Document

Title: METHOD STATEMENT FOR EQUIPMENT ROUTINE &

PREVENTIVE MAINTENANCE

Contractor ENG RYPAC LIMITED

Name:
Contractor Contractor P01
Document No: Document Revision

Document Title: METHOD STATEMENT FOR EQUIPMENT ROUTINE & PREVENTIVE MAINTENANCE

SPDC Document Number: TBA

Contract No:

Document No:

Rev Description Date Orig Chk’d App’d

01 Issued for Client Review 06-07-2020 John, O Tony, U Martins,O

Code Description of code Reviewer Discipline MGT

Approved Date
Approved
1 Not Approved

2 Approved Subject To Comments

3 Approved

4 For Information Only

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This is an electronically generated document, which has been reviewed and approved in accordance with the Quality
Management System. An audit trail of review and approval is available within the electronic system. The screen
version of this document is the CONTROLLED COPY at all times. When printed it is considered approved FOR
INFORMATION ONLY copy, and it is the holder’s responsibility that he/she holds the latest valid version. ©, Prime
Sources Limited or a subsidiary thereof, Copyright 2014 and design right reserved. Copying and/or disclosure of the
confidential information contained herein without written permission of the proprietor is prohibited.

REVISION RECORD SHEET

REV Location of Changes Brief Description of Change

P01 Throughout Issued for Client Review

Contractor Document No.: QPDUP-EI-AD-CNS-STD-PSL-000-00003_P01

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Table of Contents

1.0 INTRODUCTION 4

1.1 List of Abreviation 4

1.2 References 4

2.0 ROLES AND RESPONSIBILITY 5

3.0 SCOPE OF WORK 5

4.0 EQUIPMENT AND TOOLS 5

5.0 WORK METHODOLOGY 6

6.0 SAFETY CONSIDERATION 6

7.0 EMERGENCIES 7

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OINTRODUCTION
It details the sequential methodology of safe operations on routine maintenance of
engines and motors (Stationary & Moving)

1.2 LIST OF ABBREVIATIONS AND DEFINITIONS

JSA – Job safety Analysis
CPF– Central Processing Facility
WMS – Work Management System UN Upstream Nigeria
MS – Method Statement
DPM – Diesel Particulate Matter

1.3 REFERENCE
a) SPDC Upstream Safety Manual
b) GBARAN Safe Work Practice Manual
c) Emergency Preparedness & Response Pla
d) GP 04-09-01 Site preparation and earth works

2.0 ROLES AND RESPONSIBILITY

a) Site Supervisor – Coordinate the job and advise the site maintenance of the details
of the work.
b) Site Maintenance Lead – Supervise all routine maintenance on site and ensure
PTW/JSA are available and used for every task.
- Ensure the right tools and equipment are used to execute respective tasks.
- Ensure all damage parts are replaced like –for – like.
c) Safety Officer – Shall ensure adequate safety supervision of site activities and
involved observe all safety precautions to ensure nobody get hurts on site.

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3.0 SCOPE OF WORK

This encompasses the following, but not limited to routine activities on diesel – driven
machines/equipment.

- Daily Inspection Checks.

- Periodic Preventive Maintenance

- Critical Maintenance/Repairs

4.0 EQUIPMENT AND TOOLS INHERENT HAZARDS AND MITIGATION

S/N EQUIPMENT/TOOLS INHERENT HAZARDS MITIGATION

Pinch point between spanner and panel Work cautiously with impact
1 Spanner
wall resistant hand gloves.

Hold the hammer firmly during

Potential impact against hand /or
2 Brass Hammer swing and use impact resistant
fingers
hand gloves.

Work cautiously and use

3 Pliers Pinch point between the clippers
appropriate hand gloves

4 Allen Keys - -

5 Filter Belt - -

- Use ear plug/muff while entering

high noise area.
- High Noise Diesel/Oil spill potential
rotating parts. - Use drip pans to contain spill

- Sharp edges around machine parts
6 Diesel Driven machines
- Electrical Hazards
- Exposure to DPM at the exhaust
- Ensure all rotating parts are with
safety covers and guards
- Use appropriate hand gloves
- Isolate energy before effecting
maintenance of faulty equipment

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5.0 MAINTENANCE METHODOLOGY

The following machines on site shall undergo different maintenance/servicing

depending on the manufacturers requirement and as need arises on site.

S/N EQUIPMENT/MACHINE IDENTIFICATION OTHER MAINTENANCE

DETAILS TYPE
(Routine/Preventive)

1. JBC Generator G175QX 180 KVA Out Both

put

2 Miller DC Welding Big Blue 400P Both

Generator

3 Air Compressor Inger sollran Working Both

Pressure
(14.0 Bar)
Rpm 2600

4 BBA Pumps 21004301,PT150D180 Self – Driven Both

pistol pump
De – Watering Machines max
(Air cool engines) pressure of
20psi

5 Grove Telescopic RT85 – Hydraulic SWL – 45Ton Both

Crane System.

6 Surface water Pump Diesel Engine,KDP30 - Routine

7 Poker Vibrator KAMA, Diesel - Routine

Engine

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5.1 Machine daily Inspection

Checklist for every diesel driven machines are used to check the working condition of
the machine prior to use for work activities.

Basically, what to look out for are oil, water /fuel levels, also battery terminals and fan
belt adjuster (to avoid fan belt pulling out of the pulley which could lead to overheat in
engine top cylinder and perhaps might burn if it doesn’t have heat sensor or emergency
shutdown system.

5.2 Preventive Maintenance

All Nestoil diesel drive equipment shall undergo a periodic maintenance to prevent
unexpected/accidental shutdown according to the manufacturer’s instructions and as
follows:

Diesel – driven Machines/Heavy duty vehicles.

Periodic Maintenance (Every 250 operated hours).

 Change air cleaner

 Change water separator

 Change Fuel & Oil Filter

 Drain off old engine oil

Every 300 operated hours

 Replace radiator coolant except for air cooled machine indicator above.

Every 1000 operated hours

 Flush the fuel tank to remove condemned water, sludge etc.

 Replace spark arrestor

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S/N Routine Checks

Check Oil Level Hazards Control/Mitigation/Measures

a. Assess the machine - -

generally (Visual)

b. Identify Oil - -
compartment area

c. Open the Pinch point from Use appropriate hand gloves

compartment inherent mechanical
through oil filler cap parts/structures
and take the oil level
using the dipstick

Spill potential (oil drips Use rags to clean off oil

from oil dipstick) from dipstick. (Ensure no
open flame or spark
potential task ongoing).

Poor housekeeping Reinstate oil compartment

filler cap and tidy up or the
area.

d. Top up oil level or Spill and fire potentials Use spill absorbent and
change the oil as Over. ensure engine has cooled
deemed necessary. down before pouring or
draining oil.

1 Check water level

a. Identify water - -
compartment

b. Open the Pinch point from Use appropriate hand gloves

compartment and inherent mechanical
visually assess the hazards
water level

c. Top up water level if Water spill around Clean and dry up affected
necessary engine areas immediately

Hot surface if engine Allow radiator to cool down

was running before engaging the cap/lid

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Ensure complete PPE

especially safety goggles in
case of scalding water

Contractor Document No.: QPDUP-EI-AD-CNS-STD-PSL-000-00003_P01

 Title: METHOD STATEMENT FOR EQUIPMENT ROUTINE & PREVENTIVE
3 Check diesel level
a. Assess the level
through the diesel gauge
b. Refuel if diesel level is
below half tank using
manual hand pump
d. Conduct
Housekeeping.
4. Fan Belt Adjustment
a. Assess fan belt for
slackness
b.Use the right size of
spanner to adjust/tension
the fan belt if necessary
PREVENTIVE MAINTENANCE
1 a. Confirm location of
air filter
b. Confirm condition of
air filter using
gauge/indicator at
the top. Red color
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- -
Spill and fire potential Use absorbent and drip pan.
Ensure engine has cooled
down before refueling where
necessary.
Repetitive action of Step back 5x5 at interval
manually handling the
pump handle
Allow engine to cool before
start of work
Hot surface of engine
Tools and spill left over Ensure all spills and tools
around the work area are
carefully removed and the
spill properly wiped off.
- -
Pinch point between the Ensure the engine is not
spanner and the running.
adjuster/pulley
Work cautiously
Use impact resistant hand
gloves
- -
- -
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indicates’ due for

change while white
indicates ‘still okay’

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c. Pull out old air filter Hand could be trapped Ensure engine is not
Manually in engine structures running

Maneuver your hand safely

while changing air filter

d. Insert new air filter Same as above Same as above

2 Change Water Separator

a.Identify the location of - -

water separator

b. Use filter belt to Pinch point between Work cautiously and use
unscrew existing water water separator and appropriate hand gloves
separator from the surrounding engine
housing structures

c. Install new water Same as above Same as above

separator (Like – for –
like) using filter belt

Change Oil & Fuel Filter

a.Identify location of oil - -

and fuel filters

b. Place absorbent to - -
contain spill

c. Use filter belt to Spill potential Use absorbent to contain

unscrew and remove the and spills
filters Oil splashes to the eyes
Use safety goggles

Change Engine Oil

a. Place drain pan directly - -

under the sum area

b. Place absorbent closed - -

to the engine to contain
spill (ensure engine is not
hot)

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c. Open drain valve (at the Spill potential Ensure drain plan is in place
bottom plate) and drain to contain the spill
out existing oil. Oil Splashes to the eye
Use safety goggles

d. Close drain valve and Same as above Same as above

introduce fresh oil

e. Empty drain pan - -

content into a drum
labeled Waste Oil.

5.3 Critical Maintenance/Repairs

This applies mainly for cranes, self – loaders etc. Example is dropping of boom ram,
outriggers etc. Most of these task will be carried out off QIT facility and any
repairs/replacement of faulty parts will be like – for – like (exactly same specifications)

Minor repairs that could be managed in QIT facility will be carried out at Nestoil oil
Fabrication yard in QIT Process area.

6.0 SAFETY CONSIDERATIONS

This section details the rules and standards, which relate to all employees at the work location,
contractors, visitors and others affected by these works. It is the responsibility of all to obey
these rules and to behave in a safe manner whilst at work. Before beginning the maintenance
operations which includes:

a) Use of adequate appropriate impact resistant hand gloves

b) Use of approved PTW and JSA to work
c) Conduct JSA review meeting
d) Be Proactive on diesel/engine oil spill control during maintenance
e) Watch out for trip and fall hazard and proffer mitigations
f) Always stick to manufacturers safety instructions except otherwise recommended
g) Attached equipment checklist to all approved PTW on site as reference document
h) Establish effective communication among team members
i) Ensure good housekeeping before, during and after the task

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7.0 EMERGENCIES

All lifting operations must cease immediately in the event of of any emergency alarm
signal

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Contractor Document No.: QPDUP-EI-AD-CNS-STD-PSL-000-00003_P01