OISD 150 Fired Heater
Inspection Checklist (Excel)

OISD 150 (Inspection of Fired Heaters and Process Furnaces) is the Oil Industry Safety Directorate standard governing inspection and integrity management of fired equipment in Indian petroleum installations under MoPNG (Ministry of Petroleum and Natural Gas) jurisdiction. It applies to process heaters, fired boilers, hydrogen reformers, steam generators, catalytic cracker regenerators, and similar fired equipment in refineries, petrochemical plants, and gas processing facilities. Compliance is mandatory and audited during MoPNG inspections and statutory safety reviews. The standard prescribes inspection frequencies, acceptance criteria, and integrity tests for tubes, refractory, burners, and convection sections.

An OISD 150 inspection record needs the OISD clause reference, heater type and tag, inspection category (external visual, internal, refractory, tubes, burners, convection, stack, instrumentation, safety devices), inspection frequency (daily round, monthly, annual, turnaround), observed condition versus OISD acceptance criteria, defect description with severity, tube metal temperature readings, refractory hot spot survey reference, recommended corrective action, responsible discipline, target closure date, and closure evidence. The checklist also cross-references HAZOP actions, MoC items, and turnaround workpacks. See the OISD 150 standard reference.

Pathnovo, an engineering document intelligence platform, auto-audits an OISD 150 fired heater inspection cycle by ingesting the heater datasheet, P&ID, last inspection report, TMT survey, refractory hot spot survey, and the turnaround workpack, then mapping every finding against the OISD 150 clause table per heater type. Missing inspections, overdue items, and out-of-tolerance readings are flagged with severity and OISD clause reference. Typical audit cycle drops from 6 to 8 weeks manual to 1 week auto-audited. See the OISD 150 compliance workflow for the Indian petroleum compliance bundle and the OISD standards reference.

OISD 118 (Layout for Oil and Gas Installations) covers layout and inter-distance requirements (where equipment can be placed, Class A / B / C inter-distance, distances to plant boundary and public roads). OISD 150 (Inspection of Fired Heaters and Process Furnaces) covers inspection and integrity management of fired equipment (tubes, refractory, burners, TMT survey, hot spot survey). Both apply to the same Indian petroleum installation and both are audited together by MoPNG. The OISD 118 checklist is the layout-compliance baseline; the OISD 150 checklist is the operating-integrity baseline. See the OISD 118 checklist.

OISD 150 inspection findings are HAZOP-aware. Any tube creep, refractory failure, burner misfire, or stack temperature exceedance flagged during OISD 150 inspection must be cross-referenced to the relevant HAZOP node and may require a new HAZOP recommendation if the failure mode was not previously considered. Any Management of Change that modifies heater duty, fuel mix, burner configuration, or refractory specification must update the OISD 150 inspection plan. The checklist cross-reference column ties findings to HAZOP actions and MoC items. See the HAZOP register template and the HAZOP intelligence solution.

OISD 150 inspection has three cadences. Daily and monthly inspections happen online during normal operation and cover external visual checks, burner condition, stack temperature, and instrumentation. Annual inspections may be partially online and partially during a short shutdown depending on equipment criticality. Major internal inspection of tubes, refractory, and convection section happens during the turnaround shutdown, typically every 4 to 6 years per heater. The OISD 150 inspection plan and the turnaround workpack are tightly coupled. The checklist template supports all three cadences via the inspection frequency column.

OISD 150 findings closed only during a turnaround (tube replacement, refractory rebuild, burner overhaul, convection bank repair) are aggregated into the next-turnaround workpack with full traceability back to the inspection records that triggered them. Pathnovo, an engineering document intelligence platform, auto-generates this aggregation: every Open or In Progress finding with a turnaround-cadence closure is dropped into the workpack with the OISD clause reference, defect description, and recommended scope. This eliminates the manual cross-walk between inspection register and workpack scope. See the Indian EPC compliance bundle.