Professional Documents
Culture Documents
Number:OISD/DOC/2013/172
Page No. I
GUIDELINES
ON
MANAGEMENT OF CHANGE
Prepared By
Committee on Management of Change
Sr.Number:OISD/DOC/2013/172
Page No. II
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 selfregulation 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/2013/172
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 selfregulatory 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.
The present document on Guidelines on Management of Change for Petroleum
Refineries & Oil/Gas processing plants is prepared by the Committee on Management of
Change. This document is based on the accumulated knowledge and experience of
industry members and various national and international codes and practices. It is hoped
that the provision of this document, if implemented objectively will go a long way in
improving the safety in the hydrocarbon processing industry.
This guidelines in no way supersedes the statutory regulations and requirements
of various statutory bodies, which shall be followed as applicable.
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:
Sr.Number:OISD/DOC/2013/172
Page No. IV
NOTE
Sr.Number:OISD/DOC/2013/172
Page No. V
COMMITTEE
ON
MANAGEMENT OF CHANGE
-----------------------------------------------------------------------------------------------------------Members
Representing
-----------------------------------------------------------------------------------------------------------S/Shri
1.
G. C. Mitra
Leader
2.
R. D. Goyal
Member
3.
V. Narayanan
Member
4.
K. Madhusudan
Member
5.
M. S. Rathod
Member
6.
N.D. Raut
Member
7.
N. Rengaswamy
Member
8.
S. K. Sinha
Member
9.
A. Ghatak
(Member Co-ordinator)
In addition to the above, several other experts from industry contributed in the
preparation, review and finalisation of the document.
Sr.Number:OISD/DOC/2013/172
Page No. VI
SECTION
PAGE NO.
1.0
Introduction
2.0
Scope
3.0
Definitions
4.0
Types of Changes
5.0
5.1
5.2
5.3
10
5.4
10
5.5
11
5.6
12
5.7
Changes of Personnel
5.8
6.0
References
7.0
Annexure I
3
3
8
12
12
14
15
Sr.Number:OISD/DOC/2013/172
Page No. 1
GUIDELINES
ON
MANAGEMENT OF CHANGE
1.0
INTRODUCTION
A process industry is subjected to continuous modifications to achieve higher
efficiency, improve operability and safety, improve reliability, improvement of
the plant machineries and equipment and to accommodate technical change. Any
changes in the processing units/ facilities may have the potential to destabilise
existing safety and to introduce new hazards. The hazards connected with any
change are to be identified and controlled efficiently through an appropriate
hazard management system. These guidelines lay down procedures covering
various aspects of change and addresses the following :
-
2.0
SCOPE
These guidelines describes the
management of
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/2013/172
Page No. 2
GUIDELINES
ON
MANAGEMENT OF CHANGE
3.0
3.1
DEFINITIONS
Petroleum Refinery
Petroleum Refinery is a plant where crude oil is received and processed to
produce various intermediates and finished products.
3.2
3.3
Facility
Facility means the buildings, containers or equipment including pipeline operation
which contain a process.
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).
3.5
4.0
ii)
Sr.Number:OISD/DOC/2013/172
Page No. 3
GUIDELINES
ON
MANAGEMENT OF CHANGE
iii)
Change in metallurgy.
iv)
v)
vi)
vii)
viii)
ix)
x)
5.0
5.1
Sr.Number:OISD/DOC/2013/172
Page No. 4
GUIDELINES
ON
MANAGEMENT OF CHANGE
i)
ii)
Design philosophy.
iii)
iv)
v)
vi)
Commissioning.
vii)
viii)
ix)
x)
As built record.
i)
Is it necessary ?
Is it economic ?
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.
Is there a better alternative?
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 5
GUIDELINES
ON
MANAGEMENT OF CHANGE
ii)
a)
b)
c)
d)
Design Philosophy
The design philosophy shall include both process design information and
mechanical design information.
The process design information should include a block flow diagram or a
simplified process flow diagram, the process chemistry with relief system
and where process design material and energy balances are available, this
should also be included. The process design information should also take
into consideration environmental requirements like safety, health and
environment review to ensure compliance with respect to safety, health
and environment.
The mechanical design information should include materials of
construction, piping and instrumentation diagram (P&ID), area
classification, design codes and standards employed and equipment and
piping specifications.
The mechanical design shall be consistent with the applicable consensus
codes and standards in effect at the time the design is prepared, or in the
absence of such codes and standards, recognised and generally accepted
standard engineering practices. Where the original mechanical design
information no longer exists, information may be developed from
available equipment and inspection records.
The provision of design and engineering practice manual and applicable
codes and standards shall be followed while carrying out any
modification. Applicable statutory requirement shall also be considered
while firming up the design philosophy. Ergonomics to be well taken care
of during the design stage of modification / change.
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 6
GUIDELINES
ON
MANAGEMENT OF CHANGE
iii)
Scrutiny/Approval Procedure
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/2013/172
Page No. 7
GUIDELINES
ON
MANAGEMENT OF CHANGE
v)
vi)
Commissioning
Plants/facilities shall be commissioned after the job carried out is cleared
by multidisciplinary group approved by management and completion
certificate is available. Licence from statutory authority, wherever
applicable, is obtained.
vii)
Sr.Number:OISD/DOC/2013/172
Page No. 8
GUIDELINES
ON
MANAGEMENT OF CHANGE
ix)
x)
As-built Records
All modification records generated from the proposal stage to
commissioning stage including design review, construction documents
statutory approval shall be preserved in approved and accepted locations
for quick references. As-built documents shall be prepared incorporating
all the approved site changes.
5.2
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 9
GUIDELINES
ON
MANAGEMENT OF CHANGE
b)
Initial Start-up
Normal Operation
Need based Operation
Emergency Operations including Emergency Shutdown and
Start-up
Normal Shutdown
Start-up following a turnaround
Start-up after prolonged outage
Process Flow Schemes.
Operating Limits
i)
ii)
iii)
c)
Clear instruction for safe operation of each facility that consistent with the
process safety information.
d)
ii)
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 10
iii)
5.3
5.4
ii)
iii)
iv)
v)
vi)
CHANGE
IN
SOLVENTS
IN
Sr.Number:OISD/DOC/2013/172
Page No. 11
GUIDELINES
ON
MANAGEMENT OF CHANGE
5.5
b)
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.
f)
g)
Sr.Number:OISD/DOC/2013/172
Page No. 12
5.6
5.7
ADDITIONAL
SOFTWARE
CHECKS
FOR
CARRYING
OUT
CHANGES
OF
a)
b)
The software shall be checked offline to ensure that it does not introduce
any new bugs.
c)
d)
CHANGE OF PERSONNEL
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.
5.8
Sr.Number:OISD/DOC/2013/172
Page No. 13
GUIDELINES
ON
MANAGEMENT OF CHANGE
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.
b)
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 14
GUIDELINES
ON
MANAGEMENT OF CHANGE
6.0
REFERENCES
i)
ii)
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.
Sr.Number:OISD/DOC/2013/172
Page No. 15
ANNEXURE I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Training of personnel.
11.
Commissioning.
12.
Post-commissioning review.
13.
14.
Updation of documents like PFD, P&ID and process & operating manuals.
15.
As-built records.
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.