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Common Contents of IMPETUS Maintenance Policy Module for Western Onshore

Common Contents of IMPETUS Maintenance Policy Module for Western Onshore. IMPETUS Maintenance Policy Initiatives. The initiatives proposed are based on the current gaps in maintenance, which may be bridged by the proposed initiatives in the following pages.

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Common Contents of IMPETUS Maintenance Policy Module for Western Onshore

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  1. Common Contents of IMPETUS Maintenance Policy Module for Western Onshore

  2. IMPETUS Maintenance Policy Initiatives • The initiatives proposed are based on the current gaps in maintenance, which may be bridged by the proposed initiatives in the following pages. • The Asset/Forward Base has the flexibility to delete / add and implement the proposed initiatives at respective facilities, as required. • The O&M/Maintenance Contracts as well as Rate Contracts are proposed to be for an initial duration of 3 years. • For new critical equipment/system, it is proposed that O&M by OEM be included in the original scope of supply to ensure optimal life cycle cost.

  3. All documentation required to launch implementationof IMPETUS Project have been completed in Western Onshore Classify equipment based on criticality Develop Asset/Forward Base Specific Annual Maintenance Program Develop Facility Specific Shutdown Plans Develop Facility Specific Manpower Plan Develop Annual Maintenance Schedules Develop Spares consumption quantity plans 1 2 3 4 5 6 • Prioritise equipment at the sub-system level at asset/forward base based on criticality (priority – 90 percentile, aggregate - 10 percentile) • Develop equipment catalogue for asset/forward base • Based on the priority of each equipment sub-system, identify maintenance levels • Develop maintenance plan as per maintenance priorities • Develop Maintenance Intensity Matrix (differentiated maintenance program) • Develop asset/forward base shutdown plans to facilitate planned maintenance of equipment that require shutdown • Develop activity based manpower plan (skill and level wise) for asset/forward base to highlight resource gaps, if any • Develop activity based spares consumption plan for each asset/forward base to identify list of spares that would be required to implement the annual maintenance program • Develop detailed schedule of maintenance activities to be • performed at each asset/forward base to implement differentiated maintenance program • Total (MACs) completed • Ahmedabad - 7117 • Ankaleshwar - 7107 • Cambay - 416 • Mehsana - 6702 IMPETUS Project Maintenance Policy Module has been developed for each asset to address the gaps in manpower and spares availability

  4. Methodology on Outsourcing and Workshop Empanelment

  5. Legend O&M by OEM O&M/Maintenance by third party Maintenance by OEM (Through RCs) For select system/units, the O&M/Maintenance contract can be placed with the OEM for critical equipment or on third party for other equipment O&M / Maintenance Contracts Critical Equipment Other Equipment Maintenance by OEM (through RCs) Maintenance by Third Party(s) O&M by OEM O&M by third party • OEM will have the complete responsibility for O&M, including spares and manpower • OEM’s performance will be measured on through put / availability / other mappable parameters • Payment will be linked with performance, preferably with Penalty with Bonus clause. • ONGC will oversee the work • Outsourcing of select system / equipment to a competent third party • Third party responsible for consumables, manpower and schedule for complete O&M as per IMPETUS Maintenance Policy • Third Party performance will be measured on through put / availability / other mappable parameters • Payment will be linked with performance • ONGC will provide providing major spares through RC and supervison

  6. Workshops (Mechanical / Electrical / Instrumentation) will be empanelled for Western Onshore assets/forward base including Hazira Plant (for work value upto Rs 25 Lakhs) Workshop Empanelment Process Asset Specific Workshops (Mechanical, Electrical & Instrumentation) • Asset/forward base/plant requirement for workshops would be identified by the Asset/forward base Implementation Team/Core Team • Requirement for Western On-shore would be consolidated by all the IMPETUS Champions • Keeping Ankaleshwar as center workshops within 150 Kms radius will be empanelled as per the defined empanelment criteria for Ankaleshwar Asset and Hazira Plant • Keeping Ahmedabad as center workshops within 150 Kms radius will be empanelled as per the defined empanelment criteria for for Ahmedabad, Mehsana and Cambay Asset/forward base • Asset/Forward Base Local Workshop(s)/Central Workshop, Baroda may also utilise the services of either of the above empanelled workshops, depending on location • IMPETUS Project team, at Mumbai, will finalise the empanelment of workshops in consultation with Asset / Forward Base IMPETUS Champions • Asset/Forward Base/Plant Managers (L1 power) can approve deletion of any empanelled workshops depending on work requirements Asset/forward base/plant maintenance teams may utilise these workshops for day-to-day repair/maintenance jobs, as required

  7. Methodology on Finalizing Rate Contracts

  8. Methodology for entering into rate contracts with OEMs for supply of spares, technical services and overhauling, as applicable • IMPETUS Project Group will take support from IMPETUS champions of the Assets / Forward Base / Facilities for identification of OEMs, Spares and their services • The rate contracts may be entered initially for three years with fix discount with the OEMs,who has international printed price list for spares and services or with others for one year OR for three years with suitable escalation clause. • The committee with Head IMPETUS approved by Director (Offshore) – I/C MM, for discussion / negotiation on terms, conditions and prices / discount shall recommend the proposal to Chief-MM for approval for signing the rate contracts with OEMs. • The rate contract once approved by Chief-MM shall be applicable for all the work centers in ONGC. The Letter of Acceptance and Signing of the Rate Contract Agreement will be done by IMPETUS Project Group, Mumbai. • Further Tender Committee would not be required for purchases made from OEMs with whom Rate Contracts have been finalised. • In emergency, order may be placed by Maintenance Manager on the OEM with whom rate contract have been finalised and regularisation will be carried out by concerned MM of the Asset/ Forward Base/Services. Packager(s) or their authorised OEMs / OESs who are already established for supply of spares / technical services / overhauling, as applicable shall only be considered for Rate Contracts

  9. OEM(s)/Vendor(s) rating criteria

  10. Redesigned Policy on “Maintenance and Procurement for Maintenance”

  11. Redesigned “IMPETUS policy on Maintenance and Procurement for Maintenance” already approved for MR to be extended to other Assets/Forward Base where IMPETUS Project is rolled out Policy on process of “Maintenance and Procurement for Maintenance” • Budgeting • Facility specific, “zero based budget” linked to the annual maintenance program • One-time “Financial Concurrence and Sanction” would be taken for the annual activity at the time of budget itself • The approval for Asset Managers/Chief Services for “Regular Items” requirements for three years. To be reviewed after every three years. The approval for one-off items will be for one year and to be reviewed every year based on plan • 10% contingency in the budget for unforeseen requirements

  12. Redesigned “IMPETUS policy on Maintenance and Procurement for Maintenance” already approved for MR to be extended to other Assets/Forward Base where IMPETUS Project is rolled out (Contd) Policy on process of “Maintenance and Procurement for Maintenance” • Requisition on De-capitalisation of select items into spares category is proposed for the purpose of procurement only. Policy to be followed: • The criteria for classification of de-capitalised items for procurement purpose should meet any one of the below conditions: • If operating life is less than 12 months • If the item is a component to independent capitalised item / sub-system / system • If item is a replacement to the existing item / sub-system / system • The new additional item to the facility/system and which does not fit into the criteria for classification of de-capitalisation as mentioned above shall be treated as capital item • The select items shall be decided for de-capitalisation with the approval of Level-1 Executive under CRC

  13. Redesigned “IMPETUS policy on Maintenance and Procurement for Maintenance” already approved for MR to be extended to other Assets/Forward Base where IMPETUS Project is rolled out (Contd) Policy on process of “Maintenance and Procurement for Maintenance” • Approval • No RCMLO approval would be taken as quantity due-diligence is carried out • No ED-MR/Asset Managers/Head Drilling Services approval for imported spares as due-diligence is to be carried out at budgeting stage only • Manpower • Manpower requirement will be derived form the annual maintenance program for the facility. Gaps would be addressed through internal deployment and/or outsourcing from shortlisted manpower supply houses • The facility specific O&M by the OEM or O&M by the shortlisted supply houses for spares/services would be introduced to the possible extent

  14. Roles, Responsibilities and Reporting

  15. Identified roles and responsibilities for Asset/Forward Base Implementation team, Asset/Forward Base IMPETUS core team and Mumbai IMPETUS Project team

  16. Reporting for Asset/Forward Base IMPETUS Core Team, Asset/Forward Base Implementation Team and proposed committee at asset to recommend O&M and Maintenance Contracts Reporting Structure • Asset/Forward Base Implementation Team members will report administratively to their respective Facility Location Manager. • First Person Responsible (FPR) on facilities will be the senior most amongst the multi-disciplinary Asset/Forward Base implementation team • Senior most member of the Asset/Forward Base IMPETUS core team will be named Asset /Forward Base IMPETUS Champion. • Members of the Asset/Forward Base IMPETUS core team will report to the Asset / Forward Base IMPETUS Champion. • Asset/Forward Base IMPETUS Champion along with Asset/Forward Base IMPETUS Core Team will report administratively to Asset/Forward Base Surface Manager and functionally to Head-IMPETUS. Proposed Committee at Asset to recommend O&M and Maintenance Contracts • Surface manager/Head Services • Head, MM of Asset/Forward Base/Service • Head, Finance of Asset/Forward Base/Service

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