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MAINTENANCE MANAGEMENT SYSTEM


Guideline for Maintenance Operating
Procedures

Corrective Maintenance

ABSTRACT

This guideline supports the workflow to perform Corrective Maintenance activities both for deferred
and immediate maintenance.

01 See Revision Sheet F. Fabio E. Trovato R. Vanzini 15 Dec. 06


00 Final Issue Fabio Cadelli Vanzini 19 Dec. 03
REV REASON FOR ISSUE PREPARED VERIFIED APPROVED DATE

Documento riservato di proprietà di Eni S.p.A.- Divisione Exploration & Production. Esso non sarà mostrato a Terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of Eni S.p.A. – Exploration & Production Division. It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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MODIFICATION SHEET

Rev. 01 Revised: “Glossary”, Fig. 2.1.1 “Workflow Map”, paragraph 4.1 “CORRECTIVE
MAINTENANCE WORKFLOW”, paragraph 5 “WORKFLOW STEPS DESCRIPTION”,
paragraph 6 “responsibility matrix summary”, added paragraph 4.5 ”MINOR
CORRECTIVE MAINTENANCE WORKFLOW”, in order to reflect the inclusion of the
“Minor Corrective Maintenance” type.
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FOREWORD

This document is an integral part of the Maintenance Management System.


The Maintenance Management System gives a common framework to be followed by the
Maintenance Management function in the Facilities operated by Exploration & Production (E&P)
Division.
The aim of Maintenance Management System is to optimise the maintenance activities basing on the
philosophy and strategies defined in the Basic Design of the plant during the Concept definition and
to be considered during Development phases of the Project for CMMS selection, implementation,
and go-live.

The presented maintenance flows are described according to the “Guidelines for organisational
charts” [SVI.DMS.GL.0001] and “Guidelines for job description” [SVI.DMS.GL.0002] of the new
Development Projects/Production Fields.

The Maintenance Management System is part of the Technology Management System (TMS).
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TABLE OF CONTENTS

MODIFICATION SHEET............................................................................................................. 2
FOREWORD ............................................................................................................................... 3
ACRONYMS ............................................................................................................................... 5
JOB ACRONYMS ....................................................................................................................... 5
GLOSSARY ................................................................................................................................ 6
KEY TO WORKFLOW ................................................................................................................ 9
1. INTRODUCTION .......................................................................................................... 10
2. GUIDELINE OBJECTIVE AND SCOPE...................................................................... 11
2.1 OBJECTIVES ............................................................................................................... 11
2.2 SCOPE ......................................................................................................................... 13
2.3 APPLICABILITY ........................................................................................................... 13
3. REFERENCES ............................................................................................................. 14
4. WORKFLOW DIAGRAM ............................................................................................. 15
4.1 CORRECTIVE MAINTENANCE WORKFLOW............................................................ 15
4.2 IMMEDIATE MAINTENANCE WORKFLOW ............................................................... 16
4.3 URGENT MAINTENANCE WORKFLOW .................................................................... 17
4.4 NORMAL CORRECTIVE MAINTENANCE WORKFLOW ........................................... 18
4.5 MINOR CORRECTIVE MAINTENANCE WORKFLOW............................................... 19
5. WORKFLOW STEPS DESCRIPTION ......................................................................... 20
6. RESPONSIBILITY MATRIX SUMMARY..................................................................... 22
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ACRONYMS

CBM Condition Based Maintenance


CMMS Computerized Maintenance Management System
DCS Distributed Control System
ICSS Integrated Control and Safety System
IMIS Information Management Integrated System
NA Not Applicable
PM Preventive Maintenance
WO Work Order
WR Work Request

JOB ACRONYMS

CRSV Control Room Supervisor


DMSV Discipline (either Electrical or Instrumentation or Mechanical or
Rotating equipment or Workshop or Jacket, as applicable)
Maintenance Supervisor
EVERY Ditto
EXEC Executors
FPCO Field Production Coordinator
GMG General Manager
HDQT Headquarters supporting structures (Contract Department,
Procurement Department, etc.)
HSEQ HSEQ Superintendent
MESI Maintenance Engineering Superintendent
MESV Maintenance Engineering Supervisor
MOSI Maintenance Operation Superintendent
MPSV Maintenance Planning Supervisor
MRSI Maintenance Reporting & Controlling Superintendent
OFMG Offshore/Onshore Field Manager
OMG Operation Manager
POSI Plant Operations Superintendent
PPSV Power Plant Supervisor
PSMG Production Support Manager
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GLOSSARY

COMPANY: Owner of the facilities (Production Unit(s) or parts of them).


CONTRACTOR: An independent organisation, which supplies services of any kind to Company under
contract award.
Dependability: Collective item used to describe the availability and its influencing factors: reliability,
maintainability and maintenance supportability.
Failure: Termination of the ability of an item to perform a required function.
NOTE1 After failure the item has a fault, which may be complete or partial.
NOTE2 “Failure” is an event, as distinguished from “fault”, which is a state.
Failure cause: The circumstances during design manufacture or use which have led to a failure.
Failure descriptor: Apparent, observed cause of a failure. [ISO 14224:1999(E)]

NOTE: As normally reported into the maintenance management system.


Fault mode: One of the possible states of a faulty item, for a given required function.
Global Maintenance Service Contract assigned to a qualified independent organisation (called
Service (GMS): CONTRACTOR) relevant to maintenance activities executed in any Production Units
owned and operated by COMPANY.
A Global Maintenance Service implies that CONTRACTOR shall execute the Service
autonomously and under complete responsibility, utilising proper managerial and
operative structures and resources.
COMPANY evaluation shall be based on results achieved, without direct intervention
on maintenance management and execution flow.
Item: Any part, component, device subsystem, functional unit, equipment or system that
can be individually considered.
NOTE: A number of items e.g. a population of items, or a sample, may itself be
considered as an item
Maintenance Item: An item that represents a centre of interest from a maintenance point of view, (e.g.
for tracking costs, faults and/or maintenance history).
NOTE: From a maintenance point of view, a Maintenance Item could be intangible (a
maintenance task)
Maintenance: The combination of all technical and administrative actions, intended to retain an
item in, or restore it to, a state in which it can perform a required function
Maintenance The system of information distribution by written or electronic documents addressed
Reporting: to the involved structure suitable for giving the necessary level of knowledge for
taking actions, monitoring, implementing required corrective actions. The reporting
content is the feedback from maintenance activities derived from CMMS output,
screened and organized in order to cover the level of information needed by the
addressees.
Reporting encompasses managerial, technical, economic, administrative matters.
A reporting document shall contain mainly measurable information more than
descriptive details.
NOTE the operative documents, like maintenance plan, work orders, etc. are not
included in document reporting category. They shall be considered working tools or
maintenance records.
Maintenance Management methods used in order to achieve the maintenance objectives
strategy:
Maintenance Preventive The maintenance carried out at predetermined intervals, or
Types Maintenance: according to prescribed criteria and intended to reduce the
probability of failure or the degradation of the functioning of an item
Condition The preventive maintenance based on
Based performance and/or parameter monitoring and the
Maintenance: subsequent actions.
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NOTE: Performance and parameter monitoring


may be scheduled, on request or continuous.
Predetermined Preventive maintenance carried out in accordance
maintenance: with established intervals of time or number of
units of use but without previous condition
investigation.
NOTE: In both cases the meaning of Scheduled
Maintenance has to be intended as: The
preventive maintenance carried out in accordance
with an established time schedule or number of
units of use (strokes, machine hours, cycles, etc)
schedule
Corrective Maintenance carried out after fault recognition and intended to put
Maintenance: an item into a state in which it can perform a required function.
Deferred Corrective maintenance which is not immediately
Maintenance: carried out after a fault detection but is delayed in
accordance with given maintenance rules.
It can be associated to both “Urgent” (Unplanned)
or “Normal” (Planned) Corrective Maintenance.
Immediate Maintenance which is carried out without delay
Maintenance: after a fault has been detected to avoid
unacceptable consequences. It can be associated
to “Emergency” Corrective Maintenance.
Minor A special form of (Corrective) Maintenance that is
Maintenance: defining an activity that is so limited in scope that it
does not require assembly into a work order.
Because of their nature these activities should not
track costs in CMMS.
Extraordinary Combination of all technical, administrative and managerial actions,
Maintenance: intended to ameliorate the dependability of an item, without
changing its required function that have a considerable economic
impact.
Improvement: Combination of all technical, administrative and managerial actions,
intended to ameliorate the dependability of an item, without
changing its required function.
Modification: Combination of all technical, administrative and managerial actions,
intended to change the function of an item.

NOTE 1: Modification does not mean replacement by an equivalent


item.

NOTE 2: Modification is not a maintenance action but has to do with


changing the required function of an item to a new required function.
The changes may have an influence on the dependability or on the
performance of the item, or both.

NOTE 3: Modification may be allocated to the maintenance


organization.
Master data: All data relevant to plants, functional units, and items that allow to perform
maintenance activities.
Production Unit: Profit centre having assigned an autonomous budget and a production target.
The Unit is managed by a nominated Responsible and the structure includes internal
Operation and Maintenance organisation, with assigned targets.
In ENI O&M division, the lower hierarchical level of Production Unit organised as a
profit centre, is the Centrale or Campo (Oil Field), located in offshore or in onshore.
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Work Order: The prime document used by the maintenance function to manage maintenance
tasks. It may include such information as
ƒ required work description
ƒ task priority,
ƒ job procedure to be followed,
ƒ parts, materials, tools and equipment required to complete the job,
ƒ labour hours,
ƒ costs and materials consumed in completing the task, as well as key
information of failure causes, kind of work performed etc.
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KEY TO WORKFLOW

Shape Shape Description

start Stands for the starting point of a workflow.

finish Stands for the ending point of a workflow.

Stands for a node in which more than one flow converge/diverge.

step code job acronym Stands for intellectual or manual process. In the upper-left
corner, the step code is placed, while in the upper right corner
Intellectual or manual
process the job acronym is placed. The box colour of step code and job
acronym depends on the main job involved (see table below).

step code job acronym Stands for a process that could be performed by CMMS means
or by CMMS itself (i.e. WO automatic generation). The box
CMMS process colour of step code and job acronym depends on the main job
involved (see table below).

step code job acronym


Stands for a process that could be performed by means of a
Generic computerized computerized tool (CMMS excluded). The box colour job
process
acronym depends on the main job involved (see table below).

step code
Stands for a macro-process. In the upper-left corner, the subject
macro-process
detailed procedure code is placed, while the upper right corner
is blanketed.

decision Stands for a decision-making process, generally yes/no.

linked
procedure Stands for a reference link to the mentioned procedure.

linked
step
Stands for a reference mark made for the step mentioned within
the on-going procedure.

Colours meaning table


Managerial Position Field Position Support Position

PSMG
GMG OFMG
MRSI
OMG FPCO
HSEQ

Production Maintenance Maintenance Engineering

POSI MOSI MESI


CRSV DMSV MPSV
PPSV EXEC MESV
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1. INTRODUCTION

This document supports a specific element of the Maintenance Management System. The
Maintenance Management System has been developed to provide a comprehensive and
structured set of knowledge and an integrated framework to manage maintenance activities,
thus ensuring effective and efficient use of the Company’s resources.
The set of procedures of Maintenance Management System describes in detail the steps to be
executed in order to perform relevant activities with the eventual support of CMMS.

This document is written as a guideline and therefore represents recommended format and
content rather than a mandatory, prescriptive procedure. Individual projects may deviate from,
or modify the typical contents described here, wherever such deviations are appropriate to fit
in the organizational structure.

This document is managed by O&M Project Team, all the changes of and contributions to this
document will be shared with and validated by O&M Project Team and a new release of this
document will be issued by O&M Project Team.
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2. GUIDELINE OBJECTIVE AND SCOPE

2.1 OBJECTIVES

The main objectives of this guideline are:


• To describe the workflow to perform Corrective Maintenance activities both for deferred and
immediate maintenance.
• To define responsibility, interfaces and methods to be followed in the Corrective
Maintenance application.

On the overall maintenance workflow map, depicted on the next page, this guideline is
represented by the boxes with a bold outline.
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start

Extraordinary
Maintenance
start

Corrective
Work Request
Maintenance
no start

Modifications &
Improvements
Emergency?

no start

Minor Work Order Preventive


Urgent? no maintenance? creation Maintenance

yes

Preventive
Work request for
Work Order Maintenance Work
Minor (corrective)
planning Order auto
Maintenance
generation

yes finish

Work scheduling

yes
Maintenance
strategy review

Urgent Work
Request & Work Work execution
Order creation

“A posteriori” Work Work Order


Work execution Request & Work completion &
Order creation closure

Maintenance Continuous
Reporting improvement

start start

Data base
Maintenance
Master data updating
Budget
management
Management

finish

start start

Global
Maintenance Maintenance
Services Processes

finish finish

Fig. 2.1.1: Workflow Map


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2.2 SCOPE
The scope of the Corrective Maintenance Procedure, described within this document, is to
identify the flow of actions that must be performed after a failure occurrence to reset an item
into service.

The Corrective Maintenance can be split into Deferred Maintenance and Immediate
Maintenance. The Deferred Maintenance can be delayed in accordance with the given
maintenance rules and the Immediate Maintenance is to be understood as emergency
maintenance that is the maintenance to be promptly carried out in case of failures which can
compromise Production, Safety or Environment conditions.

The context of the Corrective Maintenance type, covered by this document, is depicted in the
following figure as bolded blocks:

MAINTENANCE

PREVENTIVE CORRECTIVE
MAINTENANCE MAINTENANCE

CONDITION BASED PREDETERMINED


Deferred Immediate
MAINTENANCE MAINTENANCE

Scheduled,
continuous or on Scheduled
request

Fig. 2.2.1: Maintenance overview

2.3 APPLICABILITY
The procedure described in this document is referred to the production phase of the facilities.

The present procedure shall be applied to any organization (external entity or internal
department) in charge of managing and executing Maintenance activities in any Production
Unit, onshore or offshore, fully owned by ENI E&P division or managed in joint venture with
other partners.

Therefore, this procedure utilizes the organization chart, the job titles and the responsibilities
and duties described for these Production Units in ENI documents: SVI.DMS.GL.0001
“Guideline for Organizational charts” and SVI.DMS.GL.0002 “Guideline for Job Descriptions”.
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3. REFERENCES

Document Code Document Description


SVI.DMS.GL.0001 Guideline for Organizational charts
SVI.DMS.GL.0002 Guideline for Job Descriptions
SVI.TMS.MA.0001.000 TMS Handbook
22000.MAN.GEN.SDS Guideline for Maintenance Operating Procedures – General
Maintenance Processes
22001.MAN.GEN.RWP Guideline for Maintenance Operating Procedures – Master
Data Management
22002.MAN.GEN.RWP Guideline for Maintenance Operating Procedures – Preventive
Maintenance
22003.MAN.GEN.RWP Guideline for Maintenance Operating Procedures – Corrective
Maintenance
22004.MAN.GEN.RWP Guideline for Maintenance Operating Procedures –
Modifications and Improvement
22005.MAN.GEN.RWP Guideline for Maintenance Operating Procedures –
Extraordinary Maintenance
22006.MAN.GEN.RWP Guideline for Maintenance Operating Procedures –
Maintenance Work Management
22007.MAN.GEN.RWP Guideline for Maintenance Operating Procedures –
Maintenance Reporting
22008.MAN.GEN.RWP Guideline for Maintenance Operating Procedures –
Maintenance Budget Management
22009.MAN.GEN.RWP Guideline for Maintenance Operating Procedures – Global
Maintenance Service Management
22010.MAN.GEN.SDS Operations & Maintenance Engineering –Guideline for RCM
Implementation
22011.MAN.GEN.RWP Operations & Maintenance Engineering –RCM Handbook

20666.MAN.GEN.SDS Maintenance Management System – Maintenance Entities


Description.
ISO 14224:1999(E) Petroleum and natural gas industries - Collection and
exchange of reliability and maintenance data of equipment
BS EN 13306:2001 Maintenance Terminology
BS 4778:Section 3.2:1991 / Quality Vocabulary Part 3 Availability, reliability and
IEC 50(191): 1990 maintainability terms
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4. WORKFLOW DIAGRAM

4.1 CORRECTIVE MAINTENANCE WORKFLOW

start

3.01.01 EVERY

Detect a failure or have


information of a failure
event and inform POSI

3.01.02 POSI

Evaluates failure impact


on Safety/Environement

3.02

Corrective Immediate
Is it an emergency? Yes Maintenance
(Emergency)

3.02.01
No
3.03

Corrective
Is it urgent? Yes Deferred Maintenance
(Urgent-Unplanned)

3.03.01
No
3.04

Corrective Deferred
Is it minor? No Maintenance
(Normal-Planned)

3.04.01

3.05

Minor Corrective
Yes Maintenance
(Work Order not required)

3.05.01
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4.2 IMMEDIATE MAINTENANCE WORKFLOW

3.02

3.02.01 POSI

Require immediate
Maintenance to MOSI
and inform FPCO

3.02.02 MOSI

Organizes immediate
maintenance

3.02.03 DMSV

Ensures the execution of


work

3.02.04 DMSV

Informs MOSI/POSI of
performed maintenance
Work

3.02.05 POSI

Creates and Approves an


"a posteriori" Work
Request

3.02.06 POSI Procedure 6


Work
Generates an immediate
(emergency) WO Management
Step 6.04.01

finish
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4.3 URGENT MAINTENANCE WORKFLOW

3.03

3.03.01 CRSV
Create an urgent Work
Request, describing fault
event and requiring
maintenance intervention

3.03.02 POSI
Check completeness of
technical requirement and
fix the required execution
date (within tomorrow)

3.03.03 FPCO

Evaluate and approve the


WR

3.03.04 MPSV
Evaluate the
Maintenance activities to
perform and the
availability of resources

3.03.05 MPSV

Creates and Approves an


urgent WO defining the
DMSV

3.03.06 DMSV
Procedure 6
Ensure the execution of Work
work Management
Step 6.03.02

finish
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4.4 NORMAL CORRECTIVE MAINTENANCE WORKFLOW

3.04

3.04.01 CRSV
Create a Work Request,
describing fault event and
requiring maintenance
intervention

3.04.02 POSI
Check completeness of
technical requirement
and fix the required
execution date

3.04.03 FPCO
Procedure 6
Evaluate and approve the Work
WR Management
Step 6.01.08

finish
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4.5 MINOR CORRECTIVE MAINTENANCE WORKFLOW

3.05

3.05.01 CRSV

Create a Work Request,


describing the minor
maintenance intervention

3.05.02 POSI

Evaluate and Approve


the WR

3.05.03 MOSI

Evaluate the work to be


done and assign to
DMSV the execution

3.05.04 DMSV
MDSV
Ensure the work
execution

3.05.05 DMSV

Sign as complete and


Close the Work Request

finish
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5. WORKFLOW STEPS DESCRIPTION

Workflow
Job title Step description
step code
3.01.01 EVERY Everybody can detect a failure on an item or have information that
a failure occurred; he must communicate the event to POSI.

3.01.02 POSI Evaluates the impact of the detected failure event on safety and
environment and decides the necessity to perform an Immediate
Maintenance or a Deferred Maintenance.

3.02 - Immediate Maintenance is carried out in order to avoid


unacceptable consequences.

3.02.01 POSI POSI informs FPCO and MOSI of the severity of the detected
failure and the necessity to perform an immediate corrective
maintenance.

3.02.02 MOSI MOSI activates the discipline maintenance supervisors (DMSV) in


order to execute immediate maintenance.

3.02.03 DMSV Supervises maintenance operators for pertaining discipline and


assures the execution of the work.

3.02.04 DMSV Informs MOSI and POSI of the work feedback and worked hours
including all maintenance and failure details and the use of
outsourcing man-hours and costs.

3.02.05 POSI POSI creates an “a posteriori”” work request into CMMS, defining
the failed item and approves the request.

3.02.06 POSI POSI creates an immediate work order into CMMS and continue
with the Step 6.04.01.

3.03 - Urgent Work Requesting: Urgent Maintenance is not immediately


carried out after fault detection but it has to be performed within
tomorrow.

3.03.01 CRSV Creates an urgent Work Request, describing fault event and
requiring maintenance intervention.

3.03.02 POSI Checks completeness of technical requirement and fixes the


required execution date (within tomorrow).

3.03.03 FPCO FPCO evaluates the work request and approves it into CMMS.

3.03.04 MPSV MPSV evaluates the maintenance activities to perform and the
availability of resources.

3.03.05 MPSV MPSV creates and approves an urgent Work Order defining the
DMSV.

3.03.06 DMSV Supervises maintenance operators for pertaining discipline and


assures the execution of the work.

3.04 Corrective Maintenance Work Requesting: the work must be


planned:

3.04.01 CRSV CRSV creates a Work Request, describing the fault event and
requiring maintenance intervention.

3.04.02 POSI POSI Checks completeness of technical requirement and fixes the
required execution date.
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Workflow
Job title Step description
step code
3.04.03 FPCO evaluates the work request and approves it into CMMS.

3.05 Minor (Corrective) Maintenance Work Requesting: the work must


not be planned.

3.05.01 CRSV CRSV creates a Work Request, describing the minor maintenance
intervention.

3.05.02 POSI POSI evaluates the work request, in particular the fitting of the
maintenance type, and approves it into CMMS.

3.05.03 MOSI MOSI evaluates the work to be done and assign to DMSV the
execution.

3.05.04 DMSV DMSV assures the execution of the work.

3.05.05 DMSV DMSV signs as complete and closes the Work Request into
CMMS:
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6. RESPONSIBILITY MATRIX SUMMARY


Workflow

EVERY

PSMG
DMSV
MPSV
MESV

CRSV

FPCO
EXEC

PPSV
MOSI

MRSI
MESI

POSI
code
step

Step description

3.01 Detect a fault or have information of a fault event x


3.02 Evaluates Fault impact on Safety/Environment x
3.02 Immediate maintenance
3.02.01 Informs FPCO and MOSI and requires maintenance execution x
3.02.02 Organizes immediate maintenance x
3.02.03 Ensures the execution of work x
3.02.05 Informs MOSI/POSI of performed maintenance details x
3.02.06 Create and Approve an “a posteriori” Work Request x
3.02.06 Generate an immediate (emergency) WO. x
3.03 Urgent maintenance
Create an urgent Work Request, describing fault event and requiring
3.03.01 x
maintenance intervention
Check completeness of technical requirement and fix the required
3.03.02 x
execution date (within tomorrow)
3.03.03 Evaluate and Approve Work Request x
3.03.04 Evaluate the type of maintenance and the availability of resources x
3.03.05 Create and approve an urgent WO defining the DMSV. x
3.03.06 Ensure the execution of work x
3.04 Planned (Corrective) Maintenance
Create a Work Request, describing fault event and requiring
3.04.01 x
maintenance intervention
Check completeness of technical requirement and fix the required
3.04.02 x
execution date.
3.04.03 Evaluate and approve the WR x
3.05 Minor (Corrective) Maintenance
3.05.01 Create a WR describing the minor maintenance intervention. x
3.05.02 Evaluate and approve the WR x
3.05.03 Evaluate the work to be done and assign to DMSV the execution. x
3.05.04 Ensure the work execution x
3.05.05 Sign as complete and close the Work Request x

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