Maintenance work equipment

Shutdown. Written procedures for normal, as well as for emergency, shutdowns should be prepared, rehearsed, and kept up-to-date. Operating supervisors must be responsible for leaving the process equipment in a safe condition or preparing plant equipment for maintenance work. 

Internal personnel will normally undertake boiler plant operation. Maintenance work may be by either internal personnel or outside contractors. Service contracts will be available from equipment suppliers covering all items of the boiler plant. Recently, companies have started offering contract energy-management schemes. These may be designed to suit individual applications and will be tailored to customer requirements. They may take over the operation of an existing plant or, if necessary, include for a new replacement plant. They will usually operate over a 3-10-year contract period. Dependent upon the terms of contract, all fuels, electricity, repairs and replacements may be covered. 

Week task forms should only require amending when either additional plant and equipment is introduced or the frequency of planned maintenance tasks is being adjusted to meet revised operational or maintenance demands. Departments in which work is to be carried out may be issued a copy of their department s week tasks four weeks in advance. This then enables them to program their operation, where necessary, so that the maintenance work can be carried out without disruption to the department s output. Alternatively, on receipt of this prior notice the departmental head can contact the engineer controlling the work to discuss departmental matters that may affect the proposed planned maintenance. This may, in some instances, require the engineer to reschedule the planned maintenance programmed for that department. 

Shutdown work request log When the planning department receives a shutdown work order, it is immediately recorded in the shutdown work request log. The maintenance clerk should verify that the item number assigned agrees with the next sequential number on the maintenance work order log. Work requests forwarded to shutdown planning should indicate equipment number and... 

Maintenance embraces regular inspection, periodic examination by competent persons , and repairs. All maintenance on equipment used with chemicals should be properly planned and recorded. Maintenance operations, particularly those which are non-routine, require a sound system of work with strict administrative procedures, e.g. permit-to-work, to avoid risks arising from modifications to established safe practices. A permit-to-work should be used wherever the method by which a job is done is likely to be critical to the safety of the workers involved, nearby workers, or the public it is required whenever the safeguards provided in normal operations are no longer available. Examples include ... 

Each vault housing a pressure-limiting, pressure-relief, or pressure-regulating station shall be examined to determine its condition each time the equipment is examined and tested in accordance with para. GR-5.23.3. For any vault which personnel enter, the atmosphere shall be tested for combustible gas. If the atmosphere is hazardous, the cause shall be determined. The vault shall be examined for adequate ventilation. The condition of the vault covers shall be carefully examined for hazards. Unsatisfactory conditions disclosed shall be corrected. No welding maybe done if a combustible gas mixture is present. Maintenance work performed in the vault shall be in accordance with procedures developed per para. GR-5.23.3, with particular consideration given to the monitoring of the atmosphere and safety protection for personnel in the vault. 

The ERP should identify equipment that can obviate or significantly lessen the impact of terrorist attacks or other intentional actions on the public health and protect the safety and supply of communities and individuals. The chemical facility should maintain an updated inventory of current equipment and repair parts for normal maintenance work. 

Train the engineering staff on the revised standard Periodically review the design of equipment carrying this material to ensure that the proper gaskets are being specified Review maintenance work orders to determine the number of gasket replacements that are performed as a result of the inappropriate gasket materials... 

Maintenance. Good plant maintenance (qv) obviates the crash shutdowns that could follow failure of critical components. Maintenance in the chemical industry differs from that in other industries because of the nature of the materials, processes, and types of equipment used. Because much chemical work involves the movement of fluids, gases, and powdered solids from one piece of equipment to another, many pipelines (qv), conveyors, forklift tmcks, and other material-handling devices are used. Containers are more likely to be tanks, drums, or some form of closed container than in other industries. Prior to maintenance inside equipment, all lines and equipment containing hazardous materials should be effectively separated, disconnected, blanked, or purged in order to minimize the possibility of release of harmful materials. Maintenance personnel must make sure that all equipment and piping is so prepared. 

Specific procedures should be developed and implemented for equipment and facility maintenance. Where feasible, tools should be dedicated for the area. Follow equipment cleaning and decontamination procedures prior to performing maintenance work... 

Process Control. The objective is to eliminate or minimise risks to people whilst carrying out their daily tasks in their working environment. For example by having performance standards for all laboratory operations and the maintenance of equipment. 

Many of the problems involved in maintenance are often caused by a lack of thoroughly evaluating the original design and layout of plant and equipment. Sufficient space for maintenance work on equipment and facilities must be provided in the plant layout, and the engineer needs to consider maintenance and its safety requirements when making decisions on equipment. 

If the repair is successful, no further work is necessary. If unsuccessful, a maintenance work order is written for craftsmen to make a second repair attempt within a prescheduled time, usually 15 days. If the second repair is successful, no further work is necessary. If the component cannot be repaired while the equip-... 

Percentage of preventive maintenance work orders for emergency response equipment that are past due X ... 

None of preventive maintenance planning models considers constraints on resources available in process plants, which include labor and materials (spare parts). For example, the maintenance work force, which is usually limited, cannot perform scheduled PM tasks for some equipments at scheduled PM time because of the need to repair other failed equipments. Such dynamic situations can not be handled by deterministic maintenance planning models or are not considered in published maintenance planning models that use Monte Carlo simulation tools. 

Note These figures are averages over several years for reliable equipment in mild to moderate service. Older equipment, severe service, aggressive ambient conditions, and similar factors can raise these estimates significantly. These figures are based on trained and experienced persoimel. New or untrained persoimel typically require two to three times the maintenance-work time shown. 

There should be periodic requalification, as well as requalification after changes (such as changes to utilities, systems, equipment maintenance work and movement). (See also point 5.2.5 above and section 12 below.)... 

The manufacturer s specifications, past experience, and history of the equipment will be used to establish the preventive maintenance schedule. Procedures will be developed for issuing work orders, performing the maintenance work, documenting the work in the proper logbooks and hies, frequency of performing preventive maintenance, reviewing the impact of maintenance on validation state, etc. 

Finally, the humid, tropical Johnston Island climate corroded parts of the JACADS building and equipment. For example, exterior steel support beams, pipes, and pipe supports rusted and required frequent repainting, and some pipe supports had to be replaced. Also, corrosion caused significant deterioration of exterior valves, instrumentation, and electrical function boxes. Army officials stated that, because they had underestimated how corrosive the environment would be on Johnston Island, they had not initially used appropriate corrosion protection materials. To correct the corrosion problems, the Army now uses corrosion-resistant paints and fiberglass equipment covers. Also, the Army hired additional maintenance personnel to perform preventive maintenance work on the building areas and equipment most susceptible to corrosion. 

Arrange for repairs and maintenance of equipment and fixtures Monitor progress of ordered work Select and order goods and services Communication... 

When equipment maintenance is carried out within the dean area dean instruments and tools should be used, and the area should be deaned and disinfected where appropriate before processing recommences, if the required standards of deanliness and/or asepsis have not been maintained during the maintenance work. 

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