TECHNICAL AUDIT DEPARTMENT
OIL INDIA LTD
DULIAJAN
FORMAT FOR PRE-AUDIT INFORMATION
A. SALIENT FEATURES AND PERFORMANCE DATA OF PUMP STATION
1.a / Brief about pump station and operation involved:1.b / Please provide the PFD and Layout Diagram of the installation:
2 / Date of commissioning :
3 / DGM’s approval letter no. :
4 / Crude oil storage capacity:
5 / Crude oil evacuation capacity:
6 / Is there any system exist to control and measure BS & W content in the crude oil before despatch to refinery? Please furnish the details:
7 / What is the BS & W content in the crude oil before despatch to refinery?
8 / Crude oil movement:
Year-> / 20___-20___ / 20___-20___ / 20___-20___ / 20___-20___ (as on the date)
Crude Dispatched in MT
Water content (%)
9 / Energy Consumption:
Year-> / 20___-20___ / 20___-20___ / 20___-20___ / 20___-20___ (as on the date)
Generation (KWH)
Consumption (KWH)
10 / Crude oil consumption in running the dispatch pump, generating set etc. run on crude oil
Year-> / 20___-20___ / 20___-20___ / 20___-20___ / 20___-20___ (as on the date)
Crude dispatch pump
Generating set
11 / Unit rate of electricity available in the market:
12 / Brief details of any major eventuality, complication, major shutdown in last 3 years:
13 / Brief details of major modifications / replacement / improvement carried out during last 5 years :
14 / Briefly describe about the firefighting system / arrangements in the installation :
15 / Furnish the details of all the equipment / asset of the installation in Annexure-II
16 / Furnish the lube oil consumption details of equipment in Annexure-III
B. ORGANIZATION & ADMINISTRATION:
1 / Is installation manager is appointed as per mines act (OMR 1984)? / Yes / No.If yes, name of installation manager.
2 / Is safety officer is appointed as per mines act (OMR 1984)? / Yes / No.
If yes name of safety officer.
3 / Is fire officer is appointed as per mines act (OMR 1984)? / Yes / No.
If yes name of fire officer.
4 / Are inspections carried out prior to starting of work? / Yes / No.
5 / Are hazards in operation made known to each other? / Yes / No.
6 / Is the site plan properly displayed at the entrance? / Yes / No.
7 / Are The Following Sign Board 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 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.
14 / Do you carryout Predictive Maintenance / Condition Monitoring of equipment / machineries? / Yes / No.
D. DOCUMENT/DISPLAY/OBSERVATIONS
1 / Are operating manuals, maintenance schedules, and charts available at the installation? / Yes / No.2 / Are display boards or charts at entrance & other places pasted indicating the permission / license to perform the activities? / Yes / No.
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 consumption records of fuel, oil & spares for equipment maintained? / Yes / No.
6 / Are statutory notifications like name of the mine, mines manager etc. displayed? / Yes / No.
7 / 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
8 / Are Hot work/cold work permit system existing, enforced & standard proforma available ? / Yes / No.
9 / 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.
10 / Whether all the rotary and static equipment have been provided & painted with Identification Numbers/Tag no/Inventory no/equipment no? / Yes / No.
11 / Is there any colour codification system existing for painting of all the equipment in respect of installation? / Yes / No.
12 / Is the fire fighting system adequate to tackle the situation of a major fire? / Yes / No.
13 / Whether all the fired vessels have been provided with flame arrestors? / Yes / No.
14 / Are these documents/registers are 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. Air 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. Machinery Inspection Report: Yes / No.
22. Recommendation File: Yes / No.
23. PM Records: Yes / No.
24. POL Consumption Records: Yes / No.
25. Running Hours of Equipment: Yes / No.
26. Form “U” Observation by Installation Manager: Yes / No.
27. List of Competent Persons: Yes / No.
28. Periodical Medical Examination of Employee: Yes / No.
29. Audiometric Checkup for employee: Yes / No.
30. Monthly Pollution Control Records: Yes / No.
31. Public Grievance: Yes / No.
32. Employee Training Register: Yes / No.
33. Form ”B” Employee Register: Yes / No.
34. Form “E” Register for Person Working Above Ground: Yes / No.
35. Form ”G” Employee Leave record: Yes / No.
36. First Aid / Fire Fighting File: Yes / No.
37. MVT & Refresher Training Records: Yes / No.
38. Equipment Maintenance Records: Yes / No.
39. Crude Oil Flow Diagram: Yes / No.
40. Electrical Line Diagram of Power Supply Arrangements: Yes / No.
41. NDT Testing Records: Yes / No.
15 / Are the document mentioned above 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 emergencies? / Yes / No.
12 / Is the illumination system in the installation is adequate? / Yes / No.
F. ENERGY AWARENESS :
1 / Leakage of POL, Diesel, Compressed Air, Crude Oil, Water and Other Liquids:OBSERVATION / REMARKS
a) Lub oil leakages
b) Diesel leakages
c) Crude oil leakages
d) Water leakages
e) Other
2 / Measurement of Fuel Consumed by Various Equipments :
Per Year (KL) / Per Month (KL)
a) Diesel Engine
b) Crude Oil Engine
c) Gas 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 / Avg. electricity generated (KWH) per year.
Avg. electricity consumed (KWH) per year.
6 / Avg. energy consumed in the installation (KWH) per year..
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?
H. SYSTEM MONITORING
1. Crude Oil Engine Driven Dispatch Pump
a. No. of Crude oil engine driven dispatch pump available at site ……… No.
b. No. of Crude oil engine driven dispatch pump in operation ……… No.
c. No. of Crude oil engine driven dispatch pump lying idle / unutilized ……… No.
Please provide details of Crude oil engine driven dispatch pump in following format:
Sl. No. / Description & Asset / Eqpt. No. / Qty / Make, Specification, Handling Capacity etc. / If Idle/Unutilized Reasons for the same2. Motor Driven Dispatch Pump
a. No. of motor driven dispatch pump available at site ……… No.
b. No. of motor driven dispatch pump in operation ……… No.
c. No. of motor driven dispatch pump lying idle / unutilized ……… No.
Please provide details of motor driven dispatch pump in following format:
Sl. No. / Description & Asset / Eqpt. No. / Qty / Make, Specification, Handling Capacity etc. / If Idle/Unutilized Reasons for the same3. Booster Pump
a. No. of Booster Pump available at site …….. No.
b. No. of Booster Pump in use …….. No.
c. No. of Booster Pump lying idle/ unutilized …….. No.
Please provide details of Booster Pump in following format:
Sl. No. / Description & Asset / Eqpt. No. / Qty / Make, Specification, Handling Capacity etc. / If Idle/Unutilized Reasons for the same4. Crude Oil Engine Driven Generating Set
a. No. of crude oil engine driven generating set available at site …….. No.
b. No. of crude oil engine driven generating set in use …….. No.
c. No. of crude oil engine driven generating set lying idle / unutilized ………No.
Please provide details of crude oil engine driven generating set in following format:
Sl. No. / Description & Asset / Eqpt. No. / Qty / Make, Specification, Handling Capacity etc. / If Idle/Unutilized Reasons for the same5. Diesel Engine Driven Generating Set
d. No. of diesel engine driven generating set available at site …….. No.
e. No. of diesel engine driven generating set in use …….. No.
f. No. of diesel engine driven generating set lying idle / unutilized ………No.