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TECHNICAL AUDIT DEPARTMENTOIL INDIA LTD

DULIAJAN

A. SALIENT FEATURES AND PERFORMANCE DATA OF THE INSTALLATION

1 Brief about the installation and operation involved:

1.b Please provide the Process Flow Diagram and Layout Diagram of the installation:2 Name of oil mines where the installation exists:

3 Date of commissioning :

4 DGM’s approval letter no. :

5 Gas handling capacity of the installation:

6 Natural Gas Produced in MMSCFD

Per Day 20___-20___ 20___-20___ 20___-20___

7 Condensate Produced in KL :

Per Day 20___-20___ 20___-20___ 20___-20___

8 Condensate Storage Capacity:

9 Brief details of major modifications / replacement / improvement carried out during last 5 years :

10 Briefly describe about how water extracted from gas is disposed off in the installation :

11 Briefly describe about the firefighting system / arrangements in the installation :

12 Furnish the details of all the equipment / asset of the installation in Annexure-II

13 Furnish the lube oil consumption details of equipment in Annexure-III

B. ORGANIZATION & ADMINISTRATION: 1 Is installation manager appointed as per mines act (OMR 1984)? Yes / No.

If yes, name of installation manager.2 Is safety officer appointed as per mines act (OMR 1984)? Yes / No.

If yes name of safety officer.3 Is fire officer appointed as per mines act (OMR 1984)? Yes / No.

If yes name of fire officer.4 Are inspections and tool box meeting are carried out prior to

starting of work?Yes / No.

5 Are hazards in operation made known to each other? Yes / No.

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6 Is the site plan properly displayed at the entrance? Yes / No.7 Are The Following Sign Boards Displayed For

(A) No Smoking / No Naked Lights: Yes / No.(B) Photography Prohibited: Yes / No.(C) Unauthorised Entry Prohibited: Yes / No.(D) Carrying Of Match Box, Lighters & Explosives Prohibited: Yes / No.

8 Are flow charts & diagrams displayed? Yes / No.9 Describe the condition of fencing / brick wall around the installation:

10 Describe the Condition of approach roads / walkways of the installation:

C. 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 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.

D. DOCUMENT/DISPLAY/OBSERVATIONS

1 Are operating manuals, maintenance schedules, and charts available?

Yes / No.

2 Are display boards or charts at entrance & other places Yes / No.

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pasted indicating the permission / license to perform the activities?

3 Are preventive maintenance schedules and lubrication schedules made and charts displayed properly?

Yes / No.

4 Are log books, history sheets of the equipment available & maintained?

Yes / No.

5 Are fuel, oil & spares for equipment consumption records maintained?

Yes / No.

6 Are statutory notifications like name of the mine, mines manager etc. displayed?

Yes / No.

7 Are fuel, oil & spares for equipment consumption records maintained?

Yes / No.

8 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 doneHydro-testing due

Remarks

(A) Pressure vessel(B) Safety valves

9 Are Hot work/cold work permit system existing, enforced & standard proforma available ?

Yes / No.

10 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.

11 Whether all the rotary and static equipment have been provided & painted with Identification Numbers/Tag no./Inventory no/equipment no.?

Yes / No.

12 Is there any colour codification system existing for painting of all the equipment in respect of installation?

Yes / No.

13 Is the fire fighting system adequate to tackle the situation of a major fire?

Yes / No.

14 Whether all the fired vessels have been provided with flame arrestors?

Yes / No.

15 Are these documents/registers available and properly maintained in the installation?1. DGMS Approval Letter: Yes / No.2. Installation Manger’s Appointment letter: Yes / No.3. Noise Level Measurement report for Installation: Yes / No.4. Junior Engr. Report Book: Yes / No.5. Gas Compressors Log Sheet: Yes / No.6. Load Testing Report of Over Head Crane: Yes / No.7. Fire Contingency Plan: Yes / No.8. Fire Extinguisher Records: Yes / No.9. Record of Fire Mock Drill: Yes / No.10. Test Record of Pressure Vessels: Yes / No.11. Test Record of Safety Relief valves: Yes / No.12. Electrical Earth Testing Records: Yes / No.13. Electrical Installation & Energisation Permit as per OISD: Yes / No.14. Insulation Resistance Test Records: Yes / No.15. Accident record: Yes / No.16. Near Miss Accident Report: Yes / No.17. Hot / cold permit record: Yes / No.18. Instruments calibration record: Yes / No.19. Tool Box Meeting: Yes / No.20. Pit Level Meeting: Yes / No.21. Gas Testing Report: Yes / No.

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22. Machinery Inspection Report: Yes / No.23. Recommendation File: Yes / No.24. PM Records: Yes / No.25. POL Consumption Records: Yes / No.26. Running Hours of Equipment: Yes / No.27. Form “U” Observation by Installation Manager: Yes / No.28. Shut-in Well Records: Yes / No.29. List of Competent Persons: Yes / No.30. Periodical Medical Examination of Employee: Yes / No.31. Audiometric Checkup for employee: Yes / No.32. Monthly Pollution Control Records: Yes / No. 33. Public Grievance: Yes / No.34. Employee Training Register: Yes / No.35. Form ”B” Employee Register: Yes / No.36. Form “E” Register for Person Working Above Ground: Yes / No.37. Form ”G” Employee Leave record: Yes / No.38. First Aid / Fire Fighting File: Yes / No.39. MVT & Refresher Training Records: Yes / No.40. Compressor Maintenance Records: Yes / No.41. Gas Flow Diagram: Yes / No.42. Electrical Line Diagram of Power Supply Arrangements: Yes / No.43. NDT Testing Records: Yes / No.

16 Are the document mentioned are checked and endorsed by MSO periodically as per guidelines:

Yes / No.

E. 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 test 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

Yes / No.

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emergencies?12 Is the illumination system in the installation is adequate? Yes / No.

F. ENERGY AWARENESS :

1 Gas Flaring, Leakage of POL, Diesel, Compressed Gas, Crude Oil, Water and Other Liquids:

OBSERVATION REMARKSa) Gas Flaringb) Lube oil leakagesc) Diesel leakagesd) Crude oil leakages

e) Water leakages

2. Measurement of Fuel Consumed by Various Equipments:

a) Gas Engineb) Diesel Engine

3. Are calibrated gauges of flow meters, energy meters, etc. available for analysis of energy consumption?

Yes / No.

4. Is there any check for energy consumption and monitoring? Yes / No.

5. Total electricity generated (KWH).Total electricity consumed (KWH).

6. Total energy consumed in the installation (KWH).7. Whether adequate care is taken while choosing equipment on the

point of energy efficiency?Yes / No.

G. COMMUNICATION SYSTEM:

A Is walkie talkie set available in the installation?

B Availability of telephone system for contacting base / regional offices.

C Is the communication system satisfactory or more improvements desirable?

B. SYSTEM MONITORING

1. Gas Lift Compressor (GLC) i. No. of GLC available at site ……… No.ii. No. of GLC in operation ……… No.iii. No. of GLC lying idle / unutilized ……… No.

Please provide details of idle GLC in following format:Sl. No.

Description & Asset / Eqpt. No.

Qty Handling Capacity Reasons for non-utilization

2. Low Pressure Booster (LPB)

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i. No. of LPB available at site …….. No.ii. No. of LPB in use …….. No.iii. No. of LPB lying idle/ unutilized …….. No.

Please provide details of idle LPB in following format:Sl. No.



3. Gas Injection Compressor (GIC) i. No. of GIC available at site …….. No.ii. No. of GIC in use …….. No.iii. No. of GIC lying idle / unutilized ………No.

Please provide details of idle GIC in following format:Sl. No.


Qty Specification Reasons for non-utilization

4. Air Compressor i. No. of Air Compressor available at site …….. No.ii. No. of Air Compressor in use …….. No.iii. No. of Air Compressor lying idle/unutilized …….. No.

Please provide details of idle Air Compressor in following format:Sl. No.

Description & Asset No.


5. Very Low Pressure Booster (VLPB) i. No. of VLPB available at site …….. No.ii. No. of VLPB in use …….. No.iii. No. of VLPB lying idle / unutilized …….. No.

Please provide details of idle VLPB in following format:Sl. No.

Description & Asset No.


6. Safety Relief Valve (SRV Unit) i. No. of SRV Unit available at site …….. No.ii. No. of SRV Unit in use …….. No.iii. No. of SRV Unit lying idle / unutilized …….. No.

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Please provide details of idle SRV Unit in following format:Sl. No.

Description & Asset /Eqpt. No.


7. Overhead Crane i. No. of Overhead Crane available -

ii. No. of Overhead Crane in operation - iii. No. of Overhead Crane lying idle -

Please provide details of the idle Overhead Crane in following format:Sl. No.



8. Knock Out Vessel (KOV) i. No. of Knock Out Vessel available -ii. No. of Knock Out Vessel in operation -iv. No. of Knock Out Vessel lying idle -

Please provide details of the idle Knock Out Vessel in following format:Sl. No.



9. Mist Extractor i. No. of Mist Extractor available -ii. No. of Mist Extractor in operation -iii. No. of Mist Extractor lying idle -

Please provide details of the idle Mist Extractor in following format:Sl. No.



10. Glycol Dehydration Plant i. No. of Glycol Dehydration Plant available -ii. No. of Glycol Dehydration Plant in operating condition -iii. No. of Glycol Dehydration Plant lying idle -

Please provide details of the idle Glycol Dehydration Plant in following format:

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Sl. No.



11. Air X Changer i. No. of Air X Changer available -ii. No. of Air X Changer in operating condition -iii. No. of Air X Changer lying idle -

Please provide details of the idle Air X Changer in following format:

Sl. No.



12. Gas Engine i. No. of Gas Engine available -ii. No. of Gas Engine in operating condition -iii. No. of Gas Engine lying idle -

Please provide details of the idle Gas Engine in following format:

Sl. No.



13. Motor i. No. of Motor available -ii. No. of Motor in operating condition -iii. No. of Motor lying idle -

Please provide details of the idle Motor in following format:

Sl. No.



14. Pump i. No. of Pump available -ii. No. of Pump in operating condition -iii. No. of Pump lying idle -

Please provide details of the idle Pumps in following format:

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Sl. No.



15. Fuel Scrubber i. No. of Fuel Scrubber available -ii. No. of Fuel Scrubber in operating condition -iii. No. of Fuel Scrubber lying idle -

Please provide details of the idle Fuel Scrubber in following format:

Sl. No.



16. Fuel Filter i. No. of Fuel Filter available -ii. No. of Fuel Filter in operating condition -iii. No. of Fuel Filter lying idle -

Please provide details of the idle Fuel Filter in following format:

Sl. No.



17. Re-Boiler i. No. of Re-Boiler available -ii. No. of Re-Boiler in operating condition -iii. No. of Re-Boiler lying idle -

Please provide details of the idle Re-Boiler in following format:

Sl. No.



18. Flash Tank i. No. of Flash Tank available -ii. No. of Flash Tank in operating condition -iii. No. of Flash Tank lying idle -

Please provide details of the idle Re-Boiler in following format:

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Sl. No.



19. Very Low Pressure Compressor (VLPC) i. No. of VLPC available -ii. No. of VLPC in operating condition -iii. No. of VLPC lying idle -

Please provide details of the idle VLPC

Sl. No.



20. Other Equipment 1 if any i. No. of equipment 1 available -ii. No. of equipment 1 1in operating condition -iii. No. of equipment 1 lying idle -

Please provide details of the idle equipment

Sl. No.



21. Other Equipment 2 if any i. No. of equipment2 available -ii. No. of equipment2 in operating condition -iii. No. of equipment2 lying idle -


Sl. No.



22. Other Equipment3 if any i. No. of equipment3 available -ii. No. of equipment3 in operating condition -iii. No. of equipment3 lying idle -

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DULIAJAN


Sl. No.



Annexure-IUn-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

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PRESENT PRODUCTION SCENARIO:

Gas handling capacity in SCUMDGas production per day (Average)Gas sold per day (Average)Gas flare (Average)Total Gas Produced in SCUM 20___-20___ 20___-20___ 20___-20___

Total Gas sold Total Gas FlaredAverage Condensate Produced /day KL Per DayTotal Condensate Produced in KL 20___-20___ 20___-20___ 20___-20___

INSTALLED CAPACITY:

Equipment Qty Handling Capacity Low Pressure Booster (LPB) Nos. MMSCFDGas Lift Compressors (GL) Nos. MMSCFDGas Injection Compressors (GI) No.Gas Dehydration Plant Unit MSCMD

MAINTENANCE COST:

20___-20___ 20___-20___ 20___-20___ 20___-20___

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LUBE OIL CONSUMPTION:

20___-20___ 20___-20___ 20___-20___ 20___-20___Maintenance L L L LOperation L L L LTotal L L L L

` Lakhs ` Lakhs ` Lakhs ` Lakhs

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 LimitCarbon 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.

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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.

DETAILS OF EQUIPMENT / ASSET IN THE INSTALLATION Annexure-II

Sl. No

Description of Equipment / Asset PO / Contract

No.

Date of Commiss

ioning

Cumulative

Running Hrs

Running Hrs after

last Overhaul

ing

Next OverhaulingDue

on R/ Hrs

Maintenance Cost in INR

Current Status

Equipment / Make

Handling Capacity/Rating

Serial / Equipt / Asset No.

20___-20___

20___-20___

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LUBE OIL CONSUMPTIONSl. No.

Description of Equipment Lube Oil Consumption Rate Remarks

Equipment Serial / Equipt. / Asset No

As Per OEM Recommendation (L / Hr)

Present Consumption (L/ Hr)

Annexure-III

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