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Factors PDF
Factors PDF
This Technical Measures Document refers to the maintenance procedures that are necessary
to mitigate a major accident or hazard.
• 5.2.1.3(29)f [4]
• 5.2.4.1 [5]
• 5.2.4.2 [6]
• 5.2.4.4 [7]
General principles
The following aspects should be considered with respect to Maintenance Procedures:
• Human factors;
• Whether proof check periods quoted for safety critical items are adequate to ensure
risks are within acceptable limits;
• Whether the procedures to ensure quoted proof check periods for safety critical items
are adhered to;
• Whether maintenance staff have been sufficiently informed, instructed, trained and
supervised to minimise a potential human failing during maintenance;
• Whether maintenance schedules are managed and regularly inspected and reviewed;
• Whether Human factors (stress, fatigue, shift work, attitude) are addressed;
• Whether sufficient precautions are taken prior to maintenance of hazardous plant and
equipment (isolation, draining, flushing, environmental monitoring, risk assessments,
permits to work, communication, time allotted for the work);
• Whether the maintenance staff are aware of the type of environment they are working
in (flammable, corrosive, explosive, zones 0, 1 & 2);
• Whether the maintenance staff use the correct equipment in the workplace during re-
conditioning, replacement and re-commissioning (static free, intrinsically safe,
flameproof, PPE/RPE);
• Whether procedures are in place to provide detailed operating instructions for re-
commission plant after maintenance, which have been subjected to risk assessments
• Whether sufficient reporting systems are in place so that corrective maintenance can
be applied to mitigate a major accident or hazard.
Major hazards
Major hazards could arise from the following:
• The lack of control of spares such that incorrect materials or items outside
specification (e.g. non-flameproof equipment) are used in replacement of plant items
leading to increased risk of loss of containment, fire or explosion;
• Failure to drain and/or isolate plant prior to dismantling causing release of flammable
or toxic substances;
• HS(G)22 Electrical apparatus for use in potentially explosive atmospheres [9], HSE,
Not in current HSE list.
Paragraph 49 refers to the importance of good engineering practice and a knowledge
of the maintenance history for any electrical apparatus with explosive protection
capabilities.
Paragraph 51 refers to BS 5345 [10] (Code of Practice for the selection, installation and
maintenance of electrical apparatus for use in potentially explosive atmospheres (in 8
parts)) which lists the typical maintenance schedules for each type of electrical
apparatus.
Paragraph 52 refers to a routine checklist that should regularly be applied to any
electrical equipment used in potentially explosive atmospheres.
Paragraph 55 refers to the need to recognise the correct explosive markings on a
piece of electrical equipment so that the correct type of maintenance can be applied.
services in contact with flammable atmospheres (see BS 7430 : 1998 [14] Code of
practice for earthing).
Paragraph 52 refers to the need to not place too much reliance on the use of spark-
resistant tools in flammable areas but to remove all flammable materials before work
is done, if practicable, and the need to keep such tools free of imbedded particles.
Paragraphs 70 – 72 refers to the precautionary steps needed prior to carrying out
maintenance including risk assessing the environment and using a work permit
system.
• LPGA Code of Practice 1. Bulk LPG Storage at Fixed Installations (Part 1, Part 2,
Part 3 and Part 4), LP Gas Association.
• Czachur, K.J., Bright, C.K. and Beic-Kharasani, R., 'Condition Monitoring to Enhance
Safety', HSE Contract Research Report No. 120/1997. ISBN 0 7176 1254 6.
Case studies illustrating the importance of maintenance
procedures
• Associated Octel Company Limited (1/2/1994) [17]