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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: 1/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
DISCLAIMER
The information contained in this document has been prepared exclusively for internal use by L'Air Liquide S.A. and its affiliates ("Air Liquide"). Since this
document is confidential and proprietary to Air Liquide third parties are not entitled to rely on it in any !ay. "ith re#ard to third parties Air Liquide does not hold
itself out as recommendin# the use of the information contained herein or reliance thereon in any !ay !ithout its prior approval and Air Liquide does not #ive any
!arranties on the information contained in this document and assumes no liability or responsibility in connection !ith the information or su##estions herein
contained. Air Liquide ma$es no representations or !arranties as to the completeness of this document and %&S'LA&(S ALL "A))A*T&+S +,-)+SS .)
&(-L&+% &*'L/%&*0 1/T *.T L&(&T+% T. T2+ "A))A*T3 .4 (+)'2A*TA1&L&T3 A*% T2+ "A))A*T3 .4 4&T*+SS 4.) A -A)T&'/LA) /S+ .)
-/)-.S+. The present document has been issued in 4rench and in +n#lish.
This document supersedes the o!!o"in# document$s%:
#P$11 %0&
Re&ision D'te Prep'red () Appro&ed () Ch'n#es
* 1' (ebr)ary 200* +ean$,)c #-.D-/ 01ristian P2304
!ee Revision Table
-nne5 0
1 10 December 2008 Mic1el M-!!O/ 01ristiane M2,,3R
+
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T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: 2/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
TA.LE O/ CONTENTS
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T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: =/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
10 P1RPOSE
T1e p)rpose of t1is proce6)re is to 6efine t1e Maintenance Program an6 Plans to be implemente6 at
facilities8
+0 RESPONSI.ILIT2
T1e &ndustrial (ana#er s1all 6efine a maintenance strategy9 incl)6ing spare parts9 for t1e subsidiary t1at
is in compliance it1 t1e 0roup Standards. 4e/s1e s1all t1en set )p a process for i6entifying gaps
among t1e practices in vario)s facilities it1in t1e subsidiary an6 p)t in place action plans for
improvement8
- Maintenance (ana#er s1all be appointe6 for eac1 facility8 - Maintenance (ana#er can be responsible
for several facilities %e8g8 on$site plants&8 T1e Maintenance (ana#er is responsible for t1e implementation
of t1is proce6)re in 1is/1er assigne6 facilities8 4is/1er responsibilities incl)6e:
3ns)ring t1at t1e maintenance program is in place an6 aligne6 it1 t1e maintenance strategy
6efine6 by t1e &ndustrial (ana#er9
"mplementing critical equipment maintenance S.- 6efine6 by ris$ assessment st)6y9
3ns)ring s:ills9 competencies an6 reso)rces are a6e;)ate for maintenance operations9
!)pporting t1e 4acility (ana#er as t1e interface it1 t1e local a)t1orities9 for maintenance9
inspections an6 testing activities8
,0 COMPETENC2 RE31IREMENTS
T1e Maintenance (ana#er s1all 1ave:
- or:ing )n6erstan6ing of proce6)res an6 man6atory reg)latory re;)irements for
maintenance9 an6 test an6 inspections met1o6s9
0ompre1ensive :nole6ge of preventive an6 corrective maintenance met1o6ologies9
Tec1nical an6 or:ing )n6erstan6ing of t1e 6ifferent tec1nologies an6 processes at 1is/1er
facilities8
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: '/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
-0 PROCED1RE RE31IREMENTS
-010 MAINTENANCE PROGRAM
T1is program s1all be base6 on:
T1e level of reliability an6 availability re;)ire6 for t1e facility
"ns)rance contract)al obligations9
Maintenance strategy 6efine6 by t1e &ndustrial (ana#er
Man)fact)rer recommen6ations9
0)rrent #ro)p !tan6ar6s9 "nformation /otes an6 in6)stry practices9
Man6atory reg)latory re;)irements9
)is$ assessment
D)lnerability st)6ies 1en available8
T1is program s1all incl)6e9 at a minim)m9 t1e folloing:
Definition of maintenance practices for critical e;)ipment:
-reventive maintenance 1ic1 is compose6 of:
Systematic maintenance %time interval 6river&9
-redictive maintenance %)s)ally monitoring of :ey in6icators 6river&8
'orrective maintenance %repair/replace after brea:6on&0
Relevant corporate in6)strial 6epartments iss)e 0roup Technical Standards an6 "nformation
Doc)ments t1at provi6e g)i6elines on maintenance strategy an6 met1o6s8
Turnaround sc1e6)le
!pare part %incl)6ing cons)mables& analysis to establis1 t1e critical spare parts an6 to 6efine
t1e level of inventory in relation it1 critical e;)ipment
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: */10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
-0+0 ANN1AL MAINTENANCE PLAN
- yearly maintenance plan s1all be establis1e6 an6 implemente6 by t1e Maintenance (ana#er for eac1
facility8 "t s1all incl)6e9 at a minim)m:
,ist of e;)ipment9
!c1e6)ling of maintenance activity an6 planne6 o)tages9
Description of t1e maintenance or: t1at m)st be complete68
"f stan6ar6 maintenance plans e5ist9 as is t1e case for On$sites %-P!-9 etcE&9 t1ey m)st be applie68
-0+010 E4EC1TION O/ MAINTENANCE PLAN
-s a minim)m9 t1e folloing iss)es m)st be a66resse6 for maintenance activities:
Maintenance f)nctions m)st be coor6inate6 it1 facility an6 safety personnel to ass)re t1at all
safety re;)irements9 permits9 an6 proce6)res are properly folloe69
Maintenance S.- m)st be in place for ro)tine maintenance tas$s
T1e isolation %energy9 process9 mec1anical9 fl)i6sE& an6 preparation of e;)ipment as ell as
t1e or: to be performe6 m)st be 6efine6 in S.- prior to t1e e5ec)tion of t1e maintenance
tas$s
Maintenance activities9 not covere6 by S.-9 m)st be 6efine6 t1ro)g1 or: permit
proce6)res9
Maintenance instr)ctions m)st be 6efine6 by t1e ris: mitigation st)6ies an6 partic)larly t1e
ones specific to in6ivi6)al 3"!9
5obs m)st be e5ec)te6 in accor6ance it1 t1e facility maintenance S.- an6 all complete6
or: items are 6oc)mente69
Post maintenance testing s1all be performe6 to verify t1at t1e components t1at 1ave been
or:e6 on ill f)lfill t1eir inten6e6 6esign f)nction 1en ret)rne6 to service9
Personnel t1at perform maintenance inspections m)st be traine6 an6 ;)alifie6 accor6ing to
t1e r)les 6efine6 by t1e subsidiary in compliance it1 local la!s9 mandatory re#ulations an6
#ro)p !tan6ar6s8
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: 6/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
-0+0+0 TESTS5 INSPECTIONS AND CALI.RATION:
Tests an6 inspections are con6)cte6 accor6ing to local la!s mandatory re#ulations an6
#ro)p !tan6ar6s t1ro)g1o)t t1e e5ec)tion of t1e maintenance plan8 Moreover lists an6
inspections of +&S are con6)cte6 accor6ing to t1e recommen6ations of t1e ris: analysis
st)6ies8
"nspection res)lts are )se6 as inp)t to preventive maintenance an6 t1e f)rt1er refinement of
t1e e;)ipment maintenance plan8
0ontrol an6 calibration of meas)ring an6 test e;)ipment s1all be consistent it1 applicable
re;)irements an6 ens)re t1e acc)rate performance of t1e e;)ipment<s instr)mentation8
Doc)mentation of control met1o69 test interval9 responsibility an6 fee6bac: to revise t1e nee6
for testing 6epen6ing on t1e res)lt s1all be available at t1e facility8
-0+0,0 SPARE PARTS:
0ritical spare part proce6)res m)st be in place to ens)re spare part availability9 s1elf$life limits an6
integrity8
-0+0-0 E4PERIENCE /EED.AC6 LOOP:
T1e Maintenance Manager s1all ens)re t1at analysis of e;)ipment fail)re an6 maintenance
iss)es are performe68
T1e Maintenance Manager s1all ens)re t1at lessons learne6 from maFor turnarounds are
reviee6 an6 analyGe6 to improve facility maintenance S.-s an6 f)t)re t)rnaro)n6s8
- fee6bac: process s1all be p)t in place by t1e &ndustrial (ana#er to report poor reliability of
critical equipment from subsidiary level to corporate in6)strial 6epartments8
T1e fee6bac: learning points s1all be ta:en into acco)nt by t1e Maintenance Manager to improve t1e
maintenance program an6 plans8
70 RECORDS RETENTION
T1e 1istorical 6ata of maintenance activities %1istory an6 tren6ing recor6s of :ey in6icators& s1all be :ept
for t1e life of t1e e;)ipment (or all critical equipment +&S an6 ot1er e;)ipment as may be re;)ire6 by
local la!s an6 mandatory re#ulations9 a file containing t1e folloing information s1all be :ept for t1e life
of t1e e;)ipment:
Design 6oc)mentation9
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: A/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
Maintenance recor6s9
"nspections recor6s9 incl)6ing testing an6 calibrations8
80 A1DIT C9EC6-LIST
T1e implementation of t1is proce6)re s1all be a)6ite68 T1e 'hief &ndustrial Auditor s1all 6efine t1e a)6it
fre;)ency8 T1e a)6it form in -nne5 1 may be )se6 for g)i6ance8
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: 8/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
ANNE4 * : RE;ISION TA.LE
Re&ision
Indic'te the modiied section num(ers
'nd pro&ide ' short description o the ch'n#es
1
!ection '819 2
n6
b)llet B H"ns)rance contract con6itionsI replace6 by Hins)rance contract)al obligationsI
!ection '819 *
t1
b)llet B H0)rrent in6)stry practicesI replace6 by Hc)rrent #ro)p !tan6ar6s9 "nformation /otes an6
in6)stry practicesI
!ection '82819 *
t1
b)llet B Reor6e6 for clarity
!ection '82819 8
t1
b)llet B H-ir ,i;)i6e r)lesI replace6 by H#ro)p !tan6ar6sI
!ection '82829 1
st
b)llet B H-ir ,i;)i6e r)lesI replace6 by H#ro)p !tan6ar6sI
!ection '828' B Responsibility of 35perience (ee6bac: ,oop assigne6 to Maintenance Manager
!ection * B T1e 3"! are no incl)6e6 an6 t1e scope is enlarge6 to incl)6e local las
!ection A B Delete6
-nne5 1 B Mo6ifie6 accor6ing to revise6 te5t of #P
+
,
-
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: C/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
ANNE4 1 - A1DIT C9EC6LIST
T1e p)rpose of t1is a)6it c1ec:list is to g)i6e t1e #ro)p "n6)strial -)6itor in 1is/1er preparation of protocols for a)6iting compliance of
s)bsi6iary in6)strial management systems it1 #ro)p re;)irements8 "t can also be )se6 by s)bsi6iaries to self$a)6it s)c1 compliance8 "t
is not inten6e6 for )se by s)bsi6iaries to a)6it compliance of t1eir facilities it1 t1eir s)bsi6iary in6)strial management systems8
Subsidiary: JJJJJJJJJJJJJJJJJJJJJJ
Date: JJJJJJJJJJJJJJJJJJJJJJJJJJJ
-)6itors: JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ
"ntervieees: JJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJJ
Re<uirement /indin# Comments
Section + : Responsi(i!it)
18 Maintenance strategy is 6efine6 by t1e &ndustrial
(ana#er in compliance it1 t1e 0roup Technical
Standards
. /
28 - Maintenance (ana#er is assigne6 for eac1
facility
. /
=8 T1e 6escription of responsibilities in t1e
Maintenance (ana#er 6ob profile is consistent it1
t1at in section 28
. /
Section , - Competenc) Re<uirements
18 T1e 6escription of t1e re;)ire6 competencies
in t1e Maintenance (ana#er 6ob profile is
consistent it1 section =8
. /
Section - - Procedure re<uirements
18 - maintenance program is in place base6 on t1e
minim)m re;)irements 6efine6 in t1is #P
. /
28 -n ann)al maintenance plan is in place . /
=8 Maintenance S.-s e5ist for ro)tine
maintenance tas$s
. /
'8 +&S are i6entifie6 an6 covere6 by !OP . /
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8
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Reference: GP-11
Revision: 1
Date: 10 December 2008
Page: 10/10
Oner: !"!
OPERATIONS: MAINTENANCE MANAGEMENT
Re<uirement /indin# Comments
*8 - system re;)iring t1e monitoring of :ey
in6icators of t1e con6ition of t1e e;)ipment is in
place for predictive maintenance.
. /
68 Maintenance recor6s are manage6 accor6ing to
t1e subsidiary re;)irements
. /
A8 0ritical spare parts management is 6one
accor6ing to a subsidiary proce6)re
. /
88 - fee6bac: process )n6er t1e responsibility of
t1e Maintenance Manager is in place it1 i6entifie6
learning points
. /
C8 (ee6bac: process to report poor reliability of
critical equipment to corporate in6)strial
6epartments is in place8
. /
Section 7 - Records Retention
18 4istorical maintenance 6ata is available on$site . /
28 - file containing t1e re;)este6 6oc)ments
6escribe6 in t1is #P is maintaine6 for all critical
equipment an6 ot1er e;)ipment as may be
re;)ire6 by local la!s an6 mandatory re#ulations
. /
Section 8 - Audit Chec=!ist
18 T1e implementation of t1is proce6)re 1as been
a)6ite6 accor6ing to t1e fre;)ency 6efine6 by t1e
'hief &ndustrial Auditor
. /
T1is 6oc)ment is proprietary to t1e -"R ,"72"D3 #RO2P an6 m)st not be comm)nicate6 to t1ir6 parties8 "t is one of a set of #ro)p Proce6)res t1at9 toget1er9 control t1e :ey
elements affecting safety in -ir ,i;)i6e<s in6)strial/me6ical operations8 "t is not inten6e6 for implementation in6epen6ently of s)c1 system8 T1is is an )ncontrolle6 copy8 T1e
only controlle6 copy is :ept in t1e -le5an6ria 6atabase8