PLANT AND EQUIPMENT
MAINTENANCE
PROCEDURE
CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES/ADMINISTRATION
4.0 DEFINITIONS/RESPONSIBILITY
5.1 POLICY/PROCEDURE
5.2 Maintenance Process Cycle
5.3 Maintenance/Servicing
5.4 Function Testing
5.5 Certification/Calibration
5.6 Competent Third Party
6.0 RECORDS
7.1 APPENDICES/ATTACHMENTS
Appendix 1 - Instructions for Function
Testing:
(a) Notes
(b) Pass Criteria For Manual Or Air Operated Plant
(c) Pass Criteria For Air Operated Tools
(d) Pass Criteria For Diesel Driven
Plant Appendix 2 - Maintenance Process Flow
Appendix 3 - Plant Maintenance Job Card
1.0 PURPOSE
This quality procedure details the systems and methods used to ensure t h a t
the maintenance of all KURUSU plant and equipment is carried out a safe and
i n conforming way.
2.0 SCOPE
This procedure shall apply to all KURUSU plant and equipment.
3.0 REFERENCES
SNL/QC/02 - Base Control and Calibration of Inspection, Measuring
and Test Equipment
Control of Substances Hazardous to Health Regulations, 1999
Electricity at Work Regulations, 1989.
4.0 DEFINITIONS/RESPONSIBILITY
Management Representative - Management representative responsible for the
management of the Company quality, safety and
environmental management systems and
approving the programme of quality/safety audits.
Operations Manager - Responsible for developing and maintaining
the
Material Control System.
- Ensures that the flow of material and equipment
through the Materials Control Department and the
handling and storage thereof is performed in
accordance with approved Quality and Safety
Procedures.
- Ensures that these procedures are reviewed
and updated periodically by liaising with the QA
and Safety Department and that these
procedures are made available to all personnel in
the Materials Control Department.
4.0 DEFINITIONS/RESPONSIBILITY (contd)
Purchasing Manager, Owerri Or Materials Controller Responsible for the daily
operation of Material
Control System.
- Maintain the flow of material and equipment
through the Materials Control Department and
ensure that the handling of storage thereof is
carried out in accordance with approved Quality
and Safety Procedures.
Purchasing Officer (Owerri)
Or Maintenance Team Leader
- Responsible for the daily operation of
the Maintenance Section.
- Ensure that the maintenance of all plant and
equipment is carried out in accordance with
approved Quality and Safety Procedures and
manufacturer's recommendations.
HSEQ Manager - Responsible for ensuring that all relevant Quality
procedures are followed and that the
maintenance system complies with ISO
9002:1994.
- Ensures that Non-Conformance reports are
resolved.
5.1 POLICY/PROCEDURE
5.2 Maintenance Process Cycle
5.2.1 The general process cycle for the maintenance of all plant and equipment through
the Materials and Logistics Department is illustrated on the enclosed flowchart
(see Appendix 3). In Owerri this will be dealt with by the stores.
5.2.2 All materials and equipment shall be processed in accordance with the system
detailed on the flowchart.
5.3 Maintenance/Servicing
5.3.1 The maintenance/servicing of all plant and equipment shall be carried out in
accordance with the Manufacturers' recommendations or otherwise determined by
the Maintenance Team Leader.
5.3.2 Maintenance records (Job Cards) shall be kept on all equipment listed in “Job Card
Plant (Major Equipment)” kept with Maintenance Team Leader, Aberdeen and
Purchasing Officer, Owerri (see Appendix 2). A label identifying status will be
attached to each piece of plant.
All (Minor Equipment) plant not registered in “Job Card Plant (Major
Equipment)” will be recorded separately in respect of general maintenance.
5.3.3 On receipt of the item of plant or equipment by maintenance, an initial inspection
will be carried out, to ascertain the general condition and/or nature of the defect(s).
These will subsequently be entered onto the Plant Maintenance Job Card if
applicable.
5.3.4 The item of plant or equipment will only then be maintained or serviced when it
is next required for a specific project or otherwise agreed.
5.3.5 All spares/materials used and time spent in maintaining/servicing the item of plant
and equipment will be entered onto the Job Card if applicable.
5.3.6 A maintenance manual will be issued to the Purchasing Officer at Owerri and
the Maintenance Team Leader Aberdeen comprising manufacturer's data sheets
on each piece of equipment.
5.4 Function Testing
5.4.1 On completion of the maintenance process all plant and equipment will be function
tested to the satisfaction of the Maintenance Team Leader who will approve the
item for service. A label identifying status will be attached to each piece of plant.
5.4.2 Function testing will be carried out in accordance with the function test instructions
(see Appendix 3).
5.0 POLICY/PROCEDURE (contd)
5.4 Certification/Calibration
5.4.1 All recertification/recalibration of appropriate plant and equipment will be carried
out by approved third party test companies in accordance with the applicable
regulations and at the required intervals.
5.4.2 All items of plant and equipment costing £5000 or over when new, shall be classed
as major.
5.4.3 All Electrical Plant (Major Equipment) requires competent Third Party
Inspection/ Certification at all times prior to mobilisation.
5.4.4 All Lifting Assemblies/Slings require a minimum of 2 months current competent
Third Party Inspection/Certification prior to mobilisation.
5.4.5 All Pressure Vessels require 2 months current competent Third Party Inspection/
Certification prior to mobilisation.
5.4.6 Safety Valves fitted on pressure vessels require 2 months current competent
Inspection/Certification prior to mobilisation.
5.4.7 All Inspections and Certifications above are performed and issued in accordance
with current legislative rules and regulations.
Requirements beyond the above are defined on a project/client adhoc basis.
5.5 Competent Third Party
5.5.1 All electrical maintenance work shall be carried out by a competent third party
in accordance with the Electricity at Work Regulations, 1989.
5.5.2 All breathing air (BA) equipment maintenance shall be carried out by a
competent third party.
6.1 RECORDS
The following shall be treated as ‘Quality Records’ for the purpose of the
KURUSU Management System in line with BSEN ISO 9002:1994 4.16:-
• Records of all maintenance/servicing carried out on major plant
and equipment
• All relevant test certificates, insurance certificates etc for all applicable
plant and equipment
These records will be retained for a period of 3 years.
7.1 APPENDICES/ATTACHMENTS
Appendix 1 - Instructions for Function
Testing:
(a) Notes
(b) Pass Criteria For Manual Or Air Operated Plant
(c) Pass Criteria For Air Operated Tools
(d) Pass Criteria For Diesel Driven Plant
Appendix 2 - Maintenance Process Flow
Appendix 3 - Plant Maintenance Job Card
APPENDIX 1 (a)
INSTRUCTIONS FOR FUNCTION TESTING
NOTES
1. Gauges on KURUSU Machines are for indication purposes only.
2. Paint units are to be function tested with solvent thinners.
Hydraclean, Fire Proofing machines, High Pressure Setting Units are tested with clean water.
All specialist, i.e. Hydracats : Harben Century (Slurry Blast), are tested by operators using product
to be applied/used on site.
APPENDIX 1 (b)
INSTRUCTIONS FOR FUNCTION TESTING
PASS CRITERIA FOR MANUAL OR AIR OPERATED PLANT
1. Machine identification/tag plate legible and secure.
2. Machine safety guards are of correct type and securely fitted.
3. Machine is free from mechanical damage.
4. Hoses/pipes free from mechanical damage or leaks.
5. Confirm all pneumatic connections are correct type and secure.
6. Confirm safety valves regulators and gauges are correct type and secure.
7. Confirm all moving parts are lubricated and functional.
8. Confirm operation of equipment is satisfactory.
9. Confirm maintenance job card is raised on major items.
10. Confirm equipment documentation/certification is complete and available.
APPENDIX 1 (c)
INSTRUCTIONS FOR FUNCTION TESTING
PASS CRITERIA FOR AIR OPERATED TOOLS
1. Machine identification/tag plate legible and secure.
2. Machine safety guards are of correct type and securely fitted.
3. Machine is free from mechanical damage.
4. Hose free from mechanical damage.
5. Confirm all pneumatic connections are correct type and secure.
6. Confirm all filters are in a serviceable condition.
7. Confirm all moving parts are lubricated and functional.
8. Confirm operation of equipment is satisfactory.
9. Confirm equipment documentation/certification is complete and available, if
applicable.
APPENDIX 1 (d)
INSTRUCTIONS FOR FUNCTION TESTING
PASS CRITERIA FOR DIESEL DRIVEN PLANT
1. Machine identification/tag plate legible and secure.
2. Machine safety guards/doors are of correct type and securely fitted.
3. Machine is free from mechanical damage.
4. Confirm spark arrestor of correct type and secure.
5. Confirm machine ESD control operational.
6. Confirm machine is free from leaks, i.e. fuel oil/lube oil/water/exhaust emissions.
7. Confirm operation of equipment is satisfactory.
8. Confirm plant meets all requirements of the site.
9. Skid earthing point fitted.
10. Confirm a job card is raised.
11. Confirm equipment documentation/certification is complete and available.
APPENDIX 2
PLANT MAINTENANCE JOB CARD Card No. :
PLANT DESCRIPTION : WORK CARRIED OUT
IDENTIFICATION NO.
LAST LOCATION :
CONTRACT NO. :
DATE RETURNED :
MANIFEST NO. :
MATERIALS LABOUR
MATERIALS USED QTY VALUE DATE HRS
TOTAL MATERIAL COST TOTAL HRS
APPENDIX 3
EQUIPMENT MAINTENANCE - FLOW CHART
Equipment on Site New Site
Returned to Returned to
Stores/ Consignment Quantities
Logistics Checked
Aberdeen Plant Nos. Recorded
Visual Check
General Condition
and Defects
Transferred to Returned to Stores
Check Test Cert.
Where Applicable
Requisition
Maintenance Spares
Department
Effect
Repairs
Function
Test
Complete
Job
Card
