Maintenance records, review

The main objective of the In-Plant Reliability Data System (IPRDS) was to develop a comprehensive and component-specific data base for PRA and other component reliability-related statistical analysis. Data base personnel visited selected plants and copied all the plant maintenance wor)c requests. They also gathered plant equipment lists and plant drawings and in some cases interviewed plant personnel for Information on component populations and duty cycles. Subsequently, the maintenance records were screened to separate out the cases of corrective maintenance applying to particular components these were reviewed to determine such things as failure modes, severity, and, if possible, failure cause. The data from these reports were encoded into a computerized data base. 

Test demands Periodic equipment testing is an important source of demands, especially for safety system components that are often in a standby state. A review of the test procedures can be performed to obtain this information if it is not recorded in the maintenance records. 

Computerized systems should be included in facility inspections of field sites and analytical laboratories. Items discussed previously, such as computer maintenance records and personnel training records, can be reviewed more thoroughly during the facility inspection. 

Quality assurance (QA) involves (a) review and approval of all procedures related to manufacturing and maintenance, (b) review of records, and... 

Maintenance records Application software documentation Data reproduction accuracy Documented verification of process steps Operator identification Data record review by quality control Electronic record/signature type, use, control, and audit trail... 

A request to lengthen a test frequency may result from a long record of no failed test and good maintenance records. The request is reviewed and documented by the Loss... 

The maintenance group should periodically review the maintenance records for evidence of incipient or recurring failures. Wheu a need for remedial maintenance is identified, either in this review or during preventive maintenance of the plant, the maintenance group should initiate remedial maintenance in accordance with the... 

FoUow the checkhst given below perform the service run preparation process [5,6,10,11]. In addition, the equipment maintenance records provided in Section 4.4 should be reviewed prior to start-up. 

Periodic evaluation of operational experience should be performed, including periodic review and analysis of operations, surveillance, testing and maintenance records and reports. This is to ensure that all data which has been collected will be taken into account during analysis of the safety state of the facility. Also the operation and maintenance procedures should be modified to compensate for changes due to ageing. 

To quantify a fault tree, failure rates are assigned to the basic events at the bottom levels of the tree. The occurrence rates for human error and equipment failure used in the fault trees are based either on information reported in the literature, specific facility or company history, or analyst estimates that combine information supplied by the company (operating procedures, personnel organization and experience, and design information) with information from other sources in the literature. If available, it is best to use site-specific failure data when quantifying the tree. This data is often available from preventive maintenance records or from a review of incident reports. 

C. Review maintenance records and equipment failure investigation reports ... 

For each item considered in this inventory you must estimate the average length of time before the maintenance work becomes reactive rather than preventive or breakdown. Plan to perform the maintenance before the average time. Review maintenance records periodically to understand how much reactive maintenance (repair or replacement of defective parts after failure) has been done. After the record review, make new estimates of average time, and adjust your maintenance timetable accordingly [2]. 

To determine if it is effective, the FMCSA will monitor the company s roadside inspections conducted by trained oflScers. If the company is receiving too many vehicle violations dm-ing roadside inspections, the company may be subjected to an audit. During the audit, the investigator will review the company s maintenance records, and will ask to inspect vehicles that the company has on-site that are considered as being in service. If the maintenance records are found to be inadequate, the company is not adhering to the maintenance schedules that have been established, or the vehicles are not in adequate condition, the company may be fined. 

Records on leased vehicles and owner-operators who were leased must be readily available for review as well. The inspector will ask for general maintenance records, driver vehicle inspection reports (DVIRs) from the past 3 months, and maintenance records from the past year for specific vehicles. Failure to keep minimum records of inspection and vehicle maintenance is a violation. 

Maintenance records should be periodically reviewed for reactive maintenance repair or replacement of defective parts after failure (breakdown maintenance) has been completed. Poor maintenance and poor housekeeping are... 

To be effective, maintenance should be performed on a routine basis and as recommended by the process designer and equipment manufacturers (Safety et al., n.d. Roughton Crutchfield, 2008,2013). Reviewing and comparing the work order list, maintenance records, and inspections/reviews gives a strong indicator about actual facility and operational conditions. 

Once it is determined that data exist, the next step is to begin the collection process. If sufficient thought and training is provided in the development and operation of the maintenance and operating reporting systems, much of the collection process can be automated. Automation assumes that a well-thought-out taxonomy is in place. If this is not the case, then an analyst must collect and review the records manually. In either case, the analyst must collect data from the plant sources previously discussed in order to determine the numerator (number of failures within a unique plant equipment population), and denominator (the operating time or number of demands for the equipment) of the equation to calculate failure rates. 

Sometimes it is necessary to review the narrative in raw data records to determine whether a failure has occurred, to establish failure modes and severities, and to see if a record is a duplicate or new failure. Often, the narrative section is the only way the data analyst can determine if the document, especially a work order, is for a legitimate failure, routine maintenance, or a specified test. 

The records available as a result of leakage surveys and normal maintenance work shall be promptly reviewed for evidence of continuing corrosion. Whenever a buried facility is exposed during normal maintenance or construction activities, a visual examination shall be made of the coating condition and any exposed metal surface. 

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