Operations Controlled Document

MAINTENANCE

WORK INSTRUCTION

STANDARDRev 1

MAINTENANCE

WORK INSTRUCTION

STANDARDRev 0

OPERATIONS CONTROLLED DOCUMENT

MAINTENANCE

WORK INSTRUCTION

STANDARD

Document No: Custodian: O-64

Supersedes

Revision no:

Date:Revision no:

Date: Filename: MWI standard

Administered by:

F.C. HartDate: 20/01/03Verified: Date:O-10

Verified: Date:

Approved: Date:O-1O-1D

Approved: Date:

Reason for revision: newly developed standard

Content

31.Introduction

2.Objectives33.MWI34.Authorities35.Maintenance Work Instruction Definition36.Maintenance Work Instruction Numbering Structure47.MWI Custodians58.MWI Initiation68.1Internal68.2Projects78.3MWI Reference Sheets79.MWI Presentation99.1Identification99.1.1MWI categorisation109.2Work Preparation109.3Work Close Out119.4Work Instructions119.4.1Failure mode References119.5Static Work Instructions129.5.1Static Work Preparation129.5.2Static Work Instructions1210.Template1311.Dos & Donts1312.Nomenclature14

1. IntroductionAsset integrity and HSE is managed through the rigorous application of documents such as Standards and Procedures. This portfolio of documents needs to be controlled in order to ensure that it meets the Companys requirements throughout the lifecycle of its facilities. Work Instructions are Controlled Documents and this document sets the Standard for Maintenance Work Instructions, numbering and layout.

2. Objectives

The objectives of this Standard are to:

provide a common structure for the generation of Maintenance Work Instructions (MWIs)

specify the actions required to allow an MWI to be initiated, deleted, amended and recorded in the Global Maintenance Management System (G.M.M.S) and who is responsible for these actions

to facilitate central storage on an Electronic Document Management System (E.D.M.S) or equivalent (i.e. Fileserver)

to facilitate the management of MWIs

3. MWIMaintenance Work Instructions determine what activity needs to be executed and how often according to the relevant Equipment Maintenance Strategy. They refer, where appropriate, to SUCO Work Procedures, -Checksheets or vendor manuals that describe in detail how the activity should be carried out. These work procedures should therefore be accessible, its content kept up to date, and they should comply at any time with the cross-references in the MWI.

4. Authorities

a) Maintenance Work Instructions are verified by the respective discipline Engineer in accordance with Section 7 of this Standard.

b) Maintenance Work Instructions are approved at Department Head level (O-1, O-1D).5. Maintenance Work Instruction Definition

A Maintenance Work Instruction is a document that defines the detailed technical Maintenance requirements and the frequency of their execution.

Custodian for MWIs is O-10. MWIs are mandatory documents.

6. Maintenance Work Instruction Numbering Structure

Document unique numbering code: XXX.X.XXX.XXXSerial Number: 001 - 999

Maintenance interval in Weeks Last digit onlyMaintenance interval in MonthsFirst two digits only

Subject code:

The characters in this field identify the responsible discipline

- Mechanical.

M

- Instrument

I

- Electrical

E

- Static

S

- Condition MonitoringC

Equipment group Code

a) -

6.1 MWI numberingThe MWI shall be uniquely numbered according to the document numbering structure as shown in Section 6 above. Based on this numbering structure, all Maintenance Work Instructions start with a 3 digit Equipment group code, followed by a letter denoting the responsible discipline, followed by 3 digits of which the first two denote the maintenance interval in months and the third denote the maintenance interval in weeks, followed by a 3 digit unique sequential serial number. Maintenance Work Instructions code identifying the MWI responsible discipline is thus as follows: xxx.M.xxx.xxx for Mechanical MWIs

xxx.I.xxx.xxx for Instruments MWIs

xxx.E.xxx.xxx for Electrical MWIs

xxx.S.xxx.xxx for Static (Inspection) MWIs

xxx.C.xxx.xxx for Condition Monitoring MWIs

MWI serial numbers are issued by the focalpoint for RB MWIs, currently O-64 Maintenance Control Section. The existing MWIs will be transferred to the Global Maintenance Management System (GMMS)

7. MWI Custodians

The department responsible for Maintenance (O-10) shall appoint a custodian for MWIs per discipline (I, E, M, S & C). These MWI custodians shall have at least the following responsibilities: verify by signature on new or revised MWIs that their content is in accordance with the relevant equipment maintenance strategy and complies with this Standard have the MWI approved and signed by the appropriate authority (O-10) before it is officially issued

manage a hard copy master file of signed MWI originals

hold electronic versions (and back-ups thereof) of approved MWIs

ensure transfer of electronic versions onto the fileserver (or equivalent, such as GMS) where appropriate

ensure that only those MWIs that are in his controlled portfolio, under his management, are active

disseminate the content of this Standard (and that of those Controlled Documents that are related to MWIs, such as the MWI Change procedure) among the users and potential originators of MWIs within his discipline

be the custodian of spare parts lists and spare part kit lists for his discipline

be the custodian of lubricant specifications and applications (Mechanical)

be the custodian of trip & alarm setpoint Check Sheets for his discipline

8. MWI Initiation

8.1 Internal

b) Field initiated new MWIs or changes to an existing MWI are submitted to O-10 via the appropriate Area Maintenance Manager. It is subsequently sent to Cairo for registration and further processing to O-10.c) The MWI shall be accompanied by some or all of the following information where appropriate:

Justification for initiation or change with background information

Supporting history failure data, i.e. from the GMS, to allow the appropriate type of maintenance instruction and its interval to be determined

Spares and materials consumption

Workshop /repair reports

Copy of the text of the original MWI where applicable

Proposed text change, interval change etc. where applicable

Copy of the relevant pages of the associated RCM analysis if one has been carried out on the equipment in question

Copies of relevant parts of P&IDs

Description of changes in operating context

Plant Change Proposal data and documentation

Product deferment figures

Vendor Documentation

Changes to ECR register i.e. redundant/removed equipment

The number of the MWI(s) that need to be amended or superseded (removed from the system)

Any other documentation and/or data that will assist in the analysis of the MWI (change) request and that will facilitate a short processing time

d) Following receipt of MWI, the appropriate discipline Engineer shall review the request, carry out the appropriate analysis (such as RBI and RCM) and, if accepted, issue a new/revised MWI in accordance with this Standard.

e) The discipline Engineer shall identify other similar MWIs that may be effected by the change and to ensure there is no duplication of MWIs.

f) If the MWI (change) request is rejected, a copy MWI Form is returned to the originator, following registration by O-10 of its status, advising the originator of the reason for rejection.

g) If accepted and processed, a copy of the MWI will be returned to its originator, following registration by O-10 of its status, with the relevant advice and/or copies of the deliverables and follow-up actions.

h) The discipline engineer shall discuss the deliverables with its originator and request the Area Planner in the field to update the GMS with the new/revised MWI or associated job file. The discipline Engineer shall, in the latter case, transfer the MWI to the Fileserver for central storage and access. The Planner shall ensure that the GMS Asset Register and Planning Module are updated (with i.e. set points, start dates and maintenance interval). The discipline Engineer shall maintain paper copies of MWIs and other relevant information such as Check Sheets, Spare parts kit lists, and this portfolio shall be kept up to date. Superseded MWIs shall be removed from the GMS, paper-copy portfolio and/or Fileserver.

i) The original Service Request Form will be archived with its conclusions, recommendations or advice by O-10.

8.2 Projects

New, project initiated MWIs shall be accompanied by MWI reference sheets (see Section 8.3) and shall be reviewed by the appropriate discipline Engineer as part of the overall project documentation review process, as defined in the Operations/Engineering project deliverables agreement. The data contained by the MWI reference sheets shall be loaded in the GMS. The MWIs and their reference sheets shall be delivered to Operations in electronic form (MsWord) as part of the project handover documentation.

8.3 MWI Reference Sheets

a) An MWI is invoked by the GMS through a Workorder of which a copy is shown on page 17 of this Standard. The Workorder is produced by the GMS. It links the MWI to: a specific equipment TAG number(s)

associated equipment time planning information, such as maintenance interval (frequency) and specific start date

total discipline resources required to carry out the work

auxiliary resources required to carry out the work, such as for scaffolding

Check Sheets (such as for checking trip & alarm set points and for Operator checks)

other MWIs that should be executed concurrently

b) Reference sheets that identify these links shall therefore accompany new MWIs. An example of such a sheet, or associated database, is shown below.

TAGMWIINTERVALREMARKS

12-A-V1101.M.004.0014 weeksCheck Sheet no.

12-B-P2101.M.005.0025 weeks

12-A-K1I01.M.060.0246 months

101.E.060.0316 monthsTo be executed together

101.I.060.0416 months

102.E.120.05212 moths

11-V3-01101.E.060.0496 months

101.E.120.05012 months To coincide with 6 monthly

10-P1-02101.M.060.0066 months

c) A MWI is preferably written generically without cross-references to specific areas, locations and TAG numbers

d) A MWI is furthermore written for a single discipline (M, E, I, C or S) to facilitate the management of MWIs by discipline portfolio, in accordance with Section 7. The Workorder links MWIs of different disciplines that need to be carried out concurrently.

9. MWI Presentation

9.1 Identification

j) The following information is identified on the MWI:

MWI Noxxx.x.xxx.xxxRESPONSIBILITY FORMDROPDOWN

REVISION DATEPAGE1OF

TITLEDURATION

INTERVAL12 M

EQUIPMENT NEEDS TO BE SHUT DOWN FORMCHECKBOX

OR RUNNING FORMCHECKBOX

CRITICALITYA

MANNINGXHOURS =MAN-HOURSCLASS CODE

MWI No. A unique number as per Section 6 of this Standard. Includes discipline.

RESPONSIBILITYResponsibility for execution of the MWI; Maintenance (M), Production (P) or Inspection (I).

REVISION DATERevision date; the date that the MWI was generated or amended.

PAGE OFIndividual page numbering and total number of pages.

TITLEDescription of type of equipment, such as reciprocal pump, model no. No TAG numbers!

DURATIONTotal elapse time it will take to execute the MWI (hours, not man-hours). This is also the time that the equipment is likely to be down, if so required.

INTERVALMaintenance interval in units of months or weeks (3 Months, 6 Months, 12 Months etc.), or running hours.

MWI CRITICALITYCategorisation (A, B or C). A qualification of MWIs assigned on the basis of the potential consequence if they are not executed properly and/or on time (see Section 9.1.1). The Priority identified on the Workorder must agree with this category.

CLASS CODE3 digit, generic equipment code for GMS input. First digit is discipline (i.e. IAC for Instruments, Air Compressor). A list of codes is available with the custodian of this document.

SHUT DOWNIdentifies the required equipment status to carry out maintenance (tick box).

RUNNINGIdentifies the required equipment status to carry out maintenance (tick box).

MANNINGNumber of men times man-hours equals total man-hours required to carry out the (single trade) MWI for input into GMS.

9.1.1 MWI categorisation determining Criticalitya) MWIs shall be categorized by criticality, identifying the requirements for compliance with their associated Maintenance Strategies, legislation or Company Policies and standards during their execution phase. This provides guidance during the scheduling phase to ensure that the planned sequence of maintenance activities maintains system integrity. It provides a decision tool for delaying MWIs (backlog) when forced by unforeseen circumstances such as manpower constraints. MWI categorisation is applied on the basis of the potential consequence if MWIs are not carried out:

Crit. A:MWIs which, if not carried out, are likely to have a Health, Safety, Production loss or Environmental consequence

Crit. B: MWIs which, if not carried out need the utilisation of installed standby Equipment and have no HSE or Production loss consequences. Crit. C: MWIs that are not covered by cat. A or B above (long term cash flow)The MWI criticality is derived from the RCM analysis, if carried out on the equipment in question. If this is not the case it shall be estimated. Each failure mode in the RCM analysis has a specific consequence category identified. Each failure mode should correspond in principle to one or more instructions on the MWI. The most critical consequence category of all instructions (failure modes) on the MWI is adopted as the MWI criticality. This criticality is copied onto the Workorder or determined in the same way if the Workorder refers to a multiple of MWIs. Criticality A Workorders should, in principle, not appear in the backlog as these are safety related and therefore non negotiable.

9.2 Work Preparation

a) The following standard work preparation text shall be included in Maintenance Work Instructions. These shall be identified by A, B, C etc. The text below in Italic is optional and is added for guidance only:

This Maintenance Work Instruction is a Controlled Document in accordance with the SUCO Document Management Manual XXXXX. Changes to this MWI shall be approved by the Document Custodian (see approval box below) in accordance with the MWI Standard no. XXXXXAComply with permit to work system and all relevant safety precautions. Check whether it is necessary to include instructions regarding stopping of running equipment and re-instating of same.

BConsumables: Spare parts/kit list a

Lubricant b for pumps tag x

lubricant c for motor tag y.

Distilled water

CSpecial tools:Hydrometer (Lead acid)

Dead weight tester

DJob specific preparatory instructions: Text

9.3 Work Close Out

a) The following standard work close out text shall be included in Maintenance Work Instructions. These will be identified by Z, Y, X etc.

YEnsure work place is clean, all tools and test equipment have been withdrawn.

ZEnsure that the work permit is signed off, that maintenance supervisors are informed about all observations, test results are recorded on the appropriate check sheets and maintenance history recorded on the Work History section of the Workorder for input into Maintenance Management System.

9.4 Work Instructions

a) Individual work instructions shall be identified by numbers, 01, 02, 03 etc. Examples of instructions are:

01ALL FLANGED CONNECTIONS.

Carry out an external visual inspection and check status of gaskets, clean where appropriate.

Grease nuts and bolts

Assure tightness

Check for painting damage

02FLAME RETENTION RING.

Carry out an external visual inspection, clean where appropriate

03AIR REGULATION BLOCK

Check that it slides freely in the vertical guide.

Visual inspection of fixing screw and clean where necessary.

Grease screws

Visual inspection of gas spray nozzle and clean where necessary

9.4.1 Failure mode References

a) Each instruction on the MWI should, in principle, correspond to a unique failure mode identified in the RCM analysis, if such an analysis is carried out. The unique failure mode identification applied in the RCM process shall be shown against the instruction(s) on the MWI for audit and control purposes.

9.5 Static Work Instructions

9.5.1 Static Work Preparation

a) The additional work preparation text specific to a Static Work Instruction for PSVs is as follows:

EJob specific preparatory instructions: Associated PSVs to be checked and certified in accordance with procedure: referenceb) The additional work preparation text specific to a Static Work Instruction for Vessels is as follows:

EJob specific preparatory instructions: If vessel is to be isolated and depressurised for opening, prepare and agree P&ID with isolation arrangements with Production Operations staff.

9.5.2 Static Work Instructions

a) Examples of typical work instructions are:

01 OPEN VESSEL

Verify whether vessel is likely to be contaminated with N.O.R.M

Isolate, drain, and remove external insulation

Open vessel, degas and check for N.O.R.M

Clean vessel according to procedure: reference02 INTERNAL INSPECTION

Inspect vessel according to procedure: reference

Accept/reject criteria

Fill in standard Vessel Inspection report

03 CLOSE VESSEL

Upon completion box-up with new gaskets

10. Template

a) A template has been developed for the creation of MWIs of which a copy is shown on page 15. MWIs shall be generated using this template which is available with the Custodian of this Standard, and can be found on the O-10 Fileserver.

11. Dos & Donts

a) Maintenance Work Instructions shall:

not refer to organisations, names or indicators.

avoid generic statements such as check pump but clearly specify what this means, such as visually inspect pump externally for leakage or open pump housing and inspect internals for corrosion of flame paths etc.

show reject/accept criteria.

indicate what needs to be done and only reference to procedures that indicate how this is to be done. MWI work instructions shall therefore refer to procedures and check sheets by unique number where appropriate with details of where the information can be found (such as Section number or page).

avoid repeating information, MWI work instructions can refer to lists or tables if need be.

not refer to Area (code)s, TAG numbers or any area specific equipment, locations etc. but shall be written generically. Cross-reference of MWIs to Areas, equipment TAG numbers etc. is done by MWI Reference Sheets.

have only one (1) responsibility per MWI.

have only one (1) category per MWI.

have only one (1) discipline trade per MWI. Non discipline trades, such as scaffolding, shall not be included on the MWI. These are only identified on the Workorder.

state on the MWI Reference Sheet if an MWI needs to be executed in combination with other MWIs, for instance when MWIs with higher intervals are to be executed together with MWIs with lower intervals (i.e. Yearly-MWI with Six-monthly-MWI), or MWIs of different discipline are to be executed together.

12. Nomenclature

SUCO

Suez CompanyAsset RegisterA module in the GMS that contains all information on the asset, such as make, model, manufacturer, and associated data such as set points

Check SheetSeparate sheet, referred to by a Workorder or MWI, that lists e.g. the trip & alarm set points or the checks required by an Operator that are related to specific equipment on which an MWI is executed

Discipline EngineerThe Cairo based Maintenance engineer for the appropriate discipline, M, E, I, S & CE.D.M.SElectronic Document Management System

G.M.SGlobal Maintenance Management System

FileserverA central, multi-access electronic file storage unit

HSEHealth, Safety and Environment

Job FileA module in the GMS that refers to paper copies of MWIs

ManualA document which contains Sections and Chapters stating Policies and describing organisations, procedures and processes (BS EN ISO 8402)

MWIMaintenance Work Instruction

MWI CategorisationA qualification of MWIs assigned on the basis of the potential consequence if they are not executed

MWI Reference SheetA sheet, or copy of relevant part of a database, linking generic MWIs to other MWIs, specific assets and planning data

N.O.R.MNaturally Occurring Radioactive Material

P&IDProcess & Instrument Diagram

Permit To Work SystemA work approval system to control work and associated process isolations in hazardous areas under hazardous conditions

PSVPressure Safety Valve

Spare Part Kit listA list of spare parts that are kept (boxed) as a set, for a specific maintenance activity (usually for Workshop overhauls)

TAGAn equipment code indicating type and location

Technical IntegrityTechnical Integrity is achieved when, under specified operating conditions, there is no reasonably foreseeable risk of failure endangering the environment, asset value or safety of staff

WorkorderA work initiation sheet issued by the GMS specifying what work is to be carried out, where, when and by whom

MWI Noxxx.x.xxx.xxxRESPONSIBILITY FORMDROPDOWN

REVISION DATEPAGE1OF

TITLEDURATION

INTERVAL12 months

EQUIPMENT NEEDS TO BE SHUT DOWN FORMCHECKBOX

OR RUNNING FORMCHECKBOX

CRITICALITYA

MANNINGXHOURS =MAN-HOURSCLASS CODE

WORK PREPARATION

This Maintenance Work Instruction is a Controlled Document in accordance with the SUCO Document Management Manual, XXXXXX Changes to this MWI shall be approved by the Document Custodian (see approval box below) in accordance with the MWI Standard no XXXXXX.

A

B

C

DComply with permit to work system and all relevant safety precautions. Check whether it is necessary to include instructions regarding stopping of running equipment and reinstating of it. Consumable:

Special tools:

Job specific preparatory instructions:

WORK INSTRUCTIONS

CONTINUED ON PAGE

WORK CLOSE OUT

Y

ZEnsure work place is clean, all tools and test equipment is withdrawn.

Ensure that the work permit is signed off, that maintenance supervisors are informed about all observations, that test results are recorded on the appropriate check sheets and that maintenance history is recorded on the Work History section of the Work order for input in the Electronic Maintenance Management System.

MWI Noxxx.x.xxx.xxxRESPONSIBILITY FORMDROPDOWN

REVISION DATEPAGEOF

WORK INSTRUCTIONS (CONTINUED)

WORK CLOSE OUT: SEE WORK CLOSE OUT INSTRUCTIONS ON PAGE 1.

SUCO WORK ORDERArea codeUnit TAGPriorityCopies

Location

FROM:TO:Unit description

Item codeSystem

Type jobTrade required

PLANNEDACTUAL

MechanicalMechanical

ElectricalElectrical

InstrumentInstrument

OtherOther

Auxiliary/TravelAuxiliary/Travel

TotalTotal

ISSUED ON:

Authorised Please enter the actual man-hours utilised in executing the work in the right hand column above.

Please also enter the auxiliary or travel man-hours utilised in executing the work.

Report details of work done and History comments below:WORK COMPLETION

Name:

Start:

Finish:

Section Head

DEFECT ANALYSIS

Defect

Cause

Action

Date : 04-May-03RB MWI standard.docPage 6 of 17Page 4 of 17