & Spare Planning M R/P C

20 Base Line data M R P/C

21 Certification & Compliance of IMS/ (QMS,EMS,OHSAS) M R P/C -

22 Declaration of Critical equipt./components along with details of Vendor and required quantity

M R P/C -

23 Review of Technological Obsolescence / up-gradation M R/P C

24 Healthiness of safety interlocks M R P/C

25 Preventive/Predictive /Breakdown Maintenance M R P/C

26 Statutory Compliances M R/P C

27 Compliance to Maintenance Policy audit recommendations

M R P C

28 Preparation, implementation & periodic review of Comprehensive Maintenance Manual

M R P C

29 Major Maintenance / Overhauling of notified / Critical Equipment

M R/P C

30 Performance/Efficiency Monitoring and mitigation M R/P C

31 Planning & Execution of Annual Turn Around M R P

32 Environment initiatives and compliances M R/P C

33 Stake holder Management M R P C

34 Technology & Education M R P C

35 Indigenization of imported non critical spares M R/P C

36 Inventory Management M R P/C

37 Plan, Monitor, Control and report M R/P C

38 Management of change M R/P C

M-Monitor; R-Reviewer; P- Process Owner; C –Controller

* For safety issues, all officers are accountable to their job and respective HODs are responsible. In addition, HOD (F&S) is also responsible.

Note: (1) Designated Engineer / Officer: The officer in respective department to whom the Job is

assigned. (2) HOD / WIC: Respective Head of Departments / WIC (in JLPL & VSPL) for their job. Responsibility

to whom designated officer reports. (3) OIC: Respective OIC / CGM (4) ED (O&M): Respective ED (O&M) for their jurisdiction.

operation and maintenance guidelines for gas processing units · 2020-01-29 · rev-03: january 7,...

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