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

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Presentation on theme: "Project IMPETUS Maintenance Policy Module – Common Contents 1 Common Contents of IMPETUS Maintenance Policy Module for Western Onshore."— Presentation transcript:

1 Project IMPETUS Maintenance Policy Module – Common Contents 1 Common Contents of IMPETUS Maintenance Policy Module for Western Onshore

2 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 3 Develop Annual Maintenance Schedules All documentation required to launch implementation of IMPETUS Project have been completed in Western Onshore 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 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 Classify equipment based on criticality Develop Spares consumption quantity plans Develop Facility Specific Manpower Plan Develop asset/forward base shutdown plans to facilitate planned maintenance of equipment that require shutdown Develop Facility Specific Shutdown Plans Develop Asset/Forward Base Specific Annual Maintenance Program IMPETUS Project Maintenance Policy Module has been developed for each asset to address the gaps in manpower and spares availability Total (MACs) completed 1.Ahmedabad Ankaleshwar Cambay Mehsana Total (MACs) completed 1.Ahmedabad Ankaleshwar Cambay Mehsana

4 Project IMPETUS Maintenance Policy Module – Common Contents 4 Methodology on Outsourcing and Workshop Empanelment

5 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 5 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 Maintenance by OEM (through RCs) O&M by third party Critical Equipment Other Equipment O&M by OEM 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 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 Maintenance by Third Party(s) O&M by OEM O&M/Maintenance by third party Legend Maintenance by OEM (Through RCs)

6 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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 Project IMPETUS Maintenance Policy Module – Common Contents 7 Methodology on Finalizing Rate Contracts

8 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 8 Methodology for entering into rate contracts with OEMs for supply of spares, technical services and overhauling, as applicable 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 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.

9 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 9 OEM(s)/Vendor(s) rating criteria

10 Project IMPETUS Maintenance Policy Module – Common Contents 10 Redesigned Policy on “Maintenance and Procurement for Maintenance”

11 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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” 1. 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 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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” 2. 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: a) If operating life is less than 12 months b) If the item is a component to independent capitalised item / sub-system / system c) 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 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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” 3. 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 4. 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 Project IMPETUS Maintenance Policy Module – Common Contents 14 Roles, Responsibilities and Reporting

15 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 15 Identified roles and responsibilities for Asset/Forward Base Implementation team, Asset/Forward Base IMPETUS core team and Mumbai IMPETUS Project team Implementation Team at Asset/Forward Base Asset/Forward Base IMPETUS Core Team IMPETUS Project Team at Mumbai Members  Functional FPRs  Asset/Forward Base Maintenance teams  Asset/Forward Base IMPETUS Champion  Asset/Forward Base IMPETUS Core team members  Head, IMPETUS  IMPETUS Project Team members Key Roles and Responsibilities  Decision Making Formation of maintenance groups Resolution of issues / conflicts Daily Monitoring and control  Hands-on-execution Work order generation and execution Provide inputs for rate contracts Preparation of budgets, Netting off of inventories, business cases etc. Spares consumption/inventory tracking Target Compliance – min. 95% Preparation of compliance and monitoring reports Responsible for performance measurement  Program Management Monitor overall schedule Monitor compliance reports and report road blocks to Asset Senior Management and Head- IMPETUS  Facilitation Rate Contract Workshop empanelment  Facilitation, finalisation and revalidation Outsourced Maintenance Review MAC yearly and include new items, if any Skills / knowledge transfer Provide clarification on any aspect of IMPETUS  Content support  Provide overall guidance on policy matters related to IMPETUS Project  Finalise Rate Contracts with selected OEMs  Finalise workshop empanelment  Support in finalising scope and BEC for Outsourced Maintenance  Finalizing O&M by OEM for select common critical equipment across the Assets/FB.  Monitoring compliance and address major bottlenecks, if any

16 108319_Macros Project IMPETUS Maintenance Policy Module – Common Contents 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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