Sr.

Number:OISD/DOC/2016/418

Page No. I

OISD - RP- 126

First Edition, August 1990
Amended edition, August 1999
Revised Edition, August 2007

Specific Practices for Installation and Maintenance

of
Rotary Equipment

OISD RECOMMENDED PRACTICES-126

First Edition, August 1990
Amended Edition, August, 1999
Revised Edition, August 2007

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
 Sr.Number:OISD/DOC/2016/418

Page No. II

OISD - RP- 126

First Edition, August 1990
Amended edition, August 1999
Amended Edition, August 2007

Specific Practices for Installation and Maintenance

of
Rotary Equipment

Prepared by
Functional Committee

OIL INDUSTRY SAFETY DIRECTORATE

8th Floor, OIDB Bhavan,
Plot No. 2, Sector – 73,
Noida – 201301 (U.P.)
 Sr.Number:OISD/DOC/2016/418

Page No. III

Preamble

Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.

While statutory organizations were in place all along to oversee safety aspects of Indian
petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of
Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of
constantly updated world-scale standards for design, layout and operation of various equipment,
facility and activities involved in this industry. Moreover, OISD was also given responsibility of
monitoring implementation status of these standards through safety audits.

In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts
and iterating through seeking & validating inputs from all stake-holders – operators, designers,
national level knowledge authorities and public at large – with a feedback loop of constant
updation based on ground level experience obtained through audits, incident analysis and
environment scanning.

The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in
the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not
affected implementation of the OISD standards. It also goes to prove the old adage that self-
regulation is the best regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.

Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge
Organizations – both in the field of standard development and implementation & monitoring in
addition to updation of internal knowledge base through continuous research and application
surveillance, thereby ensuring that this OISD Standard, along with all other extant ones, remains
relevant, updated and effective on a real time basis in the applicable areas.

Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This,
besides other issues, calls for total engagement from all levels of the stake holder organizations,
which we, at OISD, fervently look forward to.

Jai Hind!!!

Executive Director

Oil Industry Safety Directorate

 Sr.Number:OISD/DOC/2016/418

Page No. IV

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 feedback 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 experiences 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 Directorate,
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
 Sr.Number:OISD/DOC/2016/418

Page No. V

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.
 Sr.Number:OISD/DOC/2016/418

Page No. VI

LIST OF FUNCTIONAL COMMITTEE MEMBERS

S.N Name Organisation Position in Committee

01 Mr. D.K. Puri Reliance Industries Leader
Limited
02 Mr. S.K. Hindustan Petroleum Member
Chatterjee Corporation Limited
03 Mr. P. Hindustan Petroleum Member
Veerabhadra Corporation Limited
Rao
04 Mr. T.V. Reliance Industries Member
Venkateswaran Limited
05 Mr. A.K. Dash Indian Oil Corporation Member
Limited
06 Mr. Deepak Mangalore Refinery Member
Prabhakar and Petrochemicals
Ltd.
07 Mr. R.C. Bharat Petroleum Member
Agarwal Corporation Limited
08 Mr. K Ravi Kochi Refineries Member
Limited
09 Mr. Shamsher Oil Industry Safety Member
Singh Directorate Coordinator
 Sr.Number:OISD/DOC/2016/418

Page No. VII

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 04

7.0 Root Cause Failure Analysis 04

8.0 Safe Utilization Lifting Tools and Tackles 05

9.0 Equipment Documentation 05

10.0 References 07

11.0 Annexure-I 08

12.0 Annexure-II 09

13.0 Annexure-III 10
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 1

Specific Practices for Installation and Maintenance of
Rotary Equipment

Specific Practices for Installation 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 organization’s
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.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 2

Specific Practices for Installation and Maintenance of
Rotary Equipment

3.3 Lifting Tools & 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.

3.6 Potential Risk

The degree of probability for occurrence.

3.7 Root Cause Failure Analysis

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 Manufacturer’s 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.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 3

Specific Practices for Installation and Maintenance of
Rotary Equipment

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&ID’s/ 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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 4

Specific Practices for Installation and Maintenance of
Rotary Equipment

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.

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.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 5

Specific Practices for Installation and Maintenance of
Rotary Equipment

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

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 6

Specific Practices for Installation and Maintenance of
Rotary Equipment

a) Data sheets

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.

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 7

Specific Practices for Installation and Maintenance of
Rotary Equipment

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

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 8

Specific Practices for Installation and Maintenance of
Rotary Equipment

Appendix –I

Sample 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)

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 9

Specific Practices for Installation and Maintenance of
Rotary Equipment

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 O’clock 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

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
 Sr.Number:OISD/DOC/2016/418

OISD – RP – 126 Page No. 10

Specific Practices for Installation and Maintenance of
Rotary Equipment

Appendix –III

SAMPLE ROOT CAUSE FAILURE ANALYSIS SHEET

UNIT DATE
EQUIPMENT REPORT NO. <<Unique Report No>>

PROBLEM:
<<Brief Description of Failure>>

OBSERVATION:
<<Description of Failures of as observed by Analyst with details of failed parts and patterns of
failure>>

Part No. Description Damage

<<A>> <<ABCD>> <<Type of Damage>>

ANALYSIS:

<<Detailed Analysis of the Causes, Identification of Root Cause etc>>

ROOT CAUSE

<<Brief statement of most probable cause of failure>>

CORRECTION, CORRECTIVE & PREVENTIVE ACTION:

<< Describe immediate correction, Proposed Corrective Action and Preventive action to prevent
future failures>>

CIRCULATION

<<Copies to concerned personnel>>

“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”