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Maintenance
This ebook describes the topic of process safety maintenance, where the term maintenance refers to repairing equipment that has failed, either totally or partially, and preventive actions taken prior to equipment failure.
Maintenance activities exclude upgrades and changes to the system — they are to do only with “replacements in kind”. If new types of equipment or instrumentation are to be installed then these activities should be handled through the facility’s Management of Change (MOC) program. Even larger changes constitute stand-alone projects in their own right.
Maintenance work frequently involves potential contact with sources of high energy such as electricity, process fluids at high temperature and pressure or toxic and flammable materials.
Table of Contents
Introduction
Regulations and Standards
Maintenance Management System (MMS)
Types of Maintenance
Repair Maintenance
Condition-Based Maintenance
Scheduled Maintenance
Reliability-Centered Maintenance
Procurement
Spare Parts
Documentation
Factory Acceptance Tests (FAT)
Maintenance Task Organization
Step 1 — Plan the Work
Step 2 — Conduct a Job Hazards Analysis
Step 3 — Prepare / Issue a Work Permit
Step 4 — Shutdown and Isolate Equipment
Step 5 — First Break
Step 6 — Perform the Work
Step 7 — Close Out the Work
Step 8 — Handover to Operations
Equipment Check
Inspected, Tested, and Documented
System Completion
Operational Readiness/Prestartup Safety Review
Pressure Tests
Testing Procedure
Installing Blinds
Test Medium
Hydrostatic / Liquid Test
Pneumatic / Gas
Tightness Test
Strength Test
Pressure Test Manual
Records
On-Line Cleaning and Repair
Corrosion
Cathodic Protection
Corrosion under Insulation
CO2 Corrosion
Sulfide Stress Cracking
Controlling Corrosion
Simultaneous Operations (SIMOPs)
Managing SIMOPs
SIMOPS Matrix
Conducting SIMOPs
Kickoff Meeting
Communication Meetings
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