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Technical Audit Of
Sui Southern Gas Company - 2007
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Objective
To carryout a systematic and objective verification, analysisand appraisal of the operational functionality.
Performance evaluation of the system (safety, managements,documentation, data acquisition and control aspects of the
system functions) Operations of equipments/ tools under SSGC use.
Appraisal means technical appraisal only and exclude:
Financial evaluation
Estimation of worth..
Physical execution
Inspection, testing
Measurement and calibrations
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Tasks
Operational functionality and performance evaluation ofthe system (Integrity, adequacy, effectiveness & efficiency)
System Management
Means technical systems and procedures only.
Compliance with relevant legislation, policies, standards
and HSE measures in the companys areas of operation.
Legislation and policies are those required to
meet laws of GOP.
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Scope Of Work
I) Projects System
II) Transmission System
III) Compression System
IV) Corrosion SystemV) Telecommunication System
VI) Metering System
VII) Distribution System
VIII) Civil Works
IX) Procurement of materialX) Customer service
response and operation
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Projects System
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Projects System
a) Pipelines System Construction & Installation activities
Project means the pipeline construction and laying fortransmission and distribution systems.
Reference Documents
Section 2, 3, 5 & 6 OGRA GTTS
ASME B 31.8
API RP 5L 1
API 1104
API RP 1102
Gas Rules 1960
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Project System
SSGC to provide:
List of various projects in hand/ongoing
Planning of each project showing work break down
Project Schedule - Planned Vs Actual
Manpower & Equipment Deployment - Planned vs. actual General Pipeline construction Manual
QA / QC documentation (In house / 3rd Party)
Design Dossier/Drawings of fewsignificant completed and on going projects
Material inspection procedures & reports
cont .
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Projects System
Right - of - Way (ROW) Drawings Stringing & Storing records
Welding - QA / QC docs, Weld Test Result (NDT& DT),Welder qualification procedure & Records
Coat & Wrap - Design Specs, MDS, QA / QC documents
Ditching & Lowering / Backfill - Approved & As built drawings
Crossings - Approved & As built Drawings
Cathodic Protection - Design documents, Soil survey report,Approved & as built drawings
Testing procedures & records including Holiday Detection,Leak Detection, Hydro Static Testing
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Projects System
b) Procurement of material & equipment for projects (procedure& conformance)
Exclusions:
Warehousing
Issues relating to land acquisition / land rehabilitation
Reference Documents - API 5L and other related codes
SSGC to provide
Procurement procedure
Pre qualification of suppliers
Criteria for acceptance and rejection of material
Issuance of material
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Transmission System
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Transmission System
a) Pipeline operations (operation and maintenance planning and control
Management) including right of way (ROW), Patrolling, ROWmaintenance, River crossing, valve assemblies maintenance, BlockValve and actuator operation, commissioning and de commissioning ofpipeline.
Ref Doc - OGRA GTTS SEC 8, ASME B31.8 2, OGRA GTTS SEC 8.5
SSGC to provide Transmission Net Work diagram showing all installations & facilities:
Pipeline Terminal Stations Divisional Stations/HQ Stations SMS Repeater Stations Valve assemblies Major Road, Railway, Bridge or Barrage crossings Pipeline Diameters Approach from nearest highway, Railway Station or Airport
cont ..
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Transmission System
Right of WayROW Dimensions at various sections of pipeline Net work
Patrolling Procedure & Inspection Record
Maintenance Record of ROW
Work orders to Contractors - HQs/Terminal Stations.
Encroachments reports and measurestaken
Pipeline Maintenance
Periodical inspection & maintenance reports including thicknesschecks, Sleeving, Coat & Wrap repairs.
Pigging arrangements locations and records.Hot tap/stoppling design, procedure and reports.
Maintenance of Civil Structure and Protective Works records
Valve Assemblies - Maintenance procedures and inspection records
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Transmission System
b) Compressor operation (operation planning and control only)
SSGC to provide:
Compressor Operation Plan Vs Actual of last three yearscovering
Un-interrupted running hours
Standby time
Down time for scheduled maintenance
Log book or Shift Status Chart
Daily Operation Activity reports transmitted to Zonal /Central Offices.
Maintenance work records
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Transmission System
c) Pre- Invoice verification of Gas source. Debit invoice includingcircular chart reading, strip chart reading, Gas volumecalculations and transmission UFG.
Post Invoicing verification of Gas supply
Ref Doc - AGA REPORT 3, MNOP&R MODEL GSA
SSGC to provide
Gas Sales Agreements
Billing Trail
Circular charts
Strip charts
Gas chromatograph data
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Transmission System
d) Filtering, Metering and pressure regulation arrangementsRef Docs - ASME B31.8 SECTION 803.3 / 853
SSGC to provide
P & IDs
Filter design specifications and drawings Pressure regulators and meter data sheets
e) Operation data recording arrangements
KT / other stations
SSGC to provide
P & IDs and Instrument data sheets
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Transmission System
f) SCADA System Data Acquisition from sources and SMSs
SSGC to provide
Vendors Manual
SOPs
Records / Data
g) Meter Proving and maintenance
Ref Doc - AGA Report No.3 & 8, AGA Report 9
SSGC to provide Vendor manuals
in-house SOPs
Maintenance and calibration record
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Transmission System
h) Joint calibration of custody transfer metering equipment atgas source
Ref Doc - AGA Report, GSA with producers
SSGC to provide
GSA
Record of joint calibration
i) Joint calibration of SMS with Distribution Department
Ref Doc - AGA Report No.3. SOPs
SSGC to provide
SOPs
Maintenance and calibration records
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Transmission System
j) Gas Quality Monitoring Ref Doc - GSA
SSGC to provide
GSA
Gas chromatograph readings provided by seller
k) Operation and maintenance of Power Generating sets atRepeater stations
Ref Doc - SOPs / Vendor Maintenance Manuals
SSGC to provide
Schedules
Log books
Maintenance report
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Transmission System
l) Operation and Maintenance of construction equipment Ref Doc - Operations & Maintenance manuals
SSGC to provide
Operation and maintenance manuals
Maintenance record of individual machine Maintenance schedule
n) Transport Fleet Management
SSGC to provide
Fleet maintenance register
Maintenance manuals.
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Transmission System
M & o) Safety & Fire Protection & ERP:
Ref Docs - NFPA Codes, API code
SSGC to provide
HSE Manual Safety checklists
Safety records
Fire drill records
Emergency Response Procedures
Incident reporting procedures and records
investigation procedures and records
List of Safety & Fire Fighting equipment at each installation
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Transmission System
p) Rehabilitation of Transmission lines (Coat & Wrap, Sleeving) Ref Doc - OGRA GTTS, ASME B31.8
SSGC to provide:
Thickness and PSP / HOLIDAY / DCVG Reports
Sleeving, Coat & Wrap procedures and record
q) PCV remote operation through SCADA
Ref Doc - Operation and maintenance manual.
SSGC to provide:
Schematics
Operation reports
Operations and maintenance manuals
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Transmission System
r) Pigging of pipelines wherever required
Ref Doc - ASME B31.8, SOPs
SSGC to provide:
Pipeline schematic showing pig launching and receivingarrangements
Pigging procedures and reports
s) Hot tapping / Stoppling
Ref Doc - Operation & maintenance manuals
SSGC to provide:
Hot Tap / Stoppling procedure and records
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Transmission System
t) Daily / hourly maintenance of flow pressure data of GasControl
Refer item e of SOW
u) Maintenance of Civil Structure and protective works.
Refer item a of SOW
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Compression System
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Compression System
a) Compressor Operations evaluation
Ref Doc - API 616, API 617
SSGC to provide
Operation Manual / Design & As built Manual
FAT report, performance curves
Gas Turbine & compressor operating parameters recorded atnormal / average operating conditions and at peak load
b) Compressor efficiency evaluation
Ref Doc - API 616, API 617
SSGC to provide
Detail of studies carried out for improvement
Recommendation & Implementation
Methodology adopted & results of improvements
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Compression System
c) Maintenance of equipment installed at compressor station
Ref Doc - OGRA GTTS, ASME B31.8
SSGC to provide
Maintenance manual.
In-house SOPs.
Planned maintenance schedules vs. actual.
Maintenance record of individual unit
Maintenance report prepared after each overhaul / Scheduledinspection
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Compression System
d) Controls of Gas Turbines SSGC to provide
Detail of studies carried out for improvement
Recommendation & Implementation
Methodology adopted and results of improvements.
e) Optimization of pipeline flow, pressure for better utilization ofavailable horse power
SSGC to provide
Detail of studies carried out for improvement
Recommendation & Implementation
Methodology adopted and results of improvements.
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Compression System
f) Improvement of compression efficiency through restagingredundancy and standby equipment requirement to meet thegoals and objectives / targets
SSGC to provide
Detail of studies carried out for improvement
Recommendation & Implementation
Methodology adopted and results of improvements.
h) Gas Filtration facilities functioning
Ref Doc - ASME B31.8, OGRA GTTS
SSGC to provide
P & IDs
Filter design specifications and drawings
Filter element change-out frequency records
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Compression System
i) Discharge cooling system functioning Ref Doc - API 661
SSGC to provide
Design data sheet
Vendor data
Discharge temperature
Number of fans
Operating Parameters recorded during normal / averagecondition and peak load / peak ambient condition.
Winter data
j) Operations and maintenance of Generators installed atcompressor stations
SSGC to provide
Vendor manuals, operations Log, running hours, standby,downtime maintenance history of individual Gensets
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Compression System
k) Designing, Planning and implementation work for revamping/ De bottlenecking of Compressor stations
SSGC to provide
Reports on modification for De-bottlenecking efficiencyimprovement.
Plans for ongoing & those to be taken in hand in near future.
l) Fuel measuring facilities installed at compressor station
SSGC to provide
P & IDs
Drawings
SOPs
Vendor manuals
Operations Log
Maintenance logs / reports
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Compression System
m) Evaluation of overhauling function and appraisal ofoverhauling activities
SSGC to provide
OEMs guidelines / Manuals, Drawings.
Workshop facilitates availability of essential machines.
Availability of requisite hand tools / special tools.
No of overhauls carried out with / without OEM support.
Maintenance reports including Post overhaul performancetesting.
n) HSE condition at all the above mentioned activities
SSGC to provide
Refer items m,o of Transmission System
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Corrosion System
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Corrosion System
a) Physical and operating conditions of CP System installations vis-
-vis DC source (T/R, TEG units), ground bed (Horizontal, deepwell ), Negative distribution box, drain point etc.
SSGC to provide
Complete route map indicating CP system.
Installed Equipment detail, Data sheets.
Operations and maintenance Procedures and records
b) Calibration of the CP Measuring and Monitoring Devices.
SSGC to provide
Maintenance & Calibration records of all CP Measuring and
Monitoring devices.
Measurement and calibration traceability
Equipment manufacturer manual
In-house calibration setup & procedures
Pre-qualification of calibration service providers
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Corrosion System
c) Testing of CP Isolation devices, insulating flanges SSGC to provide
Test record of insulating flanges
d) Pipeline Integrity Assessment through indirect surveys vis-
-vis Close Interval Potential (CIP) survey, Direct CurrentVoltage Gradient (DCVG) survey, Soil Resistively survey,Soil Analysis of the selected pipeline sections
SSGC to provide
Record of integrity assessment surveys Recommendations and implementation reports
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Corrosion System
e) Pipeline Integrity Assessment through direct examination ofpipeline vis--vis, Bell Hole (visual coating inspection, pipesurface condition of the selected pipeline sections.
SSGC to provide
Record of integrity assessment surveys
Recommendations and implementation reports
f) Recommendation for CP System up-gradation and coatingrehabilitation of the vulnerable pipeline section.
SSGC to provide
Record of integrity assessment surveys
Recommendations and implementation reports
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Tele-communication System
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Tele-communication Stations
a) Maintenance of the existing Telecommunication Network,
comprising of Digital Microwave Back Bone Radio Link, LowCapacity Digital Spur Links, Single Channel Radio Telephonelinks and Base to Vehicle UHF Wireless Radio System forminimum outage time.
Ref Doc - ITUT standards or PTA regulatory authority code.
SSGC to provide
SOP
Lay out diagrams
Vendors Manuals
Maintenance procedures
Down time analysis reports
Record for the calibration of test equipment
License for getting required frequencies
Spares record
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Tele-communication Stations
b) Maintenance of existing SCADA system for reliable Dataacquisition from Gas Sources, Sales Meter Stations,Compressor Stations, Repeater Stations and RemoteControl Operation of Pressure Control valves and MainlineBlock valves.
SSGC to provide SOP
Lay out diagrams
Vendors Manuals
Maintenance procedures
Down time analysis reports Record for the calibration of test equipment
Procedure of calibrating the pressure, temp and flow fromSMS, compressors stations and controlling the remote blockvalve operation.
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Telecommunication Stations
c)Operation and maintenance of Digital Telephone Exchangesinstalled from SUI to Peshawar on our Microwave RadioNetwork.
SSGC to provide
SOP
Lay out diagrams Customer Manuals
Spares record
d) Provision and maintenance of internet facilities in SNGPLthrough Companys dedicated radio network.
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Tele-communication Stations
e) Routine calibration of SCADA instruments for Data Integrity
SSGC to provide Procedure adopted for the calibration of SCADA instruments
Record of routine calibration performed on different instrumentsfor the data integrity.
f) Planning, equipment indenting and Bid Evaluation ofTelecommunication system.
SSGC to provide
Prequalification procedure for supplier
Bid evaluation procedure
g) Planning and execution of new projects for up grading of theexisting telecommunication system.
SSGC to provide
Future plans and upcoming projects to upgrade the existingtelecommunication system.
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Distribution System
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Distribution System
a) Laying of distribution mains and service lines
Ref Doc - OGRA GDTS Sec-2 thru 4ASME B 31.8 Sec 849, 850 & 852
SSGC to provide
SOPs
Pipeline route, Layout drawings showing rail / road crossings QA/QC Procedure
b) Testing and commissioning of mains
Ref Doc - OGRA GDTS Sec-5
SSGC to provide
Testing Procedure
Test reports
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Distribution System
c) Meter installation at different domestic, industrial and
commercial customers Ref Doc - ASME B31.8 SECTION 848, OGRA GDTS sec 8.15
SSGC to provide
Installation Procedure
Maintenance procedure and records Calibration procedure and records
d) Service line shifting
Ref Doc - ASME B 31.8 Sec 849, OGRA GDTS Sec 8.20
SSGC to provide
Work Procedure
Completion reports / log reports
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Distribution System
e) Control valves maintenance Ref Doc - ASME B 31.8 Sec 841.126
SSGC to provide
Maintenance Procedure
Maintenance register
f) Maintenance of regulatory stations
Ref Doc - OGRA GDTS Sec 8.15 thru 8.19, ASME B 31.8Sec 848
SSGC to provide
Maintenance procedure
Maintenance register
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Distribution System
g) Gas Leakage rectification Ref Doc - OGRA GDTS Sec 7.2 & 7.3 & 8.6, ASME B 31.8
Sec 851.3, 851.6 & 852.3 Appendix M
SSGC to provide
Leakage Survey reports
Leakage rectification Procedure
Leakage rectification reports
h) Gas Quality Monitoring
Ref Doc - AGA Report No.3
SSGC to provide
Specs from GSA, Gas chromatograph readings
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Distribution System
i) Meter proving at central metering shop and at mobile test van Ref Doc - AGA Report No.3
SSGC to provide
Meter proving Procedure and reports
Practical demonstration
j) Maintenance of industrial, commercial and domestic meters
Ref Doc - ASME B 31.8 Sec 848, OGRA GDTS 8.15
SSGC to provide
OEM Manuals
SOP's
Maintenance record and reports
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Distribution System
k) Maintenance of Town border stations, District regulatorystations and consumer meter station
Ref Doc - OGRA GTTS Sec 8.15, ASME B 31.8 Sec 848 &803
SSGC to provide
SOP's
Maintenance manuals of individual equipment
Maintenance records
l) Painting of over head crossings and service valves. SSGC to provide
SOP's
Maintenance records
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Distribution System
m) Material inspection test laboratory (If available)
SSGC to provide
SOP's for individual tests and equipment used.
Sample test report for individual item.
Test record keeping system
n) Maintenance of construction equipment like welding plants,compressors etc
SSGC to provide
Maintenance manuals
Maintenance Schedules and reports
o) Transport Fleet Management
Refer item n of Transmission System
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Distribution System
p) Pipeline patrolling
Ref Doc - ASME B 31.8 Sec- 851.2
SSGC to provide
Pipeline patrolling log book.
Pipeline Patrolling Guidance note
Report on special / abnormal situations noted during patrolling
q) Safety and fire protection at Area level
Refer item o of Transmission System
r) Preparation of master plan at regional level
Extent of Scope of work to be deliberated.
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Procurement of Material& Equipment for Projects
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Procurement of Material of Projects
Procurement
SSGC to provide
Purchasing manual
Procedure and criteria for prequalification of suppliers
Tendering procedures
Criteria for technical bid evaluation
Standard Specifications
SSGC to provide RFQs, P/Os
Technical Evaluation
Test / inspection Reports
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Procurement of Material of Projects
Customized Specification - Manufacturer certificates for Q.A
Technical Evaluation - Technical Evaluation Procedures
In-house Quality Assurance - In-house QA Procedures
Inspection - In-house Inspection Procedures
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Customer Service Response
& Operation
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Customer Service Response & Operation
Performance Standards
Gas Emergencies
Telephone Calls
Complaints
Investigation of Pressure Complaints
Making and Keeping Appointments
Notification of Planned Work
Connection to Distribution System
Energy / Safety advice
Replies to correspondence
Visits
Estimating Procedures for billing
Meter alteration & replacement at consumers request
Responding to meter problems
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Customer Service Response & Operation
Performance Standards
Meter Accounts (Meter reading / billing )
Meter Reading Frequency
Special Meter Readings
Appointment for reading
Providing additional meter
Notifying consumer for non-payment
Termination of service for default
Reconnection after payment of dues
Refunds to the Consumers
Backfill, Restoration
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Customer Service Response & Operation
SSGC to provide
Customer response manual/ Guidelines / Procedure
Customer response facilities / Location
Customers complaint record and close out formats.
Customers complaints visit reports
Connection restoration records after payment dues.