Oil India · Web viewYes / No. Please furnish the following details (as per OMR / OISD Guidelines): Equipment Total Nos. Hydro-testing already done Hydro-testing due Remarks (A) Pressure

TECHNICAL AUDIT DEPARTMENTOIL INDIA LTD

DULIAJAN

A. 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)

2. 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)

3. Emulsion Treater

i. No. of E.T. available at site ……… No.ii. No. of E.T. on operation ……… No.iii. 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

4. Indirect Heaters

i. No. of Indirect Heaters available at site …….. No.

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ii. No. of Indirect Heaters in use …….. No.iii. No. of Indirect Heaters lying idle/unutilized ………No.

Sl. No.

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

5. Boilers

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

Sl. No.

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

6. 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

7. 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 :

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

Sl. No.

Description & Asset No. Qty Handling Capacity Reasons for non-utilization

8. 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 FWDPSl. No.

Description & Asset / Eqpt. No.

Qty Handling Capacity

Specification Reasons for non-utilization

9. 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 CODPSl. No.


Qty DespatchRate/Hr

Specification (Engine/ Motor Driven)

Reasons for non-utilization

10. Re-Charging Pump

i. No. of Pump available -ii. No. of pump in operation -iv. No. of pump lying idle -

Please provide details of the idle CP

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Sl. No.


Qty DespatchRate/Hr



11. Chemical Dozing Pump

i. No. of Pump availableii. No. of pump in operationiii. No. of pump lying idle

Please provide details of the idle CDPSl. No.


Qty DespatchRate/Hr



12. 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.


Qty DespatchRate/Hr



B. SALIENT FEATURES AND PERFORMANCE DATA OF OCS

1 Brief about OCS and operation involved (Pl include a Process Flow diagram and OCS layout):

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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 Scenarioi. 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 Installationi. 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)

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12 Any Measures undertaken to maintain the Crude quality / BS&W:

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 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.

D. 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 doneHydro-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

Yes / No.

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last filling/testing painted on the body?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.

E. SAFETY STANDARDS:

1. Are all the new workers appointed or posted on transfer to Yes / No.

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the installation given guidance, training on safety and operations involved, etc.?

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.

F. 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?

Annexure-I

G. 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

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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 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.

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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:__________________

I. MONTHLY WELL TEST DATA – OCS

Well No.

Type of lift

Flow armBean (mm)

G/L chock size /

TCC/Duration of shot

Total producing

hour

Test ResultTesting

hourTotal fluid

KLPD

Oil KLPD

Water KLPD

Date of testing

Water % (lab result)

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INSTALLATION:___________________

J. FORMATION WATER DISPOSAL WELL INJECTIVITY RATE AS ON:

WELL NO.

INJECTIVITY RATE DISPOSAL PRESSURE

DATE OF TESTING

REMARKSORIGINAL

(KLPD)PRESENT

(KLPD)

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INSTALLATION:_________________________

K. CONDITION OF EQUIPMENT

SL.NO.

DESCRIPTION OF ITEMS

DESP RATE (KL / HR) DATE OF COMMISSI

ONING

CUMULATIVE

RUNNING HRS

UPTO………

DATE OF LAST

OVERHAUL

HOURS RUN

AFTER OVERHAUL

REMARKSRATED PRESENT

1. COD PUMPS

a

b

c

d

2 FWD PUMPS

a

b

c

d

3 DRENCHING PUMPS

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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-I7 TPS-II8 TPS-III 9 Horizontal Stabilizer – I

10 Horizontal Stabilizer-II

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11 Horizontal ET-I12 Horizontal ET-II13 Horizontal ET-III14 Horizontal ET-IV15 Horizontal Fuel Gas Scrubber16 Horizontal LPMS-I, 30 PSI17 Vertical LPMS-I, 30 PSI18 Vertical LPMS (Stabilizer), 10 PSI19 Vertical HPMS-I, 250 PSI20 Vertical HPMS-II, 250 PSI21 Horizontal HFMS, 250 PSI-I22 Vertical Gas-Oil Separator TU-I23 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

RATINGKg/Cm2(for coil)

TESTED PRESSURE

Kg/Cm2(for coil)

LAST DATE OF TESTING(Fire tube)

PAINTING CONDITION

REMARKS

1 Indirect Heater (Double Coiled)






7 Indirect Heater (Double

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Coiled)

8 Indirect Heater (Single Coiled)

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Documents

Oil India · Web viewYes / No. Please furnish the following details (as per OMR / OISD Guidelines): Equipment Total Nos. Hydro-testing already done Hydro-testing due Remarks (A) Pressure