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Management of Change (Maintenance Department)

Document ChangeTest Run AuthorizationSubtle ChangeTemporary RepairSub HSE (M)

Controlled Documents

• Mechanical AdministrativeProcedures

• Mechanical Work Procedures

• Area Maintenance ManagementManuals

• Job Plans

• Area Specific StandardOperating Procedures

• Centralized maintenancemanagement system (CMMS)technical database (SAP)

• Equipment specificationdocument/data sheet

• Fixed equipment and machineryreliability

• hprogramme documentation

Final Approval By

• Maintenance Manager

• It includes any kind of changesand revisions in controlleddocuments.

• Any additions or deletions tocontrolled documents also fallunder this catagory .

Examples

• Changing Teporary Repair intopermanent modification.

• For example: Continuous dropwise leakage through furnace

ID Fan U-201 turbine side journal bearing

• New process facilities

• For example: Installation ofElectro chlorination Plant

• Safety devices / systemmodifications

• Changes to material ofconstruction

• For example: Plasma coatedwear rings for 1st, 2nd, 4thstage in P-02 B

• Reinforcement of CDR blowerU-801 inlet guide plate

• New civil facilities required

• For example: Construction ofFM Shacks

• Change in dimensions ofequipment or drawing

Final Approval By

• Sub-HSE (M) Chairman

• Test Run Authorization is required torecord the behaviour of differentparameters after a change isperformed on an equipment or

troubleshooting• TRA is also required to test run t he

plant to establish increasedproduction rates.

• It is a permanent change.

• It includes all the changes which are notreplacement in kind.

•

Any permanent change in processspecifications, change in P&IDs) andsafety critical equipment is not coveredin subtle change

• It is a temporary change.

• It includes all the changes carried outin emergency situations.

• It is for a limited period of time.• Debox date is mentioned on the

temporary repair form and repairshould be reverted before that date

Examples

• Box up of leaks

• Temporary Modif ications

• For example: Temporarymodification required on P-3001

A/B nitrogen vent line• Temporary arrangement for oil

make up at scrapper gear box atH-01 A/B

• Equipment replacement or repairusing non-documented spares

• Replacement of any spares withanother spare which is notrecommended by OriginalEquipment Manufacturer.

• For example: Wear ring materialchange from cast iron to SS410 at11-P-553 B

• Flushing of lines with a fluid notspecified in the procedures because

of unavailability.

Final Approval By

• Sub HSE (M) Chairman

Examples

• Replacement of different brand bearingbut of same type

• For example: Use of FAG bearing insteadof SKF make at 11-H-421

•

Replacement of gasket.(If material isupgraded.

• Installation of a higher grade piping inplace of existing system.(For non-hydrocarbon services)

• Relocation/extension of drains/samplepoints(if open space)

• Replacement of type of valves on drainlines only(if material is upgraded andservice is non-hydrocarbon)

• K-02 compressor packing line valveremoval

• Change of material towards a bettermetallurgy

• Adjustment / extension of monkey ladder

/ support structure, to improveaccessibility(with OSHA standards)

• Change of orientation of valve handwheels

Final Approval By

• Maintenance GL & Operations GL

Applicable to

• The plant is to be operated withindesigned authorized limits, asdetailed in the equipmentprocedures

• The equipment is to be operatedwith some change in manufacturerrecommendations

• For example: P-1403Bintermediate shaft materialchange & In-house machining ofBar

• Startup or shutdown with approvalof new or changed, facilities orprocedures.

Final Approval By

•Sub HSE (M) Chairman(Maintenance Department)

• It is a permanent change

• It includes all the modifications to theplant facilities.(examples given below)

• Any change in already approvedprocess specification, pipe isometrics,change in P&IDs or drawings of aproject also falls under this catagory

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