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

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 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

7th 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 Directorate,
7th 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 Member
Corporation Limited
03 Mr. P. Veerabhadra Rao Hindustan Petroleum Member
Corporation Limited
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 Member
Petrochemicals Ltd.
07 Mr. R.C. Agarwal Bharat Petroleum Corporation Member
Limited
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 Installation and Maintenance
of
Rotary Equipment

An asset & its associated parts

1 INTRODUCTION /auxiliaries which are essential to
achieve organization’s business goal
The proper upkeep and maintenance plays
and requires strategic operational &
an important role in trouble free, safe
maintenance attention from time to time
operation of rotating equipment in the
and to keep it in a state of delivering
hydrocarbon industry. Sound procedures &
desired service.
practices for installation and maintenance
are required to ensure safety and integrity of 3.2 Protection

the equipment. These recommended The device or integrated system to

practices should be helpful in forming prevent an equipment or group of

systems & procedures. This document equipment from undergoing potential

covers Rotating Equipment such as Pumps, failure or unsafe conditions.

Blowers, Fans, Steam Turbines, Gas 3.3 Lifting Tools & Tackles
Turbines, Compressors, Motors, Generators,
The devices & systems like Slings,
Expanders, Gearboxes and Engines
Chain Blocks, Winches, Shackles, EOT,
installed in hydrocarbon industry.
HOT and Cranes etc that are required to
lift, carry, load & unload, support, install,
2 SCOPE
and remove different equipment in
The following specific maintenance practices
course of various maintenance &
for rotating equipment are covered in these
operational activities.
recommended practices;
3.4 Change Management
a) Equipment Protection & Change
Management System Mechanism to control and manage
changes to operating conditions,
b) Lubricant and lubrication System
protection systems and mechanical
c) Safe Commissioning Practices systems of equipment that affect safe
d) Root Cause Failure Analysis operation of the equipment.

e) Safe Utilization of Lifting Tools and 3.5 Documentation

Tackles A system to keep information in
f) History Recording systematic manner, which is retrievable

3 DEFINITIONS whenever required.

3.1 Equipment (1)

3.6 Potential Risk Records of such changes shall be
maintained.
The degree of probability for occurrence.
4.5 The record of such changes should be in
3.7 Root Cause Failure Analysis
specific format mentioning, but not
A data based analytical approach to
limited to the following:
identify the basic cause/s of failure
a) The details of equipment/ tags being
3.8 Commissioning
considered for change
Process of releasing an asset for normal
b) The proposed nature of change
operation.
c) The reasons for the change
3.9 Manufacturer’s Report/ Record
d) The potential risk involved in proposed
Book (MRB)
change
The documentation supplied by the
e) The time span of change (duration)
manufacturer along with the equipment.
f) The precautions to be taken for
4.0 EQUIPMENT PROTECTION
AND CHANGE incorporation of change
MANAGEMENT g) The precautions to be taken during
operation and after implementation of
4.1 The equipment protections considered
change
for safe operation include but not limited
to critical parameters like vibration, h) Define functional responsibility and

bearing temperatures, axial authorization for implementation

displacement, motor winding i) Feedback to initiator on incorporation of

temperatures, lube oil pressure/ change
temperatures, cooling water
j) Incorporation of change in “as built
temperatures, and process parameters
drawing/ data sheet/ P&ID’s/ Eqpt.
as applicable.
Drawing and other relevant records.
4.2 Records of equipment protection
k) Information of changes implemented to
systems shall be maintained as per
concerned authorities
OISD 124.
A sample procedure & format is attached as
4.3 Alarm and danger values for the above
Appendix-1 for reference.
parameters shall be part of the record.
4.6 Change management procedures shall
4.4 Procedures shall be in place to control
include modifications to critical
changes to these protection systems.
components like Seals, Bearings,
Procedures shall include authorizations
Couplings, Shafts, Impellers and
required for carrying out these changes.
Lubricants.
5 LUBRICANT AND 6 SAFE COMMISSIONING
LUBRICATION SYSTEMS PRACTICES

6.1 Procedures should be in place to ensure

5.1 Systems and procedures shall be in
place to ensure the following; proper installation and safe
commissioning of rotating equipment
a) Selection of correct lubricant in
as per specific practices mentioned
line with OEM recommendation/
in the relevant OISD standards and
National & International
OEM guidelines.
standards/Standard Engineering
6.2 Procedure shall cover the following:
Practices.
a) Checks for completeness of all
b) Adequacy of protections against
systems and subsystems
lubrication failure.
including fire protection
c) Lube oil condition monitoring as
systems as per OISD-STD-116
per OISD-RP-124.
and OISD-STD-117
d) Replenishment/ replacement of
b) Adequacy of space around
lubricant.
equipment for safe movement
e) No mix up of lubricant grades/
c) Availability of operating
brands during replenishment.
procedures including startup
5.2 Make-up of lubricant shall be done and normal/ emergency
ensuring that proper grade of shutdowns
lubricant in recommended quantity is
d) Checks for functioning of
applied.
interlocks and configuration of
5.3 Recommended grade of lubricant shall set-points of all protections like
be displayed prominently on or near alarms and trips
the equipment.
e) Identification of equipment
5.4 Procedure for proper storage and specific hazards and steps
identification of lubricants should be taken to mitigate and to create
followed. A recommended procedure awareness about hazards to all
for storage is given in appendix-II. concerned.

5.5 Procedure for identification of sampling f) Training of manpower deployed

points and sampling of lube oil should
g) Use of personal protective
also be established to ensure proper
equipment
collection and identification of samples.
h) Availability of commissioning
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spares and their replenishment.
6.3 Records of base data and specific b) Component failure
problems faced during the
c) Design failures
commissioning shall be maintained.
d) Human failure
7 ROOT CAUSE FAILURE e) Failure of systems and
ANALYSIS
procedures
The action taken record on the
7.1 System shall be established to carry out
recommendations shall be maintained.
root cause analysis for failures that
have impact on safety and
environment. 8 SAFE UTILIZATION OF LIFTING
TOOLS AND TACKLES
7.2 The analysis should identify the cause of
the failure and recommend 8.1 To ensure safe utilization of lifting tools &
corrective and preventive measures tackles, periodic inspection and
to prevent failure from recurring. A testing as per applicable statutory
sample failure analysis report is rules and regulations applicable
attached in Appendix-III. shall be carried out.

7.3 Root cause failure analysis should be 8.2 Each lifting tool & tackle shall have
based on the following broad steps; unique identification and shall
display the safe working load, testing
a) Data collection, observation and
date and next due date for testing.
organization of data
8.3 Records shall be maintained for
b) Sequence of events leading to
verification
failure

c) Identification of probable causes

9 EQUIPMENT DOCUMENTATION
d) Analysis of probable causes and
9.1 Proper documentation system shall be
identification of most probable
available to ensure safe operation of
cause
rotating equipment.
e) Recommendation of corrective
9.2 Documentation shall include the
measures to prevent recurrence
following
f) Implementation of corrective
a) Data sheets
action and preventive action in a
time bound manner (4)

7.4 Cause of failure shall be categorized b) Performance curves

broadly as below: c) Cross sectional & constructional
a) Process failure 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

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)

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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 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

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 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>>

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