Present 0peration and maintenance system

 HPCL is presently having ISO certified Operation and

Maintenance system for all its pipelines.
 ISO system developed for preventive maintenance activity in
accordance of OISD standards and equipment manufacturer reco.
 ISO system consists of predefined procedures , work instructions
for reference and 200+ Various Dept. formats for records building.
 Every format is filled as per the OISD requirements with proper
work permit system.
 Schedules are prepared for timely maintenance activity as
reminder and status Update.
 Drawbacks with current operation and maintenance system

 ISO system require large number of papers for keeping records.

Easy and immediate reference is not possible.
 In some cases maintenance activities are done but records are
prepared little later.
 Some cases calibration plan, schedule activities are missed out.
 Log books ,files and register ; they required space to
maintained them.
 Searching for specific technical information is time consuming
in equipment manuals and other technical references.
 Generating any specific reports is manual process and is time
consuming.
 E - Operation and Maintenance system
 HPCL has taken a step ahead by converting paper base
ISO system to E-Operation and maintenance
 This System has resulted in reduction from large no of
paper consumption to almost nil.
 Only printout of work permits which are prepared online
is taken in both side of paper as per OISD requirement.
 All manual are scanned in searchable PDF , they are
linked with specific equipment for easy reference.
 New system will result in timely maintenance activity
without fail ; Historical records are easily retrievable
 System developed is very flexible , it can be replicated in
any of the pipeline with minor customisation.
ISO Management System Organogram

Top
Management

MR LIC

Location Department
Audit System
DMR head
 E- Maintenance Flow
User Prepare All Schedules
Dept
dept Approved by
Register Assignment
schedules LIC

Perform Prepare
System Audit Data Entry Maint. Permit
Activity online

Format History card

Reports
Approval update
 E- Operation Flow
Product Receipt at
Pumping Plan Batch Formation
Dispatch Station

Other Entry from

SCADA- Tank Dip Entry Receipt at TOP
Pressure/Pump Manual/SCADA
status etc

Location DOR DOR Approval by Final Daily MDPL

Report Dispatch Station DOR
 Salient Features of the system
 Department Assignment system (Primary/Secondary
Roles)
 Schedules are auto prepared, User only required to
Select the start date.
 Notification (Email/System)
 Schedule approval for LIC, Upcoming Schedule for user
 Format Approval LIC, Deviations (User/LIC) , Upcoming calibration
 Audit notification, MRM Plan .
 Mandatory provisions format entry
 Work Permit
 Deviation approval if any
 Salient Features of the system
 Data from the SCADA system
 Tank Level, Pump parameters, Energy data , Flow rates,
Pressure/Temp/Density readings.
 Graphical representation of Maint or Opns Activities
 Special Features
 Previous records preview.
 Checks on each data entry.
 Auto history card update (Spares/Breakdown)
 Auto linking for format with equipments.
 Hindi is being used in every format.
 Store inventory is maintained by equipment , Alert for
minimum , reorder level and shelf expiry generated.
Bar code system implemented.
Menu System of E-O&M
Department Assignment
Maintenance Schedule
Maintenance Activity
Maintenance Data Entry
Format approval & report
 Future Possibilities
 New system will facilitate have common operation and
maintenance formats for all the present pipelines and
future pipelines.
 In future HPCL pipelines operation and maintenance
activities can be brought to one platform.
 Various Business Intelligence reports can be generated in
no time for top management which would help in
critical decision making.
 Single point monitoring of all pipeline performance live
from HQO as SCADA data is linked.
 Present Status
 Department Covered : Operation, Electrical,
Instrumentation, Mechanical , Scada, telecom, CP, Stores,
Purchase, ROU , FAS, EMS – OHSAS is Under Process

 Currently it is being put on trial run at MDPL , trial run

is running successfully.
 Effective April-2011 System will be put in 100% use in
MDPL. Phase wise implementation to other pipelines
would be done.