Revised OISD STD 126

OISD - RP- 126

First Edition, August 1990

Amended edition, August 1999

Revised Edition, August 2007

Specific Practices for Installation and Maintenance

of

Rotary Equipment

OISD RECOMMENDED PRACTICES-126

First Edition, August 1990

Amended Edition, August, 1999

Revised Edition, August 2007

Oil Industry Safety Directorate

Government of India

Ministry of Petroleum & Natural Gas

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OISD - RP- 126

First Edition, August 1990

Amended edition, August 1999

Amended Edition, August 2007

Specific Practices for Installation and Maintenance

of

Rotary Equipment

Prepared by

Functional Committee

OIL INDUSTRY SAFETY DIRECTORATE

7th FLOOR, “NEW DELHI HOUSE”

27, BARAKHAMBA ROAD

NEW DELHI-110 001

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NOTE

OISD publications are prepared for use in the oil and gas industry under Ministry of Petroleum and Natural Gas. These are the property of Ministry of Petroleum and Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.

These documents are intended only to supplement and not to replace the prevailing statutory requirements.

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FOREWORD

The oil industry in India is 100 years old. As such a variety of practices have been in vogue because of collaboration/association with different foreign companies and governments. Standardisation in design philosophies and operating and maintenance practices at a national level were hardly in existence. This, coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need of the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.

With this in view, the then Ministry of Petroleum & Natural Gas in 1986, constituted a State Council assisted by Oil Industry Safety Directorate (OISD) staffed from within the industry, in formulating and implementing a series of self-regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly, OISD constituted a number of Functional Committees of experts nominated from the industry to draw up standards and guidelines on various subjects.

The present document on " Specific Practices for

Installation and Maintenance of Rotary Equipment "

was prepared by Functional Committee constituted for

total review of OISD standards on Rotary Equipment.

This document is based on the accumulated knowledge and experience of Industry members various manuals, national and international codes of practices. This document is meant to be used as a supplement and not as a replacement for existing codes, standards and manufacturers' recommendations. It is hoped that provision of this document if implemented objectively may go a long way to improve safety and reduce accident in the oil and gas industry. Suggestions for amendments, if any, to this document should be addressed to:

This document in no way supersedes the statutory regulations of CCE, Factory Inspectorate, or any other statutory body which shall be followed as applicable.

Suggestions for amendments to this document should be addressed to

The Coordinator,

Oil Industry Safety Directorate,

7th Floor, New Delhi House

27, Barakhamba Road

New Delhi – 110 001

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LIST OF FUNCTIONALCOMMITTEE MEMBERS

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CONTENTS

S.NChapterPage No.

1.0Introduction01

2.0Scope 01

3.0Definitions01

4.0Equipment Protection and Change Management02

5.0Lubrication and Lubrication Systems03

6.0Safe Commissioning Practices03

07Root Cause Failure Analysis04

08Safe Utilization Lifting Tools and Tackles04

09Equipment Documentation05

10References05

11Annexure-I06

12Annexure-II07

13Annexure-III08

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Specific Practices for Installation and Maintenance

of

Rotary Equipment

1INTRODUCTION

The proper upkeep and maintenance plays an important role in trouble free, safe operation of rotating equipment in the hydrocarbon industry. Sound procedures & practices for installation and maintenance are required to ensure safety and integrity of the equipment. These recommended practices should be helpful in forming systems & procedures. This document covers Rotating Equipment such as Pumps, Blowers, Fans, Steam Turbines, Gas Turbines, Compressors, Motors, Generators, Expanders, Gearboxes and Engines installed in hydrocarbon industry.

2SCOPE

The following specific maintenance practices for rotating equipment are covered in these recommended practices;

a)Equipment Protection & Change Management System

b)Lubricant and lubrication System

c)Safe Commissioning Practices

d)Root Cause Failure Analysis

e)Safe Utilization of Lifting Tools and Tackles

f)History Recording

3DEFINITIONS

3.1Equipment

An asset & its associated parts /auxiliaries which are essential to achieve organization’s business goal and requires strategic operational & maintenance attention from time to time and to keep it in a state of delivering desired service.

3.2Protection

The device or integrated system to prevent an equipment or group of equipment from undergoing potential failure or unsafe conditions.

3.3Lifting Tools & Tackles

The devices & systems like Slings, Chain Blocks, Winches, Shackles, EOT, HOT and Cranes etc that are required to lift, carry, load & unload, support, install, and remove different equipment in course of various maintenance & operational activities.

3.4Change Management

Mechanism to control and manage changes to operating conditions, protection systems and mechanical systems of equipment that affect safe operation of the equipment.

3.5Documentation

A system to keep information in systematic manner, which is retrievable whenever required.

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3.6Potential Risk

The degree of probability for occurrence.

3.7Root Cause Failure Analysis

A data based analytical approach to identify the basic cause/s of failure

3.8Commissioning

Process of releasing an asset for normal operation.

3.9Manufacturer’s Report/ Record Book (MRB)

The documentation supplied by the manufacturer along with the equipment.

4.0EQUIPMENT PROTECTION AND CHANGE MANAGEMENT

4.1The equipment protections considered for safe operation include but not limited to critical parameters like vibration, bearing temperatures, axial displacement, motor winding temperatures, lube oil pressure/ temperatures, cooling water temperatures, and process parameters as applicable.

4.2Records of equipment protection systems shall be maintained as per OISD 124.

4.3Alarm and danger values for the above parameters shall be part of the record.

4.4Procedures shall be in place to control changes to these protection systems. Procedures shall include authorizations required for carrying out these changes. Records of such changes shall be maintained.

4.5The record of such changes should be in specific format mentioning, but not limited to the following:

a)The details of equipment/ tags being considered for change

b)The proposed nature of change

c)The reasons for the change

d)The potential risk involved in proposed change

e)The time span of change (duration)

f)The precautions to be taken for incorporation of change

g)The precautions to be taken during operation and after implementation of change

h)Define functional responsibility and authorization for implementation

i)Feedback to initiator on incorporation of change

j)Incorporation of change in “as built drawing/ data sheet/ P&ID’s/ Eqpt. Drawing and other relevant records.

k)Information of changes implemented to concerned authorities

A sample procedure & format is attached as Appendix-1 for reference.

4.6Change management procedures shall include modifications to critical components like Seals, Bearings, Couplings, Shafts, Impellers and Lubricants.

5LUBRICANT AND LUBRICATION SYSTEMS

5.1Systems and procedures shall be in place to ensure the following;

a)Selection of correct lubricant in line with OEM recommendation/ National & International standards/Standard Engineering Practices.

b)Adequacy of protections against lubrication failure.

c)Lube oil condition monitoring as per OISD-RP-124.

d)Replenishment/ replacement of lubricant.

e)No mix up of lubricant grades/ brands during replenishment.

5.2Make-up of lubricant shall be done ensuring that proper grade of lubricant in recommended quantity is applied.

5.3Recommended grade of lubricant shall be displayed prominently on or near the equipment.

5.4Procedure for proper storage and identification of lubricants should be followed. A recommended procedure for storage is given in appendix-II.

5.5Procedure for identification of sampling points and sampling of lube oil should also be established to ensure proper collection and identification of samples.

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6SAFE COMMISSIONING PRACTICES

6.1Procedures should be in place to ensure proper installation and safe commissioning of rotating equipment as per specific practices mentioned in the relevant OISD standards and OEM guidelines.

6.2Procedure shall cover the following:

a)Checks for completeness of all systems and subsystems including fire protection systems as per OISD-STD-116 and OISD-STD-117

b)Adequacy of space around equipment for safe movement

c)Availability of operating procedures including startup and normal/ emergency shutdowns

d)Checks for functioning of interlocks and configuration of set-points of all protections like alarms and trips

e)Identification of equipment specific hazards and steps taken to mitigate and to create awareness about hazards to all concerned.

f)Training of manpower deployed

g)Use of personal protective equipment

h)Availability of commissioning spares and their replenishment.

6.3Records of base data and specific problems faced during the commissioning shall be maintained.

7ROOT CAUSE FAILURE ANALYSIS

7.1System shall be established to carry out root cause analysis for failures that have impact on safety and environment.

7.2The analysis should identify the cause of the failure and recommend corrective and preventive measures to prevent failure from recurring. A sample failure analysis report is attached in Appendix-III.

7.3Root cause failure analysis should be based on the following broad steps;

a)Data collection, observation and organization of data

b)Sequence of events leading to failure

c)Identification of probable causes

d)Analysis of probable causes and identification of most probable cause

e)Recommendation of corrective measures to prevent recurrence

f)Implementation of corrective action and preventive action in a time bound manner

7.4Cause of failure shall be categorized broadly as below:

a)Process failure

b)Component failure

c)Design failures

d)Human failure

e)Failure of systems and procedures

The action taken record on the recommendations shall be maintained.

8SAFE UTILIZATION OF LIFTING TOOLS AND TACKLES

8.1To ensure safe utilization of lifting tools & tackles, periodic inspection and testing as per applicable statutory rules and regulations applicable shall be carried out.

8.2Each lifting tool & tackle shall have unique identification and shall display the safe working load, testing date and next due date for testing.

8.3Records shall be maintained for verification

9EQUIPMENT DOCUMENTATION

9.1Proper documentation system shall be available to ensure safe operation of rotating equipment.

9.2Documentation shall include the following

a) Data sheets

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b) Performance curves

c)Cross sectional & constructional drawings and relevant P&ID

d)O&M manuals and MRBs

e)Commissioning data

f)Maintenance History

g)Break down/ failure analysis reports

h)Change management procedures and records

9.3Records/ documents should be maintained either in soft/ computerized or in hard/ paper form.

10.REFERENCES

This document refers to the following standards/documents:

a)OISD STD - 105, 116, 117, 119, 120, 121, 123, 124 & 125

b)API STD - 614

c)API RP - 686

d)Relevant API standards for specific equipments

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Appendix –I

Sample Record for Alarm/ Trip Changes

Date:Request No.:

Initiated by:

Approved by:

Change Implemented:

Date & Time

(Note: Authority for Initiating, Approving and implementing these changes shall be spelt out clearly)

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Appendix – II

SAMPLE PROCEDURE FOR STORAGE OF LUBRICANTS

1. There shall be no direct contact between the drum and the ground, if storage is for period greater than 3 months.
2. Long term storage of lube oil shall be in covered area.
3. Containment facility shall be provided in Drum Storage Areas.
4. Drums in long-term storage shall be positioned horizontally. (Grease drums shall be stored Vertically)
5. The nozzles on the drum shall be kept at 9 and 3 O’clock positions.
6. Areas where short-term storage of Drums is done shall not have more than 5 drums.
7. For drums provided with valve and nozzle, a tray shall be provided underneath the valve. The tray shall periodically be drained to “Used Lube Oil Drum” or to OWS
8. A First In – First Out policy for lubricant usage shall be used.
9. Shelf life of lubricants shall be mentioned

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Appendix –III

SAMPLE ROOT CAUSE FAILURE ANALYSIS SHEET

PROBLEM:

<Brief Description of Failure>

OBSERVATION:

<Description of Failures of as observed by Analyst with details of failed parts and patterns of failure>

ANALYSIS:

<Detailed Analysis of the Causes, Identification of Root Cause etc>

ROOT CAUSE

<Brief statement of most probable cause of failure>

CORRECTION, CORRECTIVE & PREVENTIVE ACTION:

< Describe immediate correction, Proposed Corrective Action and Preventive action to prevent future failures>

CIRCULATION

<Copies to concerned personnel>

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