Revision Date 01/24/06/2013

Document No. MP-AP-10

Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 1 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 1 / 15 Area: Maintenance

INITIATED BY :
MAINTENANCE ENGINEER (SUM) DATE

REVIEWED BY :
UNIT MANAGER MAINTENANCE (AnA) DATE

APPROVED BY :
MAINTENANCE MANAGER (SN) DATE

CHANGE RECORD

S# REV. # DATE PAGE # SECTION DESCRIPTION OF CHANGE

DISTRIBUTION
1. MAINTENANCE MANAGER
2 LAN

TABLE OF CONTENTS
1. INTRODUCTION
Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 2 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 2 / 15 Area: Maintenance

1.1 PURPOSE....................................................................................................................................................................................... 3

1.2 SCOPE............................................................................................................................................................................................ 3

1.3 DEFINITIONS / ABBREVIATIONS................................................................................................................................................... 3

2. FACILITY CHANGES

2.1 APPROVING FORUMS / AUTHORITIES........................................................................................................................................ 5

2.2 APPROVED PROJECT / SPECIFICATION CHANGES.................................................................................................................. 5

2.3 APPROVING FORUM / AUTHORITIES........................................................................................................................................... 5

3. SUBTLE CHANGES

4. TEMPORARY CHANGE

4.1 APPROVING FORUMS / AUTHORITIES........................................................................................................................................ 7

5. TEST RUNS / AUTHORIZATION (TA)

6. DOCUMENT CHANGE

6.1 APPROVING FORUMS / AUTHORITIES........................................................................................................................................ 9

7. TRAINING REQUIREMENTS

7.1 CHANGE TRAINING........................................................................................................................................................................ 9

7.2 TRAINING DOCUMENTATION....................................................................................................................................................... 9

8. RESPONSIBILITIES

8.1 ENGRO CHEMICAL PLANT PERSONNEL (MPT / NMPT)............................................................................................................. 9

8.2 CHANGE CUSTODIAN.................................................................................................................................................................... 9

9. EXEMPTIONS

10. REFERENCES

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 3 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 3 / 15 Area: Maintenance

1. INTRODUCTION

1.1 PURPOSE
The procedure describes & covers management of change process in Maintenance Department complying with Process Safety
& Risk Management (PSRM No. 4 & 8).

The purpose of this procedure is to ensure that the changes to the documented process safety information package are reviewed
and approved before implementation.

This procedure applies to ALL changes (process chemicals, technology, equipment, procedures, and changes to facilities that
may affect a covered process) in the plant, except "replacement-in-kind". This procedure assures that the following
considerations are addressed prior to any change:

1. Purpose of the change

2. The technical basis for the proposed change
3. Impact of change on health, safety and environment aspects
4. Modifications to operating procedures
5. Necessary time period for the change
6. Training and communication requirements
7. Authorization requirements for the proposed change

1.2 SCOPE
The following classifications of changes have been covered in this procedure. They shall all follow the change paths described
in this procedure unless otherwise exempted in section 8. Facility Changes [Requires Sub-SOC (M) Approval]
1. Temporary Changes [Requires temporary repair authorization]
2. Subtle Changes [Requires subtle change authorization]
3. Test Run Authorization.

Procedure is applicable wherever Maintenance has taken up the responsibility of the facility.

1.3 DEFINITIONS / ABBREVIATIONS

1.3.1 ME MAINTENANCE ENGINEER
1.3.2 MS MAINTENANCE SUPERVISOR
1.3.3 IE INSPECTION ENGINEER
1.3.4 SA SAFETY ADVISOR
1.3.5 MM MAINTENANCE MANAGER
1.3.6 I&E INSTRUMENTATION & ELECTRICAL
1.3.7 JSA JOB SAFETY ANALYSIS
Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 4 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 4 / 15 Area: Maintenance

1.3.8 PM PREVENTIVE MAINTENANCE

1.3.9 PdM PREDICTIVE MAINTENANCE
1.3.10 SOC SAFE OPERATION COMMITTEE
1.3.11 PSRM PROCESS SAFETY RISK MANAGEMENT
2. FACILITY CHANGES

To properly manage changes to technology, equipment and facilities, a change shall be defined, categorized and authorized. This
section details the change types, which includes all modifications to equipment, procedures, other than "replacement in kind".

Management of change covers changes in:

1. Process technology.
2. Changes to equipment and machines.

Equipment changes include among others change in materials of construction, equipment specifications, experimental equipment, and
addition of equipment and test runs.
To ensure safety and competitiveness, an existing facility has to be constantly changed, or put a new facility. Any plant employees may
propose facility changes, however, these changes must be accomplished without compromising safety, health or the environment.

Facility change includes:

1. Addition or deletions of components or hardware, including equipment, instrumentation, and electrical facilities.
2. New process facilities involving installation & commissioning of new equipment.
3. Temporary equipment attached to a process (e.g., test equipment, cryogenic nitrogen systems, water treatment chemical tanks)
4. Replacement using non-identical or non-conforming equipment and spares.
5. Safety Critical Devices / system modifications
6. Re-rating of equipment
7. Changes to material of construction
8. Structure / supports modification which could affect structural integrity.
Notes:
1. Safety aspects and specifications of process equipment and relevant supporting structures will be part of and in jurisdiction of
Sub-SOC (M). However, the design specification shall have the approval of Sub-SOC (P)
2. All the design & document changes which occur as a result of modifications are required to be reviewed by relevant functional
interface of Maintenance group
3. For detailed functioning of Sub-SOC (M), see Project Manual

2.1 APPROVING FORUMS / AUTHORITIES

The minimum team for review of facilities change is as follows & it is approved by Sub-SOC (M) chairman.
2.1.1 Functional reviews / Peer Reviews :
Review of Engineering, Design, and operational aspects by;
2.1.1.1 Project Engineering Unit Manager / Process Engineering Manager ( or Group Leader)
Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 5 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 5 / 15 Area: Maintenance

2.1.1.2 Inspection Section Head/ group Leader (In case of Stationary Equipment)
2.1.1.3 Machinery Section Head / Group Leader (In case of Rotary Equipment), if any
2.1.1.4 Concerned Area Field Maintenance Unit Manager, if available
2.1.1.5 Concerned Area Operations Unit Manager
2.1.1.6 HSE Advisor
2.1.2 Sub- SOC (M) to review the package and relevant safety concerns.

2.2 APPROVED PROJECT / SPECIFICATION CHANGES

Any alteration to an approved project or specification which occurs after issuance of fabrication & implementations layouts to
field maintenance, shall be re-approved by the same approving authority. This includes, any of the items listed below:
2.2.1 Deviation from standards (unless specified)
2.2.2 Changes in equipment / design conditions or metallurgy
2.2.3 Change in dimensions of equipment or other specifications
2.2.4 Significant equipment location changes
2.2.5 Change of manufacturers and vendors who are not included in EPCL approved list.
2.3 APPROVING FORUM / AUTHORITIES
For above changes as described in Section 2.2, the minimum team for review is as follows:
2.3.1 Operations Section Head / Unit Manager
2.3.2 Field Maintenance Unit Manager / Section Head,/ Sr.Engineer as nominated by Technical / appropriate Maintenance
Manager ( mechanical or Instrument/ Electrical) whoever is Sub-SOC (M) Chairman
2.3.3 Concerned Process engineering Unit Manager / Section head / Sr.Engineer
2.3.4 Project Engineering Unit Manager / Section head ( if any, future position)
2.3.5 Inspection Section Head (In case of Stationary Equipment)
2.3.6 Machinery Section Head (In case of Rotary Equipment- future position)
2.3.7 Safety Advisor
2.3.8 Sub SOC (M) Chairman
Information of revised operating conditions should be sent to equipment vendor, supplier or consultancy services to get their
views & concerns.

3. SUBTLE CHANGES

Subtle changes are the changes, which are with in the documented process technology (PSI) but are not replacement in kind. These
subtle changes must be reviewed and authorized BY Sub-SOC (M) chairman . These changes will be considered ‘permanent’ and will
not be reverted as in the case of ‘Temporary Repairs’. For example:
Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 6 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 6 / 15 Area: Maintenance

3.1 Replacement of different brand bearing but of same type

3.2 Replacement of gasket type ( to higher grade)
3.3 Installation of a higher grade piping in place of existing system
3.4 Relocation/extension of drains/sample points (without modification in the main tie-in point)
3.5 Replacement of type of valves on drain lines
3.6 Change of material towards a better metallurgy (of pipes, valves etc.)
3.7 Adjustment / extension of monkey ladder / support structure, to improve accessibility
3.8 Modifications/simple changes in non-load bearing structural members
3.9 Gusseting/reinforcement pads/supports modification on small bore (non-SC) piping
3.10 Change of orientation of valve hand wheels (either for ease of operation or to prevent falling of gate incase of valves on PSVs
or PSDs)
3.11 Rerouting of steam tracing
3.12 Any change in replacement of turning machines and mobile equipment spares other than original OEM supply
3.13 Change in grinder wheels of pedestal grinders
3.14 Other miscellaneous small scaled changes on the discretion of concerned .Maintenance Group Leader
Items that do not come under the scope of Subtle Change are:
3.15 Change in P&ID
3.16 Change in Process Specification or Engineering Package (Mechanical)
3.17 Change that requires WPS / PQR preparation
3.18 Any change in Safety Critical Equipment / Business Critical Equipment / High Hazardous Process as defined in PSI package
3.19 Any change for which a JSA is required
* Incase of doubt in defining a subtle change, Safety Adviser can be consulted.
The minimum requirement for preparation and completion of package shall include following in addition to general requirements given
in PSRM / SOP / 05, Section 11.1 Change Process Requirements:
1. Stock card changes for vendor / supplier address
2. Update list of parts on (CMMS) Maximo
4. TEMPORARY CHANGE

4.1 Temporary changes may cause a number of catastrophes over the years, therefore, these changes shall be documented so that
they are distinguished from repairs or permanent changes. Temporary changes are subject to the management of change process. In
addition, the management of change procedures is used to insure that the equipment and procedures are returned to their original or
designed conditions at the end of the temporary change. It is important that a time limit for temporary changes be established and
monitored since, without control, these changes may tend to become permanent.

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 7 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 7 / 15 Area: Maintenance

Examples of Temporary changes are:

1. Box up of leaks
2. Temporary bypass lines.
3. Equipment replacement or repair using non-conforming spares
4. Machinery adjustment or repair where there is deviation from standards.
5. Flushing of lines with a media not specified in the procedure.
6. Flushing of lines with temporary connections which are not covered through the procedure.
7. Installation of temporary winch or lift.

Note: All the temporary changes / test runs which are complex, that is, involve more than two control systems integration / networking
should be considered through Sub- SOC forum.

At times in emergency situations, temporary changes are necessary to keep the process continued. The minimum requirement for
preparation and completion of package shall include following. Also see Section 11 of PSRM / SP / 05, Management of Change
Process.

a. A time limit shall be set to remove this temporary change which shall not be exceeded.
b. Temporary repairs shall be stewarded by Inspection Section or Planning Unit Manager / Section Head ( future position) or by the
designate as nominated by Technical / Maintenance Manager, to ensure that all elements have been completed.
c. All the temporary repairs shall also be stewarded in Safe Operations Committee (SOC) by Inspection Section including I & E
related.
d. Extension of the estimated date of removal may be made only after re-evaluation and approval by the Operations Unit Manager
or the SOC Chairman.
e. Temporary changes must be removed from service (decommissioned and dismantled) when the active date expires.

4.1 APPROVING FORUMS / AUTHORITIES

The minimum team for review of temporary change is as follows:
4.1.1 Peer Review (Review of Engineering, Design, and Inherent Safety, at least by one relevant supervisor or Engineer)
4.1.2 Concerned Unit Operations Unit Manager
4.1.3 Concerned Unit Maintenance Manager / Section Head
4.1.4 Process Engineering Unit Manager (Relevant Area), if required.
4.1.5 Inspection Section Head (In case of Stationary Equipment)
4.1.6 Machinery Section Head (In case of Rotary Equipment- a future position)
4.1.7 Safety Engineer / Supervisor
4.1.8 Sub SOC (M) Chairman
5. TEST RUNS / AUTHORIZATION (TA)

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 8 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 8 / 15 Area: Maintenance

Test runs may be required at times to ensure a particular phenomena or reason, troubleshooting, to establish increased production
rates etc. Test runs must be prepared to provide operating guidance for the following situations:
5.1 The plant is to be operated outside of authorized limits, as detailed in the equipment procedures.
5.2 Any fundamental changes in procedure must be documented, such as adding or eliminating process materials or equipment.
5.3 The equipment is to be operated with some change in manufacturer recommended spares.
5.4 Startup of new or altered, facilities with different procedures, hardware, instrumentation or operating conditions than existing
facilities
5.5 Troubleshooting
5.6 Establish the envisaged production rates for future modifications.
6. DOCUMENT CHANGE

All documents and procedures shall be controlled and kept evergreen. It includes changes, revisions, additions or deletions to
controlled documentation and databases.
Examples of controlled documentation and database include, but are not limited to those listed below:
6.1 Mechanical Administrative Procedures
6.2 Mechanical Work Procedures
6.3 Area Maintenance Management Manuals
6.4 Job Plans
6.5 Area Specific SOPs
6.6 Centralized Maintenance Management System (CMMS) technical database
6.7 Fixed equipment and machinery reliability program documentation
The minimum requirement for preparation and completion of package shall include following in addition to general requirements
Update of procedures on all the controlled copies (both hard and electronic copies) by relevant sections. Update of job plans on
CMMS where applicable

7. APPROVING FORUMS / AUTHORITIES

Document Change recommended minimum review team:
7.1 Area Supervisor (Peer Review)
7.2 Area Unit Manager
7.3 Maintenance Manager

8 TRAINING REQUIREMENTS

Employees, whose job tasks will be affected by any type of change, shall be informed of, and trained on the said change before the
formal implementation.

8.1 TRAINING ON CHANGE

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 9 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 9 / 15 Area: Maintenance

Training for specific changes, as identified in the evaluation or review process, shall be provided to the personnel affected with in
30 days. It also covers training on change in procedures or documentation i.e. Mechanical Procedures, Job Plans or other SOPs
thru D-Level meetings & other forums

8.2 TRAINING DOCUMENTATION

All trainings shall be documented to ensure up to date skill level of relevant employees.
9. RESPONSIBILITIES

EPCL Plant personnel (Tier 2,3 &4)) EPCL Employees are responsible for identifying changes to the facility. As appropriate,
they shall also report changes, or initiate a Job Request prior to proceeding with a change.

9.1 CHANGE CUSTODIAN

9.1.1 All relevant sections to retain the change records in respective equipment file
9.1.2 Inspection Section to record and steward changes related to equipment (less subtle change) in SOC.
9.1.3 Machinery to record and steward changes related to rotary equipment (less subtle change) in SOC.
9.1.4 Inspection or Planning Section ( future position ) to consolidate and steward all types of changes implemented in
Maintenance department.

10. EXEMPTIONS

Changes that do not require the application of this system include:

8.1 Maintenance repairs and activities which are “repair or replacement in-kind”
8.2 Routine maintenance activities as part of “Preventive and Predictive Maintenance Plans”
8.3 Standard inspections and overhauls during plant turnarounds.
8.4 Temporary installations such as air or water connections as required by operations to facilitate process requirement.

Note: Temporary installations must be removed from service (decommissioned and dismantled) when the procedure has been
completed.
11. REFERENCES

1. PSRM/ 04 & 08 Management of Change/ Subtle change -Level-2 procedure

12. ATTACHMENTS

 Attachment 01 Temporary Repair Document/ Checklist

 Attachment 02 Temporary Modification Document
 Attachment 03 Subtle Change Document

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 10 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 10 / 15 Area: Maintenance

-------------------------------------------------------------------------------------END---------------------------------------------------------------------------------------------------

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 11 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 11 / 15 Area: Maintenance

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 12 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 12 / 15 Area: Maintenance

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 13 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 13 / 15 Area: Maintenance

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 14 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 14 / 15 Area: Maintenance

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi
 Revision Date 01/24/06/2013
Document No. MP-AP-10
Issue No. / Date 04/15/10/2012
Rev No 00
Maintenance Department Manual MANAGEMENT OF Effective Date
Page No.
30/06/2013
Page 15 of 1
EPCL Manufacturing Division
CHANGE Prepared by: SUM

Unit / Section: Maintenance

Department : Maintenance Page No: 15 / 15 Area: Maintenance

Prepared by: SUM Reviewed by: Aneeq Ahmed Approved by: Shahzad Nabi