Technical Audit Department

Technical Audit Department

TECHNICAL AUDIT DEPARTMENT

OIL INDIA LTD

DULIAJAN

  1. SYSTEM MONITORING
  1. Oil Well Manifold

No. of manifold available in the installation….. No.

  • No. of manifold (in operation)….. No.
  • No. of manifold (lying idle)….. No.

(Please provide reason for idling)

  1. Pressure Vessels (Gas/Oil/Formation Water Separators)
  • No. of Pressure Vessels in operations….. No.
  • No. of Pressure Vessels lying idle….. No.

Please provide details of idle separators in the following format:

Sl. No. / Description & Asset /Eqpt. No. / Qty / Designed Press
(Kg/CM2) / Working Press
(Kg/CM2) / Handling Capacity / Reasons for non-utilization
Oil
(KLPD) / Water
(KLPD) / Gas
(SCUMD)
  1. Emulsion Treater
  1. No. of E.T. available at site……… No.
  2. No. of E.T. on operation……… No.
  3. No. of E.T. lying idle/unutilized……… No.

Please provide details of idle E.T. in following format :

Sl. No. / Description & Asset / Eqpt. No. / Qty / Handling Capacity / Reasons for non-utilization
  1. Indirect Heaters
  1. No. of Indirect Heaters available at site …….. No.
  2. No. of Indirect Heaters in use …….. No.
  3. No. of Indirect Heaters lying idle/unutilized………No.

Sl. No. / Description & Asset / Eqpt. No. / Qty / Specification / Reasons for non-utilization
  1. Boilers

i. No. of Boilers available at site …….. No.

  1. No. of Boilers in use …….. No.
  2. No. of Boilers lying idle/unutilized………No.

Sl. No. / Description & Asset / Eqpt. No. / Qty / Specification / Reasons for non-utilization
  1. Crude Oil Storage Tanks

i. No. of crude oil tanks available-

ii. Capacity of each tank-

iii. System of measurement-

iv. Availability of Tank dykes-

v. Condition of the dyke-

a. No. of crude oil tanks in use-

b. No. of crude oil tanks lying idle/unutilized-

Details of idle/unutilized tanks:

Sl. No. / Description & Asset No. / Qty / Handling Capacity / Reasons for non-utilization
  1. Formation Water Storage Tanks

i. No. of F.W. Tanks with capacity available:

ii. No. of tanks on operation:

iii. No. of tanks lying idle:

iv. Total daily production of Formation Water :

Please provide details of the idle tanks (Capacity, condition of tank etc.)

Sl. No. / Description & Asset No. / Qty / Handling Capacity / Reasons for non-utilization
  1. Formation Water Disposable Pump

i No. of FWD Pump with capacity available –

ii. No. of FWD Pump in operation -

iii. No. of FWD Pump lying idle -

iv. No. of F.W. disposal wells -

v. Rate of injectivity of each FWD Pump -

Please provide details of the idle FWDP

Sl. No. / Description & Asset / Eqpt. No. / Qty / Handling Capacity / Specification / Reasons for non-utilization
  1. Crude Oil Despatch Pump

i. No. of CODP available-

ii. No. of CODP (in operation)-

iii.No. of CODP lying idle -

Please provide details of the idle CODP

Sl. No. / Description & Asset / Eqpt. No. / Qty / Despatch
Rate/Hr / Specification(Engine/ Motor Driven) / Reasons for non-utilization
  1. Re-Charging Pump

i. No. of Pump available-

ii. No. of pump in operation-

  1. No. of pump lying idle-

Please provide details of the idle CP

Sl. No. / Description & Asset / Eqpt. No. / Qty / Despatch
Rate/Hr / Specification(Engine/ Motor Driven) / Reasons for non-utilization
  1. Chemical Dozing Pump

i.No. of Pump available

ii.No. of pump in operation

iii.No. of pump lying idle

Please provide details of the idle CDP

Sl. No. / Description & Asset / Eqpt. No. / Qty / Despatch
Rate/Hr / Specification(Engine/ Motor Driven) / Reasons for non-utilization
  1. Water Drenching Pump (WDP)

i. No. of Drenching Pump available-

ii.No. of Drenching pump in operating condition-

iii. No. of Drenching pump lying idle-

Please provide details of the idle WDP

Sl. No. / Description & Asset / Eqpt. No. / Qty / Despatch
Rate/Hr / Specification(Engine/ Motor Driven) / Reasons for non-utilization
  1. SALIENT FEATURES AND PERFORMANCE DATA OF OCS

1 / Brief about OCS and operation involved (Pl include a Process Flow diagram and OCS layout):
2 / Name of oil mines where the installation exist :
3 / Date of commissioning :
4 / DGM’s approval letter no. :
5 / Initial handling capacity (as per design)
  • Wet stream :
  • Dry stream :
  • Crude Storage capacity :
  • Crude evacuation capacity :
  • HP Gas handling capacity :
  • LP Gas handling capacity :
  • Formation Water Storage capacity :

6 / Present Production Scenario
i. Total liquid production
Oil :
Water:
ii. Total gas production
HP Gas :
LP Gas :
iii. Total gas flaring (if any) :
iv. Total no. of wells on production :
v. No. of wells produced through dry stream (as on date) :
vi. No. of wells produced through wet stream (as on date) :
vii Self flowing wells on production :
viii Artificial lift wells on production :
ix. Total no. of gas well on production (if any) :
x. No. of water disposal well & injectivity rate :
7 / Details of wells under the Installation
i. Total no. of wells drilled so far :
ii. Total no. of wells connected :
iii. No. of wells connected to Dry Stream :
iv. No. of wells connected to Wet Stream :
v. Total no. of artificial lift wells :
vi. Total no. of shut in wells due to high water cut :
vii No. of shut in wells due to technical reasons :
viii. Total no. of wells awaiting work-over :
ix Total no. of abandoned wells :
8 / Brief details of major modifications/replacement / improvement carried out during last 5 years :
9 / Briefly describe about how formation water is disposed off in the installation :
10 / Briefly describe about the firefighting system / arrangements in the installation :
11 / Average Base Sediment & Water (BS&W) content in the crude in % (pl provide data of ET outlet and Despatch pump delivery sample for last 3-months)
12 / Any Measures undertaken to maintain the Crude quality / BS&W:
  1. EQUIPMENT & ASSET MANAGEMENT

1 / Are equipment/asset master data of the installation uploaded /updated and maintained in the ERP (SAP) system? / Yes / No.
2 / Are asset identification nos. marked on the equipment and matches with ERP data? / Yes / No.
3 / Are all the engine safety systems available/working like high water/lube oil temp., switches, low lube oil pressure switches, emergency shut off valve, fuel cut off/air cut off devices, etc.? / Yes / No.
4 / Are preventive maintenance schedule of critical equipment available & implementation carried out towards preventive maintenance and lubrication schedule? / Yes / No.
5 / Are data with respect to specific equipment maintenance maintained in ERP system? / Yes / No.
6 / Are operating parameters of equipment and its preventive maintenance based on time, running hours etc. maintained in ERP system? / Yes / No.
7 / Are maintenance activities are planned during non requirement of the equipment to maximize the availability? / Yes / No.
8 / Are history sheets, log books, etc. properly maintained and timely updated for all the equipment? / Yes / No.
9 / Are corrosion resistance /painting condition of the piping’s, vessels, tanks, equipment etc are proper? / Yes / No.
10 / Is there any list for un-utilized equipment/materials in the installation? If yes, give in details as per Annexure-I / Yes / No.
11 / Are inventory register for all equipments (used / unused / spares) maintained? / Yes / No.
12 / Are there any movement register for equipments / machineries / instruments etc.? / Yes / No.
13 / Do you maintain record for incoming / outgoing materials from the installation? / Yes / No.
  1. Document/Display/Observations

1 / Are fuel, oil & spares for equipment consumption records maintained? / Yes / No.
2 / Are equipments hydro/pneumatic tested and maintained as per statutory requirement? / Yes / No.
Please furnish the following details (as per OMR / OISD Guidelines):
Equipment / Total Nos. / Hydro-testing already done / Hydro-testing due / Remarks
(A) Pressure vessel
(B) Safety valves
3 / Are Hot work/cold work permit system existing, enforced & standard proforma available ? / Yes / No.
4 / Are fire fighting equipment records (Bottles filled in) available with the identification markings and date of last filling/testing painted on the body? / Yes / No.
5 / Whether all the rotary and static equipment have been provided & painted with Identification Numbers/Tag no./Inventory no/equipment no.? / Yes / No.
6 / Is there any colour codification system existing for painting of all the equipment in respect of installation? / Yes / No.
7 / Is the fire fighting system adequate to tackle the situation of a major fire? / Yes / No.
8 / Whether all the fired vessels have been provided with flame arrestors? / Yes / No.
9 / Whether all the bath heaters and emulsion treaters have been properly tagged/insulated to conserve heat? / Yes / No.
10 / Whether the system of remote ignition exist in all fired vessels? / Yes / No.
11 / Are these documents/registers are available and properly maintained in the installation?
1. DGMS Approval Letter: Yes / No.
2. Fire Contingency Plan: Yes / No.
3. Fire Extinguisher Records: Yes / No.
4. Record of Fire Mock Drill: Yes / No.
5. Test Record of Pressure Vessels: Yes / No.
6. Test Record of Safety Relief valves: Yes / No.
7. Electrical Earth Testing Records: Yes / No.
8. Electrical Installation & Energisation Permit as per OISD: Yes / No.
9. Earth Resistance Test Records: Yes / No.
10. Accident record: Yes / No.
12. Near Miss Accident Report: Yes / No.
13. Hot / cold permit record: Yes / No.
14. Instruments calibration record: Yes / No.
15. Tool Box Meeting: Yes / No.
16. Pit Level Meeting: Yes / No.
17. Gas Testing Report: Yes / No.
18. Machinery Inspection Report: Yes / No.
19. Recommendation File: Yes / No.
20. PM Records: Yes / No.
21. POL Consumption Records: Yes / No.
22. Running Hours of Equipment: Yes / No.
23. Form “U” Observation by Installation Manager: Yes / No.
24. Shut-in Well Records: Yes / No.
25. List of Competent Persons: Yes / No.
26. Periodical Medical Examination of Employee: Yes / No.
27. Monthly Pollution Control Records: Yes / No.
28. Public Grievance: Yes / No.
29. Employee Training Register: Yes / No.
30. Form ”B” Employee Register: Yes / No.
31. Form “E” Register for Person Working Above Ground: Yes / No.
32. Form ”G” Employee Leave record: Yes / No.
33. First Aid / Fire Fighting File: Yes / No.
34. MVT & Refresher Training Records: Yes / No.
12 / Are the document mentioned are checked and endorsed by MSO periodically as per guidelines: / Yes / No.
  1. SAFETY STANDARDS:

1. / Are all the new workers appointed or posted on transfer to the installation given guidance, training on safety and operations involved, etc.? / Yes / No.
2. / First-Aid medicines, materials available at site? / Yes / No.
3. / Is there an emergency vehicle available at site? / Yes / No.
4. / Electrical Safety:
  • Are all the electrical motors / switch board / panel etc. provided with proper earthing? Yes / No.
  • Whether electrical shock treatment charts are displayed? Yes / No.
  • Are caution / danger sign displayed? Yes / No.
  • Are flame proof light fittings used? Yes / No.
  • Whether safety torch is being used? Yes / No.
  • Are all the electrical cables properly routed in cable ducts / trays? Yes / No.
  • Are insulation lost records available? Yes / No.

5. / Is fire alarm system available & working? / Yes / No.
6. / Are portable hydrocarbon detector available? Also is there any on line hydrocarbon leakage detection system? / Yes / No.
7. / Are non sparking tools used while carrying out maintenance activities? / Yes / No.
8. / Are the fire water pumps tested frequently and all the time kept in operating condition? / Yes / No.
9. / Is there provision of diesel engine driven fire water pump for fire fighting in case of power failure? If so, is it in operating condition? / Yes / No.
10. / Are the engines provided with spark arrestors in the exhaust? / Yes / No.
11. / Is there any mutual aid system developed with near by industries for extending fire services in case of emergencies? / Yes / No.
12. / Is the illumination system in the installation is adequate? / Yes / No.
  1. COMMUNICATION SYSTEM:

A / Is walkie talkie setavailable in the installation?
B / Availability of telephone system for contacting base / regional offices.
C / Is the communication system satisfactory or more improvements desirable?

Annexure-I

  1. Un-utilized Equipment and Materials

Following equipment/materials are lying un-utilized at the installation:

Sl. No. / Description / Qty / UOM / Asset/ Inventory/ Equipment No. / Remarks/Action taken

H. Installation Manager to Confirm Following Legal Compliances:

1. / Following Pollutants desirable limit is maintained as per Central Pollution Control Board (CPCB) & Occupational Safety & Health Administration (OSHA)
Pollutant / Unit / Desirable Limit
Carbon Monoxide / mg / m3 / 5000 ( As per CPCB) / Yes/No.
Nitric Oxide / mg / m3 / 120 ( As per CPCB) / Yes/No.
Oxides of Nitrogen (NOx) / mg / m3 / 120 ( As per CPCB) / Yes/No.
Oxides of Sulphur / mg / m3 / 120 ( As per CPCB) / Yes/No.
Total Hydrocarbon / mg / m3 / 327200 (As per OSHA) / Yes/No.
2. / The Batteries (Management & Handling) Rules 2001, Under Rule 10 / Yes/No.
3. / The Indian Boilers Act, 1923 Under Sec. 7, 8, 12 & 14 / Yes/No.
4. / Disaster Management Act, 2005 Under Reg. 58 / Yes/No.
5. / Environment (Protection) Act, 1986 Under Rule 6, 14 & 3(72) / Yes/No.
6. / Hazardous Waste (Management And Handling) Rules 1989 / 2000 / 2003 Under Rule 5 & 9.2 / Yes/No.
7. / Industrial Employment (Standing Orders) Act, 1946: An act to require employers in industrial establishments formally to define conditions of employment under them under sec. 9 / Yes/No.
8. / Mines Act, 1952 : An act to amend and consolidate the law relating to regulation of labour and safety of mines under different sections of Chapter V, VI, VII, VIII & IX / Yes/No.
9. / Oil Mines Regulation,1984 under reg. 7, 8, 18, 51, 58, 64 to 72, 74, 75, 78, 79, 81 to 83, 86, 87, 90, 91, 93, 95, 97 to 99. / Yes/No.
10. / Fire Contingency Plan And Guide Lines For Fire Fighting
(In Compliance of Regulation 72 of Oil Mine Regulations, 1984) / Yes/No.
11. / Payment of Wages Act, 1936 : An act to regulate certain classes of employed persons / Yes/No.
12. / Petroleum Act, 1934 Under Reg. 7 & 27 / Yes/No.
13. / The Water (Prevention and Control of Pollution) Act, 1974 / Yes/No.
Characteristics / Unit / Desirable limit as per State PCB of Assam
Appearance / --- / Clear / Yes/No.
pH / --- / 5.5 - 9.0 / Yes/No.
Chloride (as Cl) / mg / l / 1000 (max) / Yes/No.
Phenolic compounds / mg / l / 1.0 (max) / Yes/No.
Sulphate / mg / l / 1000 (max) / Yes/No.
Chromium (Hexa) as Cr / mg / l / 0.1 (max) / Yes/No.
Total Dissolves Solids / mg / l / 2100(max) / Yes/No.
Suspended Solids / mg / l / 100(max) / Yes/No.
Oil and Grease / mg / l / 10 (max) / Yes/No.
14. / Water Cess Act 1977 Under Sec. 5 / Yes/No.
15. / Workmen’s Compensation Act, 1923: An act to provide for payment by employers to the workmen of compensation on death or injury by accident under sec 10 & 10-B. / Yes/No.

INSTALLATION:______

  1. MONTHLY WELL TEST DATA – OCS

Well No. / Type of lift / Flow arm
Bean (mm) / G/L chock size / TCC/Duration of shot / Total producing hour / Test Result
Testing hour / Total fluid KLPD / Oil KLPD / Water KLPD / Date of testing / Water % (lab result)

INSTALLATION:______

J. FORMATION WATER DISPOSAL WELL INJECTIVITY RATE AS ON:

WELL NO. / INJECTIVITY RATE / DISPOSAL PRESSURE / DATE OF TESTING / REMARKS
ORIGINAL
(KLPD) / PRESENT
(KLPD)

INSTALLATION:______

K. CONDITION OF EQUIPMENT

SL.
NO. / DESCRIPTION OF ITEMS / DESP RATE (KL / HR) / DATE OF COMMISSIONING / CUMULATIVE RUNNING HRS UPTO……… / DATE OF LAST OVERHAUL / HOURS RUN AFTER OVERHAUL / REMARKS
RATED / PRESENT
1. / COD PUMPS
a
b
c
d
2 / FWD PUMPS
a
b
c
d
3 / DRENCHING PUMPS
a
b
c
d
4 / CHEMICAL DODGING PUMP (OSD AND DEOILER) / L/HR / L/HR
a
b
c
d

INSTALLATION:______

L. INSPECTION OF STATIC EQUIPMENT & OTHER EQUIPMENT

SL.
NO. / ITEM / DESGN PRES.
Kg/Cm2 / TESTED PRES.
Kg/Cm2 / OPERATIVE PRES.
Kg/Cm2(O.P) / DATE OF LAST HYDRO TEST / PAINTING CONDITION / REMARKS
1 / Horizontal Gas – Oil Separator- GU-I (Dry)
2 / Horizontal Gas – Oil Separator- GU-II (Dry)
3 / Horizontal Gas- Oil Separator – GU-III (Dry)
4 / Horizontal Gas-Oil Separator- GU-I (Wet) (1)
5 / Horizontal Gas-Oil Separator- GU-I (Wet) (2)
6 / TPS-I
7 / TPS-II
8 / TPS-III
9 / Horizontal Stabilizer – I
10 / Horizontal Stabilizer-II
11 / Horizontal ET-I
12 / Horizontal ET-II
13 / Horizontal ET-III
14 / Horizontal ET-IV
15 / Horizontal Fuel Gas Scrubber
16 / Horizontal LPMS-I, 30 PSI
17 / Vertical LPMS-I, 30 PSI
18 / Vertical LPMS (Stabilizer), 10 PSI
19 / Vertical HPMS-I, 250 PSI
20 / Vertical HPMS-II, 250 PSI
21 / Horizontal HFMS, 250 PSI-I
22 / Vertical Gas-Oil Separator TU-I
23 / Vertical Gas-Oil Separator TU-II

M. INSPECTION OF STATICE EQUIPMENT & OTHER EQUIPMENT

INSTALLATION:______DATE:

SL. NO. / ITEM / DESIGN PRESSURE
Kg/Cm2
(for coil) / OPERATING PRESSURE RATING
Kg/Cm2
(for coil) / TESTED PRESSURE
Kg/Cm2
(for coil) / LAST DATE OF TESTING
(Fire tube) / PAINTING CONDITION / REMARKS
1 / Indirect Heater (Double Coiled)
2 / Indirect Heater (Double Coiled)
3 / Indirect Heater (Double Coiled)
4 / Indirect Heater (Double Coiled)
5 / Indirect Heater (Double Coiled)
6 / Indirect Heater (Double Coiled)
7 / Indirect Heater (Double Coiled)
8 / Indirect Heater (Single Coiled)

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