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OISD - RP- 126

First Edition, August 1990


Amended edition, August 1999
Amended Editi on, August 2007






Specific Practices for Instal lation and Maintenance
of
Rotary Equipment





Prepared by
Functional Committee






OIL INDUSTRY SAFETY DIRECTORATE
7
th
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 Di rectorate,
7
th
Floor, New Delhi House
27, Barakhamba Road
New Delhi 110 001
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LIST OF FUNCTIONAL COMMITTEE MEMBERS



S.N Name Organisation Position in
Committee
01 Mr. D.K. Puri Reliance Industries Limited Leader
02 Mr. S.K. Chatterjee Hindustan Petroleum
Corporation Limited
Member
03 Mr. P. Veerabhadra
Rao
Hindustan Petroleum
Corporation Limited
Member
04 Mr. T.V.
Venkateswaran
Reliance Industries Limited Member
05 Mr. A.K. Dash Indian Oil Corporation Limited Member
06 Mr. Deepak Prabhakar Mangalore Refinery and
Petrochemicals Ltd.
Member
07 Mr. R.C. Agarwal Bharat Petroleum Corporation
Limited
Member
08 Mr. K Ravi Kochi Refineries Limited Member
09 Mr. Shamsher Singh Oil Industry Safety Directorate Member
Coordinator

















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CONTENTS

S.N Chapter Page No.
1.0 Introduction 01
2.0 Scope 01
3.0 Definitions 01
4.0 Equipment Protection and Change Management 02
5.0 Lubrication and Lubrication Systems 03
6.0 Safe Commissioning Practices 03
07 Root Cause Failure Analysis 04
08 Safe Utilization Lifting Tools and Tackles 04
09 Equipment Documentation 05
10 References 05
11 Annexure-I 06
12 Annexure-II 07
13 Annexure-III 08






















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Specific Practices for Instal lation and Maintenance
of
Rotary Equipment


1 INTRODUCTION

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.

2 SCOPE
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
3 DEFINITIONS
3.1 Equipment
An asset & its associated parts
/auxiliaries which are essential to
achieve organizations business goal
and requires strategic operational &
maintenance attention from time to time
and to keep it in a state of delivering
desired service.
3.2 Protection
The device or integrated system to
prevent an equipment or group of
equipment from undergoing potential
failure or unsafe conditions.
3.3 Li fti ng Tool s & 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.
3.4 Change Management
Mechanism to control and manage
changes to operating conditions,
protection systems and mechanical
systems of equipment that affect safe
operation of the equipment.
3.5 Documentation
A system to keep information in
systematic manner, which is retrievable
whenever required.
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3.6 Potential Ri sk
The degree of probability for occurrence.
3.7 Root Cause Fai lure Anal ysis
A data based analytical approach to
identify the basic cause/s of failure
3.8 Commissioning
Process of releasing an asset for normal
operation.
3.9 Manufacturers Report/ Record
Book (MRB)
The documentation supplied by the
manufacturer along with the equipment.
4.0 EQUIPMENT PROTECTION
AND CHANGE
MANAGEMENT

4.1 The 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.
4.2 Records of equipment protection
systems shall be maintained as per
OISD 124.
4.3 Alarm and danger values for the above
parameters shall be part of the record.
4.4 Procedures 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.
4.5 The 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&IDs/ 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.
4.6 Change management procedures shall
include modifications to critical
components like Seals, Bearings,
Couplings, Shafts, Impellers and
Lubricants.
5 LUBRICANT AND
LUBRICATION SYSTEMS

5.1 Systems 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.
5.2 Make-up of lubricant shall be done
ensuring that proper grade of
lubricant in recommended quantity is
applied.
5.3 Recommended grade of lubricant
shall be displayed prominently on or
near the equipment.
5.4 Procedure for proper storage and
identification of lubricants should be
followed. A recommended
procedure for storage is given in
appendix-II.
5.5 Procedure 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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6 SAFE COMMISSIONING
PRACTICES

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

7 ROOT CAUSE FAILURE
ANALYSIS

7.1 System shall be established to carry
out root cause analysis for failures
that have impact on safety and
environment.
7.2 The 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.
7.3 Root 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
7.4 Cause 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.

8 SAFE UTILIZATION OF LIFTING
TOOLS AND TACKLES
8.1 To ensure safe utilization of lifting
tools & tackles, periodic inspection
and testing as per applicable
statutory rules and regulations
applicable shall be carried out.
8.2 Each lifting tool & tackle shall have
unique identification and shall
display the safe working load,
testing date and next due date for
testing.
8.3 Records shall be maintained for
verification

9 EQUIPMENT
DOCUMENTATION
9.1 Proper documentation system shall
be available to ensure safe
operation of rotating equipment.
9.2 Documentation 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
9.3 Records/ 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

Sampl e Record for Alarm/ Trip Changes

Date: Request No.:

Plant
Eqpt. Tag no.
Description
Probe Tag. No.
Existing Setting
Proposed Setting
Reason for
Change

Remarks


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 Oclock 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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