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Guidelines ON Management of Change: For Restricted Circulation Only
Guidelines ON Management of Change: For Restricted Circulation Only
Number:OISD/DOC/2012/076
Page No. I
GUIDELINES
ON
MANAGEMENT OF CHANGE
Prepared By
Committee on Management of Change
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.
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
FOREWORD
The oil industry in India is over 100 years old. 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 was hardly in existence. This coupled with feedback from
some serious accidents that occurred in the recent past in India and abroad, emphasised
the need for the industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.
With this in view, Oil Industry Safety Directorate (OISD) was established in 1986
staffed from within the industry for formulating and implementing a series of self-
regulatory measures aimed at removing obsolescence, standardising and upgrading the
existing standards to ensure safer operations. OISD constituted a number of committees
comprising of experts nominated from the industry to draw up standards and guidelines
on various areas of concern.
This document will be reviewed periodically for improvements based on the new
experiences and better understanding. Suggestions from users/industry members may be
addressed to:
NOTE
Though every effort has been made to assure the accuracy and reliability of the
information 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/2012/076
Page No. V
COMMITTEE
ON
MANAGEMENT OF CHANGE
------------------------------------------------------------------------------------------------------------
Members Representing
------------------------------------------------------------------------------------------------------------
S/Shri
In addition to the above, several other experts from industry contributed in the
preparation, review and finalisation of the document.
Sr.Number:OISD/DOC/2012/076
Page No. VI
1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 2
4.0 Types of Changes 2
5.0 Procedure to implement Changes 3
5.1 Changes due to Modification of Plant/Facilities 3
5.2 Additional checks for changes in Normal Operating 8
Procedure, Start-up, Shutdown and Emergency
Procedures.
6.0 References 14
7.0 Annexure – I 15
Sr.Number:OISD/DOC/2012/076
1.0 INTRODUCTION
2.0 SCOPE
- change of software,
- changes of personnel,
- change of catalysts,
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
3.0 DEFINITIONS
‘Oil/Gas Processing Plant’ is a plant where crude oil/natural gas is collected and
processed in order to separate oil and gas and to remove impurities like water,
sulphur etc. before sending them to refinery or to obtain end products.
3.3 Facility
3.4 Process
Process means any activity involving a hazardous chemical and utilities including
use, storage, manufacturing, handling and the on-site movement of such
chemicals and utilities or combination of these activities. (These include pipeline
operation also).
The need for change arises out of various reasons like operational flexibility,
energy conservation, capacity augmentation, improvement of product
specification, yield improvement, compliance with statutory rules and regulations.
The various types of changes that take place in a process unit and related facilities
are detailed below.
iv) Change in normal operating procedure, start-up, shut down and emergency
handling procedures.
vi) Change in instrument which may include pressure, temperatures, flow, set
points, alarm points, speed, logic and control parameters.
vi) Commissioning.
vii) Updating of documents in line with the modification.
viii) Approved handing over / taking over procedure.
ix) Post commissioning review.
x) As built record.
- Is it necessary ?
- Is it economic ?
There is a possibility of introduction of new hazards as the safeguard’s
built in original design are changed. The modification proposal should
therefore achieve primary objective in a safe manner. Therefore, the
following questions are to be considered :
- How will the change impact the people and the work environment?
- Will people be able to construct / implement and operate "the change" and work
with "the change" within an acceptable level of risk ?
- How will "the change" impact inspection & maintenance activities?
- Is "the change" going to adversely affect excess / ingress for operation,
inspection, maintenance, emergencies etc.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
The design philosophy shall include both process design information and
mechanical design information.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
Design shall be completed in two stages. In the first stage, Basic design
shall be completed and in the second stage detail engineering shall be
completed. Second stage shall be taken up only after verification of first
stage design.
Design shall be verified after completion of the first stage to confirm 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/2012/076
The plant manager or his authorised person to brief and train the
contractor personnel who will be associated with this change.
vi) Commissioning
x) As-built Records
The design of the plant specifies the conditions at which it is to operate. Any
change, major or minor in technology, facilities, plant modification etc. has the
potential for disruption. Change in normal operating procedure, start-up, shut-
down and emergency handling procedure resulting from any modification /change
as mentioned above needs careful consideration to identify incorrect assumptions,
to resolve differences and to eliminate inconsistencies. The ultimate responsibility
for the operating procedures rest with the plant manager. (The modifications made
during the original design process really fall outside the discussions which is
mainly concerned with the stages of commissioning and operation).
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
i) Initial Start-up
ii) Normal Operation
iii) Need based Operation
iv) Emergency Operations including Emergency Shutdown and
Start-up
v) Normal Shutdown
vi) Start-up following a turnaround
vii) Start-up after prolonged outage
viii) Process Flow Schemes.
b) Operating Limits
c) Clear instruction for safe operation of each facility that consistent with the
process safety information.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
A written procedure shall be provided for safe handling of the changed new
solvent and the procedure shall also address at least the following items:
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
c) For incorporating the modification in logic, the group must study whether
it can be incorporated in running plant or the plant has to be shutdown. If
shutdown of the plant is necessary the downtime loss and pay back period
after modification shall be studied.
d) To change the set point of the alarm & trips the group must take into
consideration of the existing process variable whether it can
e) Accommodate the change or not, like if the set point of tripping of high
discharge pressure of a compressor is changed to higher one , the
discharge of the PSV must be taken into consideration.
b) The software shall be checked offline to ensure that it does not introduce
any new bugs.
Introduction of personnel who is new to the process may introduce new hazards.
Therefore each employee before being involved in operating newly assigned
process shall be trained in an overview of the process and in the operating
procedures. The training shall include emphasis on the specific safety and health
hazards, emergency operations including shutdown, safe work practices
applicable to employees job task.
The employer shall ascertain that each employee involved in operating a process
has received and understood the required training. A record shall be prepared
containing the identity of the employee, date of training and the means used to
verify that the employee understood the training.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
The existing system can be put at risk by the operation of the process
outside the domain of operating conditions for which the system was
originally designed. These changes will call for consideration of the
relevant codes of practice and specifications. It may affect any existing
trip or alarm system and may require additional trip and alarm protection.
Further these process changes will be capable of effecting originally
designed /existing operating and maintenance procedure, equipment
inspection frequency or may require altogether a new procedure even the
composition of effluent and its disposal has to be looked into. One thing
which may not go any major changes will be the hardware available
within the system as the design review has to be carried out to check the
suitability of originally designed and constructed system for the changed
process requirement.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
6.0 REFERENCES
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2012/076
ANNEXURE – I
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”