GAIL (India) Limited · 2014-12-17 · GAIL (India) Limited Vizag-Secunderabad LPG Pipeline System...

GAIL (India) Limited

Vizag-Secunderabad LPG Pipeline System ISO 9001:2008, ISO 14001:2004 &

OHSAS 18001:2007

ACTIVITIES & PROCESS MAPPING MANUAL

Document No. : VSPL/APM Issue No. : 3 I ssue Date : 01 .12 .2010 Contro l led Copy No. : _________ Contro l led Copy Holder : _________

GAIL (India) Limited

O PP. AY Y AP P A S W AM Y TEM PL E, S H EE LA N AG AR V I S AK H AP AT N AM – 5 30 012 AN D H R A P R AD E S H ( I N DI A)

Regd. Office: GAIL Bhawan, 16, Bhikaiji Cama Place, New Delhi-110 066

VSPL System

ACTIVITIES & PROCESS MAPPING

MANUAL

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Doc. No. : VSPL/APM

TITLE : TABLE OF CONTENTS Effective Date: 01.12.2010

Issue No : 03

Revision : 00 Sheet : 01 of 01

Sl. No. Contents No. of Pages Revision No. Effective

Date

1.

2.

3.

4.

5.

6.

7.

Table of contents List of Activities and sub processes for process Mapping Revision Record Sheet List of Controlled copy holders Abbreviations Process Mapping Process measure and Objectives Status Format

01

01

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03

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01.12.2010

01.12.2010

01.12.2010

01.12.2010

01.12.2010

01.12.2010

01.12.2010

Issued By : Management Representative Approved By : G.M (O&M )

Signature :

Signature :

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MANUAL

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Doc. No. : VSPL/APM

TITLE : LIST OF ACTIVITIES & SUB PROCESSES

FOR PROCESS MAPPING

Effective Date: 01.12.2010 Issue No : 03


Sl. No. Department No. of sheets

Revision No.

Effective Date Prepared By

1. OPN. Vizag 04 00 01.12.2010 Core group members- Operation

2. OPN. Vijayawada 04 00 01.12.2010 Core group members- Operation

3. OPN. Secunderabad 04 00 01.12.2010 Core group members- Operation

4. Mechanical 04 00 01.12.2010 Core group members- Mechanical

5. Pipeline & CP 04 00 01.12.2010 Core group members - Pipeline

6. Instrumentation 08 00 01.12.2010 Core group members- Inst.

7. Electrical 04 00 01.12.2010 Core group members- Electrical

8. SCADA 04 00 01.12.2010 Core group members- SCADA

9. Fire & Safety 06 00 01.12.2010 Core group members- F&S

10. Telecom 03 00 01.12.2010 Core group members- Telecom

11. HR 01 00 01.12.2010 Core group members- HR

12. C & P 03 00 01.12.2010 Core group members- C&P


Signature : Signature :

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TITLE : REVISION RECORD SHEET Effective Date: 01.12.2010

Issue No : 03


Process Previous

Rev. No. & Effective Date

Current Rev. No. & Effective Date

Brief Description of Changes

Reasons for Changes


Signature : Signature :

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MANUAL

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TITLE : CONTROLLED COPY HOLDERS Effective Date: 01.12.2010

Issue No : 03


Copy No. Copy Holder ( Position) Soft Copy Hard Copy

1 GM (O&M) √

2 Incharge (O&M) – Vizag √

3 OIC - Secunderabad √

4 OIC - Vijayawada √

5 MR √

6 DMR - Vizag √

7 DMR – Vijayawada √

8 DMR –Secunderabad √

9 Control Room – Vizag √

10 Control Room - Vijayawada √

11 Control Room - Secunderabad √

12 In-charge (Operation) - Vizag √

13 In-charge (Operation) – Vijayawada √

14 In-charge (Operation) – Secunderabad √

15 In-charge (Mechanical) - Vizag √

16 In-charge (Mechanical) – Vijayawada √

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Copy No. Copy Holder ( Position) Soft Copy Hard Copy

17 In-charge (Mechanical) – Secunderabad √

18 In-charge (Electrical) - Vizag √

19 In-charge (Electrical) – Vijayawada √

20 In-charge (Electrical) – Secunderabad √

21 In-charge (Instrumentation) - Vizag √

22 In-charge (Instrumentation) – Vijayawada √

23 In-charge (Instrumentation) – Secunderabad √

24 In-charge (Fire & Safety) - Vizag √

25 In-charge (Pipeline &CP) – Vizag √

26 In-charge (Pipeline &CP) – Vijayawada √

27 In-charge (Pipeline &CP) – Secunderabad √

28 In-charge (Fire & Safety) - Vijayawada √

29 In-charge (Fire & Safety) - Secunderabad √

30 In-charge (Telecom) - Vizag √

31 In-charge (Telecom) – Vijayawada √

32 In-charge (Telecom) – Secunderabad √

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33 In-charge (Telecom) - Rajahmundry √

34 In-charge (Scada) – Vizag √

35 In-charge (Scada) – Secunderabad √

36 In-charge - Rajahmundry √

37 In-charge - Suryapet √

38 In-charge (HR) √

39 In-charge (C&P) - Vizag √

40 In-charge (C&P) – Vijayawada √

41 Central Engineering Cell √

42 Certifying Body √

Note : 1. Soft copy is distributed in the form of read only version (pdf) through e-mail through DCO/DMR, Vizag. 2. DMR Copy shall be extended to auditors, as required, on returnable basis for facilitating auditors during their audits.

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TITLE : ABBREVIATIONS Effective Date: 01.12.2010

Issue No : 03


ABBREVIATION FULL FORM

ALL All Departments

BPCL Bharat Petroleum Corporation Ltd

C&P Contracts & Procurement

DCO Document Control Officer

DT Vizag Dispatch Terminal

ED Executive Director

EIL Engineer India Limited

EIPL East India Petroleum Ltd

EMP Environmental Management Program

EMS Environment Management System

FSM Fire And Safety Manual

GAIL GAIL (India) Limited

GM General Manager

HBA House Building Advance

HOD Head of the Department

HPCL Hindustan Petroleum Corporation Ltd

HR Human Resources

OMC Oil Marketing Company

Opns Operations

MCP Manual Call Point

OSRD Over Shortage Rejection Damage

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TITLE : OPERATIONS - VIZAG Effective Date: 01.12.2010

Issue No : 03


Process/ Activity

Process/ Activity owner

Input Output Measurables Source of information/ record

Reviewing authority & frequency

PLT Planning

Shift in-charge Info. From HPCL, Vizag (OMC coordinator) – verbally/email message Equipment and facilities availability.

PLT plan No. of PLTs Prepared after ___ AM.

Control room logbook

HOD (Opn.) Monthly

Pipe line transfer of LPG

Shift in-charge PLT Plan Equipment availability thro’ DPR LPG supply by HPCL / EIPL Operation parameters

Delivery of LPG to the customers OMC’s Report Joint tickets Joint monthly reconciliation statement

Quantity of LPG transported Specific energy cons. HSD consumption Interruption time Hours Transmission loss

Joint tickets DPR DPR Control room log book DPR Fortnight stock loss / gain statement

HOD (Opn.) Monthly -do- -do- HOD (Opn.) Fortnightly

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Process/ Activity




Response to LPG leakages

Shift in-charge

Alarm thru’ gas detectors Info. from operators / patrollers / external agency SCADA APPS Info. On-site emergency plan Off-site emergency plan

Attending leak effectively Analysis of LPG leak

No. of times leaks occurred Response time for arresting leak

LEL register -do-

HOD (Opn.) Monthly

Response to fire alarms

Shift in-charge

Alarm thru’ MCPs, SCADA and fire detectors On-site emergency plan Info. from operators / others

Extinguishing fire effectively

Response time Fire alarm register

HOD (Opn.) Monthly

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TITLE : OPERATIONS - VIZAG Effective Date 01.12.2010

Issue No : 03


Process/ Activity




Issue of work permits

Shift in-charge

Work Clearance application by executing dept. As per operational requirement SAP connectivity

Work permits No. of permits generated. No. of outstanding permits. No. of unsafe incidents

SAP / Manual Permits

HOD (Opn.) Fortnightly

By-passing of interlocks

Shift in-charge / HOD (Opns) / O&M I/C.

Operational requirements

Operation after by-pass

No. of interlock by-passes

Interlock by-pass register

OIC Monthly

Process/ equipment modifications

HOD (Opns)

Suggestions on modifications Audit findings Results of analysis

Modifications Audit compliance

No. of modifications No. of Audit points complied

Change management record Modification records

O&M I/C Quarterly

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Process/ Activity




HSD handling Shift in-charge

HSD requisition HSD

Issue of HSD to user Depts.

HSD quantity issued.

HSD stock register

HOD (Opn) Monthly

Flare operations

Shift in-charge

Emergency evacuations

Flaring of evacuated LPG

No. of flaring Quantity of LPG flared

Operations log book

HOD (Opn) – Monthly O&M I/C – Quarterly

Legal requirements compliance (Environmental parameters monitoring)

HOD (Opn)

APPCB norms Valid consent for Operation

Compliance to APPCB norms

Environmental parameters analysis record

O&M I/C Monthly

Submission of MIS reports

HOD (Opn)

Data on operation activities MIS requirements

MIS reports on Operation dept. activities

No. of reports No. of reports submitted beyond 6th of every month.

Operation dept. records

O&M I/C Monthly

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TITLE : OPERATIONS - VIJAYAWADA Effective Date: 01.12.2010

Issue No : 03


Process/ Activity





Shift in-charge PLT Plan from Vizag Control Room Equipment availability thro’ DPR LPG supply by Vizag OMCs readiness Operation parameters

Delivery of LPG to the customers Joint tickets Joint monthly reconciliation statement Daily PLT dispatch report

Quantity of LPG delivered Power Consumed HSD Consumption Transmission loss

Joint tickets DPR DPR DPR Fortnight stock loss / gain statement


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Shift in-charge Alarm thro’ gas detectors Info. from operators / patrollers / external agency SCADA APPS Info. On-site emergency plan Off-site emergency plan



LEL register -do-

HOD (Opn.) Monthly


Shift in-charge Alarm thru’ MCPs, SCADA and fire detectors On-site emergency plan Info. from operators / others



HOD (Opn.) Monthly

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Process/ Activity





Shift in-charge






Shift in-charge / HOD (Opns) / O&M I/C.





OIC Monthly


HOD (Opns)

Suggestions on modifications Audit findings Results of analysis

Modifications Audit Compliance



O&M I/C Quarterly

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Process/ Activity




Flare operations Shift in-charge




Operations log book

HOD (Opn) – Monthly O&M I/C - Quarterly


HOD (Opn)




O&M I/C Monthly


HOD (Opn)



No. of reports No. of reports submitted beyond 6th of every month.


O&M I/C Monthly

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TITLE : OPERATIONS – SECUNDERABAD Effective Date: 01.12.2010

Issue No : 03


Process/ Activity


Input Output Measurables Source of information/record



Shift in-charge

PLT Plan from Vizag Control Room Equipment availability thro’ DPR LPG supply by Vizag / Vijayawada OMCs readiness Operation parameters

Delivery of LPG to the customers Joint tickets Joint monthly reconciliation statement

Quantity of LPG delivered Power Consumed HSD Consumption Transmission loss

Joint tickets DPR DPR DPR Fortnight stock loss / gain statement


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Process/ Activity





Shift in-charge

Alarm thru gas detectors Info. from operators / patrollers / external agency SCADA APPS Info. On-site emergency plan Off-site emergency plan



LEL register -do-

HOD (Opn.) Monthly


Shift in-charge

Alarm thru MCPs, SCADA and fire detectors On-site emergency plan Info. from operators / others



HOD (Opn.) Monthly

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Process/ Activity





Shift in-charge






Shift in-charge / HOD (Opn) / O&M I/C.





OIC Monthly


HOD (Opn) Suggestions on modifications Audit findings Results of analysis

Modifications Audit Compliance



O&M I/C Quarterly

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Process/ Activity




HSD handling Shift in-charge

HSD requisition HSD

Issue of HSD to user Depts.

HSD quantity issued.

HSD stock register HOD (Opn) Monthly

Flare operations Shift in-charge




Operations log book

HOD (Opn) – Monthly O&M I/C - Quarterly


HOD (Opn)




O&M I/C Monthly


HOD (Opn)



No. of reports No. of reports submitted beyond __ of every month.


O&M I/C Monthly

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TITLE : MECHANICAL DEPARTMENT Effective Date: 01.12.2010

Issue No : 03


Process/ Activity




Predictive maintenance

Site In-charge (Mech.)

Equipment monitoring report Spares availability Operation feedback Work permit OEM manuals Trained/skilled manpower Tools and tackles

Behavior of equipment

Trends Availability of Equipment No of break down Cost of spares

Reports of Maintenance

HOD (Mech.) Monthly

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Process/ Activity


Input Output Measurable Source of information/ record


Preventive maintenance


Annual maintenance schedule Work instructions Spares availability Work permit OEM manuals SAP Feed back from other dept.

Compliance of maintenance Behavior of equipment

Availability of Equipment No of break down Cost of spares

Annual schedule Reports of Maintenance

HOD (Mech.) Monthly

Legal requirements compliance

HOD (Mech)

Statutory requirements Compliance to the statutory requirements

No of non compliances

Load test certificate Legal register

In charge (O&M) Monthly

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Process/ Activity




Break down maintenance

HOD (Mech)

SAP Notification/ Verbal information from control room Spares availability OEM Manuals Work instructions Work permit

Maintenance of the equipment Problem rectification

Down time Cost of spares

SAP Maintenance orders Maintenance register/log book Equipment history Breakdown analysis reports

In-charge (O&M) Monthly

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Process/ Activity




Submission of MPR


Spares and R &M cost Activities carried out

Monthly Progress Report

No of reports submitted in time

MPR HOD (Mech.) Monthly

Spares parts management


Store stock Consumption pattern OEM recommendation Lead time

Purchase req.(PR)

No. of PRs Number of times spares not available

PR HOD (Mech.) Quarterly

Modifications as per operations requirements

HOD (Mech)

Suggestions from operations Audit results P&ID

Modifications As built P & ID

No. of modifications


In charge (O&M) Quarterly

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TITLE : PIPELINE & CP DEPARTMENT Effective Date: 01.12.2010

Issue No : 03


Process/ Activity





Site In-charge (Pipeline & CP)

Equipment monitoring report Spares availability Operation feedback Work permit OEM manuals Trained/skilled manpower Tools and tackles


Trends Availability of Equipment No of break down Cost of spares


HOD (Pipeline & CP) Monthly

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Process/ Activity






Annual maintenance schedule Work instructions Spares availability Work permit OEM manuals SAP Feed back from other dept.

Compliance of maintenance Behavior of equipment


Annual schedule Reports of Maintenance

HOD (Pipeline & CP) Monthly

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Process/ Activity





HOD (Pipeline & CP)

SAP Notification/ Verbal information from control room Spares availability OEM Manuals Work instructions Work permit



SAP Maintenance orders Maintenance register/log book Equipment history Breakdown analysis reports

In-charge (O&M) Monthly

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Process/ Activity




Submission of MPR





MPR HOD (Pipeline & CP) Monthly



Store stock Consumption pattern OEM recommendation Lead time

Purchase req.(PR)


PR HOD (Pipeline & CP) Quarterly.

Modifications as per operations requirements

HOD (Pipeline & CP)


Modifications As built P & ID



In charge (O&M) Quarterly

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TITLE : INSTRUMENT DEPARTMENT Effective Date: 01.12.2010

Issue No : 03


Process/ Activity




Calibration of Instruments under Calibration plan

Site In-charge (Inst)

List of masters List of instruments for calibration Work Instructions SAP Notifications/ Work permit Contractual obligation with customers OEM manuals Trained/skilled manpower Tools and tackles International and National standards Calibration schedules

Calibrated instrument or Rejected instrument in case of instrument is beyond repair

% P/E calibration per month Down time of instrument No of days with out calibration No. of instances masters are not available

Annual schedule Maintenance Orders Quality records

HOD (Inst.) – Monthly O&M I/C – Quarterly

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Process/ Activity




Calibration of Masters in house /out sourcing

Site In-Charge (Inst)

List of masters SAP Notifications/ Work permit OEM manuals International and National standards Calibration schedules Availability of customers to witness Customer complaint Approved calibration agencies Calibration history

Calibrated instrument /masters Rejected instrument in case of instrument /master is beyond repair Calibration certificate with traceability report Proper sealing to ensure temper proof

% P/E calibration per month No. of days delayed in execution of planned

Annual calibration schedule of masters Calibration certificates Calibration History sheet

HOD (Inst) – Monthly O&M I/C – Quarterly

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Process/ Activity






Equipment monitoring report Operation feedback Notification Spares availability Work permit OEM manuals Trained/skilled manpower Tools and tackles OEM Services

Behavior and analysis of the equipment Less equipment down time Required maintenance of the equipment is ascertained

Availability of Equipment No. of break down Cost for Maintenance

Quality records

HOD (Inst) – Monthly

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Annual maintenance schedule Work instructions Spares availability SAP notifications/ Work permit Maintenance orders OEM manuals Trained/skilled manpower Tools and tackles OEM Services

Availability of instrument Compliance of schedules Proper operation/functioning of the instrument is ensured

% P/E of instruments under PM No of break down maintenance due to lack of PM No. of days instrument is with out calibration No. of deviations from PM schedule % of critical spares available Cost of maintenance

Annual Preventive maintenance schedule Quality Records Maintenance register Break down register

HOD (Inst) – Monthly

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Process/ Activity





HOD (Inst)

SAP Notification/ Verbal information from control room Spares availability OEM Manuals Work instructions Work permit Trained/skilled manpower Tools and tackles

Maintenance of the instrument/ System Problem rectification

Response time Down time Reoccurrence/ repetition of the same problem

SAP Maintenance orders Inst maintenance register/log book Equipment history

O&M I/C – Monthly

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Process/ Activity




Spares Planning and Indenting


Budget provision Store stock Consumption pattern OEM recommendation Lead time

Approvals Purchase Requisition. (PR)

No. of PRs No. of times spares not available No. of Purchase Orders not placed in time No of non operable instruments due to lack of spares

Note sheet PR

HOD (Inst) Quarterly.


HOD (Inst) Statutory / Legal requirements

Compliance to the statutory requirements

No. of non compliances

Weights & Measures certificate Legal register

O&M I/C – Monthly

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Process/ Activity




Modifications HOD (Inst) Suggestions Breakdown analysis reports Audit results As built P&ID Innovative ideas Latest and upgraded technology Availability of material and support services

Upgraded and Modified system Change in corresponding drawings

No. of modifications Reduction in downtime of the system Cost benefit after implementation of the modification


O&M I/C – Quarterly

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Spares and R&M cost Activities carried out SAP Maintenance orders Imprest/ contingency register


% of reports submitted in time

All reports Quality records

HOD (Inst.) – Monthly

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TITLE : ELECTRICAL DEPARTMENT Effective Date: 01.12.2010

Issue No : 03


Process/ Activity



REF Procedure / WI



Site In-charge (Elec.)

Equipment monitoring report Operation feedback Notification Spares availability Work permit OEM manuals Trained/skilled manpower Tools and tackles


Trends Availability of Equipment No of break down Cost of Maintenance


HOD (Elect) Monthly

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Process/ Activity




Preventive Maintenance


Annual maintenance schedule Work instructions / Formats Spares availability Work permit OEM manuals

Compliance of maintenance

Availability of Equipment No of break down Cost of Maintenance

Annual maintenance schedule Reports of Maintenance

HOD (Elect) Monthly


HOD (Elec)

Statutory requirements

Compliance to the statutory requirements

No of non compliances

Central electricity Authority

O&M I/C Monthly

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HOD (Elec.)

SAP Notification / Verbal information from Operation Spares availability OEM Manuals Procedure / Work instructions Work permit


Down time Cost of Maintenance

SAP Maintenance orders maintenance register /log book / Break down format Equipment history

O&M I/C – Monthly

Submission of MPR


Spares and R &M cost Activities carried out Energy Consumption report



MPR HOD (Elect) Monthly

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Process/ Activity




Spares Planning and Indenting


Budget provision Store stock Consumption pattern OEM recommendation Lead time

Purchase Requisition. (PR)


PR HOD (Elec.) Quarterly

Modifications HOD (Elec.) Operational requirement. Audit Reports. Approval Through Change Management

Modifications As required



O&M I/C Quarterly

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TITLE : SCADA Effective Date: 01.12.2010

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Process/ Activity





SSI, VZG SSI, SEC

Equipment monitoring report Spares availability Operation, Electrical, Mechanical & Instrumentation feedback Work permit OEM manuals Trained/skilled manpower Tools and tackles


Analog Data Trends (SCADA) Digital Data Logbook (SCADA) Availability of SCADA System No of break down


HSI, VZG Monthly

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Process/ Activity


Input Output Measurable Source of information/ Record



SSI, VZG SSI, SEC

Annual Preventive Maintenance Schedule Work Instructions Spares availability SAP – Notifications Feed back from other dept.



Annual Preventive Maintenance Schedule Reports of Maintenance (SCADA Logbook & SCADA RTU CARD DETAILS)

HSI, VZG Monthly

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Process/ Activity





HSI, VZG SSI, SEC

SAP Notification/ Verbal Information from control room Spares availability OEM Manuals Work instructions Work permit

Problem rectification


SAP Maintenance orders Equipment Breakdown Maintenance Record Spare Consumption Report Record Equipment history Breakdown analysis reports

O&M I/C Monthly

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Process/ Activity





SSI, VZG SSI, SEC

Store stock Consumption pattern Lead time

Purchase req.(PR)


PR HSI, VZG Quarterly

SCADA Database & Visual Element modifications

HSI, VZG




Change management record System Modification records

O&M I/C Quarterly

Submission of MPR

SSI, VZG SSI, SEC




MPR HSI, VZG Monthly

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TITLE : FIRE & SAFETY Effective Date: 01.12.2010

Issue No : 03


Process/ Activity




Preventive maintenance of fire fighting equipments

HOD (F&S)

Preventive Maintenance Schedule Work Instructions Spares availability SAP –generated Notifications, Orders and Plan


Availability of Fire Fighting Equipment No of break down Cost of spares & Consumables

Preventive Maintenance Schedule

Reports of Maintenance (Maintenance Register and Formats)

SAP maintenance Order

Station In-Charge/HOD(F&S) Monthly


HOD (F&S)

Verbal Field Observation Information from control room OEM Manuals

Problem rectification

Down time Cost of Maintenance

SAP Maintenance orders

Equipment Breakdown Maintenance Record

Equipment history

Station In-charge Monthly

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Process/ Activity




Work Clearance Management System

HOD (F&S) OISD Std-105

SAP generated

Work Permit Manual

Work Permit No of work permits. No of Incidents

SAP Work Permit Register

Station In-Charge Monthly

Offsite Emergency Action Plan

Station In-Charge

Offsite EAP

District Authorities

District Crisis Group

Neighboring Industries

Factory Act

OISD Guidelines

Trained Manpower

Availability of fire fighting equipments

First Aid and ambulance

Meeting Off-site Emergencies

Number of Fatalities Number of Casualties Loss of property Major Lapses

Off-site Emergency Reports

District Collector (Need basis)

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Process/ Activity


Input Output Measurables Source of information/ Record


Internal Safety Audits

HOD (F&S) OISD STD-145 Checklist (BSC,OISD ) OHSAS 18001 requirements Factory Act OISD Standards

Audit Observations

Percentage fulfillment Of Action Plan No. of deviations

Audit Compliance Reports MIS reports


External Safety Audits

HOD (F&S) Checklist (BSC,OISD ) Factory Act OISD Standards

Audit Observations

Percentage fulfillment Of Action Plan No. of deviations

Audit Compliance Reports MIS reports

Station In-charge Quarterly

Mock Drills Site In-Charge (F&S)

On-site /Offsite EAP Fire fighting Equipments First Aid and Ambulance Fire fighting Crew

Practice of Mock Drill and readiness to meet emergencies

Opportunities for Improvement Response Time

Mock Drill Reports

HOD (F&S) Quarterly

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Process/ Activity




Safety Committee meetings

Site In-Charge (F&S)

Safety Committee Formation Safety Suggestions Audit Findings Factory Act Schedule Near Misses Look Feel and Listen

Minutes of meeting

Compliance to schedule

Minutes of meetings

HOD (F&S) Quarterly

Mutual Aid Meetings


Factory Act OISD Guidelines Arrangements with the neighboring Industries Schedule Agenda

Minutes of meeting

Co-operation and opportunities for improvement

Minutes of meeting

HOD (F&S) Quarterly

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Process/ Activity




Training and Awareness


Training needs Training Plan Faculty Training Aids

Competent Workforce in Fire and Safety

Training Imparted Accident Free Manhours

Training records

HOD (F&S) Quarterly

Legal Requirements

HOD (F&S)

Statutory Requirements

Compliance to requirements

Non Compliance Legal Register


Testing and Inspection of Fire Alarm System and flooding system`


Schedule Work Instructions Observation from Field Walkie Talkie Work Permit Information to all

Availability of tested equipments

Compliance to schedule

SAP records HOD (F&S) Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity




MIS Reports Site In-Charge (F&S)

Highlights of the month Accident Statistics Availability of fire equipments Audit Compliance reports Annual Health Check Up Environmental Monitoring Safety Valves and Control Valves status

Submission of reports

Reports submitted on time

MIS data records

HOD (F&S) Monthly

Incident Investigations

HOD (F&S) Report of Incident Near Misses Reported Committee for investigation

Corrective and Preventive Action Analysis Report

Opportunities for improvements

Records Station In-charge Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM

TITLE : TELECOM Effective Date: 01.12.2010

Issue No : 03


Process/ Activity





Site In-charge (GT-T/C).

Equipment monitoring report by Network Management System / Craft Terminal. Spares availability Operation, SCADA & Field feedback OEM manuals

Health of the Telecom Network.

Telecom System / Link Availability No. of break down.

Predictive maintenance record

HOD (GT-T/C) Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity






Annual Preventive Maintenance Schedule Work Instructions Spares availability SAP – Notifications Feed back from other dept OEM Manual


Telecom System / Link Availability No of break down Cost of spares

Annual Preventive Maintenance Schedule Daily Alarm Analysis Bi-Monthly Maintenance of Telecom System

HOD (GT-T/C) Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity





HOD (GT-T/C).

Equipment monitoring report by Network Management System / Craft Terminal. SAP Notification/ Verbal Information from control room / SCADA Spares availability OEM Manuals Work instructions Vendor Services

Problem rectification.


SAP Maintenance orders Equipment Breakdown Maintenance Record Spare Consumption Report Record SAP History Breakdown analysis reports

O&M I/C Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity






Stock Position Minimum stock Lead time

Purchase req.(PR)


PR HOD (GT-T/C) Quarterly

Telecom System modifications

HOD (GT-T/C).

Suggestions from operations Audit results



Change management record System Modification records Station Modification Report

O&M I/C Quarterly

Submission of MPR





MPR HOD (GT-T/C) Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM

TITLE : HR Effective Date: 01.12.2010

Issue No : 03


Process/ Activity




Training

Site In-charge (Trg)

GTI training calendar Dept. requirement on training Training needs – identification

Training imparting

No. of trainings

Training records

HOD (HR) Monthly

VSPL System


Control Stamp

Doc. No. : VSPL/APM

TITLE : C & P Effective Date: 01.12.2010

Issue No : 03


Process/ Activity




Procurement of items and services

HOD (C&P)

GAIL C&P Manual Approved indent Approved suppliers list Suppliers from Website Materials stock status Purchase info. in SAP

Purchase order / Work Order

Purchase Lead time No. of indents pending for placement of orders beyond 90 days

SAP


VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity




Evaluation and selection of suppliers

Site In-charge (C&P)

Introduction letters from suppliers Performance of suppliers based on trial orders Recommendations from user dept. OEMs / Branded suppliers Past experience Supplier list of other GAIL units / Oil sectors

Approved suppliers

No. of new suppliers added

Purchase file HOD (C&P) Quarterly

Suppliers performance evaluation


Purchase Order / Work Orders Materials / Services supplied

Performance rating data

Performance rating

Internal MIS

HOD (C&P) Quarterly

VSPL System


Control Stamp

Doc. No. : VSPL/APM


Issue No : 03


Process/ Activity




Receipt of materials

Stores in-charge

Purchase Order Materials supplied Supplier’s documents

Goods Receipt Voucher Rejection reports

Lead time for making GR Pending OSRDs

SAP HOD (C&P) Monthly

Storage and issue of materials

Stores in-charge

GRV Material Transfer Note Preservation procedures SIV

Storage and Issue of materials

Inventory No. of stock verifications

SAP Verification reports

HOD (C&P) Monthly Station In-charge Annually

MIS



MIS reports No. of reports No. of reports submitted beyond __ of every month.

SAP

HOD (C&P) Monthly

Format No: APM/FRM-01

Rev No. : 01 GAIL (India) Limited

Vizag - Secunderabad LPG Pipeline System

PROCESS MEASURE AND OBJECTIVES STATUS

Dept.: Date: Sheet: ___ of ___

Sl. No.

Process Activity

Measurables Target Review Frequency

Status for the Month of________

Responsibility Remarks

Prepared By: Reviewed By:

GAIL (India) Limited · 2014-12-17 · GAIL (India) Limited Vizag-Secunderabad LPG Pipeline System...

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Transcript of GAIL (India) Limited · 2014-12-17 · GAIL (India) Limited Vizag-Secunderabad LPG Pipeline System...