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Maintenance Forms for Critical Equipment

Dr. Attia Hussien Gomaa


Maintenance Engineering Consultant
Engineering service - American University in Cairo (AUC)

2008
Forms

Main Forms for Critical Systems

Form

Responsibility

Work request

(CM=Process)
(PM=Maintenance +Process)

Work order (CM or PM) (Maintenance)


Job safety analysis

(Maintenance + Safety + Process)

Work permit

(Safety + Process + Maintenance )

Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

Maintenance W/O Contents: for Critical Systems


1.

W/O description (#, description, type PM / CM/ Shutdown, discipline, area, location, .. etc.)

2.

Work request (#, requester, description, .. etc.)

3.

Dates (start date, finish date, complete date, .. etc),

4.

W/O criticality (system/ equipment criticality, W/O priority, .. etc.),

5.

Safety condition (work permit #, type: cold, hot, main items, JSA,.. etc ),

6.

Last maintenance or Maintenance History (type, description, date, .. etc.)

7.

Job plan (main steps, planned duration, actual duration, .. etc.)

8.

Tool list (code, description, quantity, planned duration, actual duration, .. etc.)

9.

Spare parts list (SIR #, Stock code, description, planned quantity, actual quantity, etc.)

10. Labor list (code, description, planned quantity & hours, actual quantity & hours, . etc.),
11. Duration (planned duration, planned down time, actual down time, non-direct time ,etc.),
12. Failure (fault, code or/and description, cause, .. etc.),
13. Work Close Out ( main steps description, discipline signature)
14. Backlog = Overdue (cause, root cause, consequence, .. etc.)

15. Responsibility (Maintenance, Process, Safety signatures)


Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

W/O Types:

W/O Priority:

CM
MM
SM
PM
PD
RP
OM

P1. Emergency (within 2 hours)


P2. Critical (within 24 hours)
P3. Normal
P4. Overhaul

Corrective
Modification
Service
Preventive
Predictive
Repair Work
Overhaul

Operational Condition:
OVH
RUN
STB
STP
SUP

GENERAL OVERHAUL
RUNNING
STANDBY
STOPPED
START UP

Planned will be the summation of all (Preventive + Predictive)


Unplanned will be summation of all (Corrective)
Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

W/O status:
CANCELLED

CLOSED
IN PROGRESS
ON HOLD
PLANNED
COMPLETED
REQUESTED

Uncompleted will be the summation of all


(Planned + In progress + On hold)

Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

WORK PERMIT:
The purpose of the W/P is to achieve:
Safe jobs
Safe conditions
Safe Acts

The W/P requires the involvement of competent and


responsible persons as well as the application of
particular safety measures in a controlled sequence.
The necessary elements, as follows, contribute to safe working:
Good communications between all work groups.
Detailed planning of the work.
Thorough training of personnel.
Effective supervision of the work.
A skilled and dedicated workforce.
Regular auditing of the permit system.
Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

The W/P basically consists of three main Work permits:


1. Cold Work Permit,
2. Hot Work Permit
3. Naked Flame

Six relevant certificates:


1. Confined Space Entry Certificate.
2. Electrical Isolation Certificate
3. Spade List
4. Excavation Certificate
5. Radiography Certificate
6. Pressure Test Certificate
Do Not Do Any of These Tasks
Without A Permit To Work
Forms

Maintenance Forms - Dr. Attia Gomaa - 2007