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RABIGH REFINING AND PETROCHEMICAL COMPANY

Document Title: Maintenance Quality Program


Department: Maintenance Department

Section: Reliability Section

Document No.

Rev. No

Effective Date

Page No.

PR/MN/REL/P-

., 2015

1 of 21

Description

Name

Job Title

Initiated by

Yoshiyuki Sakamitsu

QA/QC Senior. SV

Reviewed by

Ahmed B. Naseef

Reliability Section Head

Concurred by

Abdullah M. Al-Sharif

General Manager, MNT-MF

Approved by

Yasuhiko Kitaura

Sr. Vice President, MFT

Date
Mar.31, 15

Signature

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
Rev. No.
PR/MN/REL/P-005
0

Section: Reliability Section

Effective Date
., 2015

Page No.
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Contents
Section

Titles

Page

Introduction

Perspective of Maintenance Quality Program

Scope of Maintenance Quality Program

Quality Policy for Maintenance

3.1 The Targeted Quality Objective and Goals

3.2 Responsibility of Management for Maintenance Quality

3.3 Management Review on Maintenance Quality Management System

Maintenance Quality Committee


4.1 Organization for Maintenance Quality Committee

4.2 Operation of Maintenance Quality Committee

Realization of Maintenance Quality


5.1 Basic Practices

Quality Monitoring and Improvement

9
9
11

6.1 General Procedures

11

6.2 Organization to be Monitored

12

6.3 Follow-up of Quality Monitoring

13

Rework Management

13

7.1 Action for Rework

13

7.2 Analysis for Rework

14

Documents and Formats

14

Attachment-1

15

Attachment-2-1

16

Attachment-2-2

17

Attachment-3

18

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
Rev. No.
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0

Section: Reliability Section

Effective Date
., 2015

Page No.
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1. Introduction
Quality activities are mutually affected components for all Maintenance work.
Effective implementation of Quality activities is a key for improvement of overall
reliability of equipment and mechanical integrity.
Quality activities initiate development of Program, Procedures and Work Instructions
for quality services which improve implementation of maintenance work, preserve
quality of equipment and result in reliability of equipment. These activities should be
upgraded with continuous improvement.
Management support and systematic monitoring or measurement are key effective
approaches to ensure that the organizational Quality actives soundly.

1. Perspective of Maintenance Quality Program

This program is established as a document corresponds to Quality Manual defined


Documentation requirement in ISO 9001Quality Management System-Requirement
The purpose of this manual is being a foundation to structure PRC Maintenance
Quality Management System and to deploy following items in order to realize
Quality objectives described in Section 3.
-

To clarify Quality activities in PRC Maintenance in order to implement quality


management for equipment maintenance correctly.

To equalize recognition of Quality to the staff get engaged to Maintenance


Quality activities and avoid inconsistent understanding for implementation of
their job.

To clarify role and responsibilities on Maintenance Quality for each organization.

The owner of this Maintenance Procedure is Reliability Section Head. Revision of


this procedure is conducted by only owner.

2. Scope of Maintenance Quality Program


This manual is applied to Quality activities on maintenance or repair work in the
Maintenance shop, at the field, Preventive maintenance and shutdown (T&I)
maintenance.

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
Rev. No.
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Section: Reliability Section

Effective Date
., 2015

Page No.
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3. Quality Policy for Maintenance (ISO 9001 Section 5.3)


PRC Maintenance improves equipment reliability and contributes realization of unit
continuous operation by establishing, implementing and maintaining an effective Quality
Management which meets requirement of PRC and applying it to maintenance work.
In order to realize above mentioned mission, PRC maintenance staff always should
have consciousness of Ownership on own jobs and proceed Quality activities in the
job proactively.
3.1 The Targeted Quality Objective for Maintenance and Goals (ISO 9001 Clause
5.4.1)

Quality objectives of PRC maintenance are set in order to establish, implement and
maintain an effective Quality Management System for the maintenance activities which
meets the requirements of equipment reliability by the Company and to realize own
organizational goals of PRC Maintenance.
The specific Project objectives and goals are
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Realize unit continuous operation


Ensure that Maintenance is an integral part of the business foundation of PRC
Prevent / eliminate re-work.
Deliver the maintenance work on time with required specification.
Apply adequate specifications, codes and standards.
Communicate with related organization as an integrated team.
Promote a continuous improving culture with the target of achieving excellence in
maintenance work
(8) Upskilling of performance of maintenance staff through quality activities
3.2

Responsibility of Managements for Maintenance Quality (ISO 9001 Section


5.1)

The all managements of PRC maintenance should have comprehensive


responsibilities keeping PRC Quality Management System sound and maintenance
work meets requirement of quality. In order to realize it, managements of PRC
maintenance always should have consciousness following 6 items in their daily work.
(1)

Establish Quality policy and objective

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Managements undertake to investigate and decide at the start of every year


what their long-term Quality objectives are.

The targeted periods will be for the coming 3 to 5 years

Annual Quality objective should be developed based on the long term quality
objectives.

The resultant Quality policy should explain resolution of managements on


quality and consist of following three items
i.

Aims : The reasons why the quality policy implemented


ii. Goals : The direction to move in, how far to go, and the deadline
iii. Priority procedures : The methods / tools to be used

Demonstrate a commitment to the Quality policy and ensure the Quality policy is
understood at all levels of Maintenance Department

(2) Allocate appropriate resources for quality management, responsibilities and


authorities
-

Managements ensure organization for Quality management and clarify Job


Description for each organization and Role/Responsibilities for staff in the
organization.

Resource for Quality management includes staff for maintenance work execution,
QA, QC, training, and implementation of Quality monitoring.

The resource for Quality management is fixed based on Role/Responsibilities


described above.

Managements consider not only responsibilities but also authorities on staff for
Quality management in order to implement quality activities smoothly.

Managements define and document employee responsibilities and communicate all


responsibilities to them so that they fully understand what is expected of them, in
regard to this Quality Program.

Managements provide a healthy work environment to ensure that PRC Maintenance


employees and contractors can effectively do their responsibilities

All employees and contractors for PRC Maintenance are responsible for Quality
performance. This carries with it the responsibility to review and inspect all work
pieces, documentation, equipment and tools for maintenance.

All employees and contractors for PRC Maintenance have responsibilities to ensure
that work performed by them meets all quality requirements.

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Resource for Quality management include staff for maintenance execution.

(3) Plan and lead Quality monitoring


-

Managements always interested in


management and implement it themselves

Managements order Quality Committee (described Section 4) to plan Quality


monitoring in Shop or Field in order to confirm implementation level on quality policy
set by managements.

Managements themselves join the monitoring teams as a team leader.

Managements set the focal points of Quality monitoring and nominate


appropriate staff as monitoring members.

The Quality monitoring preferably implemented quarterly base at least every halfyear.

continuous

improvement

of

Quality

(4) Set Quality KPIs and monitor


-

Managements request numerical data on quality and if it considered effective to


improvement of Maintenance Quality, it will be candidate of Quality KPI

Candidate of Quality KPI is discussed in the Quality Committee (Section 4) and


applied.

Owner for New KPI (reporter) is nominated by the Quality Committee

(5) Identify Quality training


-

In order to implement this Quality Program, Managements provide the training and
resources to ensure its successful introduction and application within PRC
maintenance.

Managements always take care of information of Quality related training by 3 rd party


and provide actual information to Quality Committee.

(6) Budgeting for quality activities


-

Managements always make consideration on Quality activities such as environmental


improvement or Quality training and budgeting these activities.

3.3. Management Review on Maintenance Quality Management System (ISO

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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9001 Section 5.6)

Management should review the PRC Maintenance Quality Management System at


planned intervals to ensure its continuing suitability, adequacy and effectiveness. The
Management Review shall be planned under the responsibility of the Owner of
Quality Committee (described in Section 4) and conducted in the meeting of Quality
Committee attended by key Function Managers from Maintenance. Management
Reviews should be planned at annually and included into annual schedule of Quality
Committee. The frequency may be increased in response to perceived quality issues.
The chairperson for Quality Committee is responsible for the coordination of the
reviews and should consolidates the review material/data collected from the
contributing parties which typically consists of
-

Results of previous audits


Status of corrective action from audits
Unit operation condition
History of rework
Rework KPI (see Section 7.3)
Follow-up actions from previous management reviews
Changes which could affect the Maintenance Quality Management Systems

Management review should include assessing opportunities for improvement and


the needs for changes to the Maintenance Quality Management System including the
Quality policy and Quality objectives.
The attendees should review the agenda issues with the aim of identifying and
agreeing problem causes. Proposals for corrective and improvement actions shall be
made by the concerned Managers and implementation plans should be drawn up
with responsibilities and deadlines.
The improvement actions include:
-

New and revised Quality Management System documents.


Audit, review or surveillance in particular areas.
Suitability and adequacy of organization and resources.
Processes, systems, tools for implementation of improvements
Training

As a result of Management review, the PRC Quality Management System should


be updated as required to incorporate improvement actions identified during or
consequent to review. The Owner of Quality Committee should be responsible to
supervise the updating of the PRC Quality Management System.

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Effective Date
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4. Maintenance Quality Committee (ISO 9001 Section 7)


In PRC, all quality related activities and items for maintenance are discussed
and managed by Maintenance Quality Committee. Key discussion items in
Maintenance Quality Committee are
(1) Review and approve documents such as maintenance standards, procedures, and
check lists which related to maintenance quality.
(2) Indicate concerned staff or organization to develop maintenance procedures, checklists
if necessary
(3) Plan and schedule each Quality monitoring (Shop, Field, and Preventive Maintenance).
(4)

Plan and schedule Quality monitoring by management.

(5) Review the Recommendations in QA/QC report submitted in last one month and share
information between related organizations or indicate standardization of these
recommendation to adequate organization.
(6)

Review and approve annual bad actor elimination program.

(7) Investigate root cause of rework in Rework memo, review corrective action in the
memo and advice correction if necessary, and indicate implementation of corrective
action.
(8) Set maintenance quality KPI, monitor the results, and indicate additional improvement if
necessary.
(9) Set maintenance quality KPI, monitor the results, and indicate additional improvement if
necessary.
(10) Recommend corrective action for maintenance quality and review steward report.
(11) Collect information on Quality related training by 3rd party and nominate trainees.

4.1. Organization of Maintenance Quality Committee


The Maintenance Quality Committee is organized following members
-

Committee Owner : Maintenance General Manager

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Chairperson : Reliability Section Head

Committee members : Several Section Heads nominated as member by the


Committee owner, QA/QC Senior Supervisor

Extend members : TSU Senior Supervisor, TSU staff, QA/QC staff

Administrator : QA/QC Senior Supervisor

Secretary : Secretary for Reliability Section

4.2. Operation of Maintenance Quality Committee


The Maintenance Quality Committee is operated as follows:
-

Maintenance Quality Committee is held monthly base

Administrator checks distributed quality related materials such as QA/QC report and fixes
agenda.

Chairperson fixes date of committee and sends invitation letter to committee owner,
committee members and extend members if necessary

Explanation of matters in agenda is executed by initiator of documents or proposer of


subject.

Matters for resolutions are documented as official documents and send to related

Organization as information or orders for implementation.

5. Realization of Maintenance Quality (ISO 9001 Section 7)

In order to realize maintenance quality, ensure observing Quality Procedures and


Work Instructions are one of key factors. Based on the Quality Policy described in
Section 3, all PRC maintenance staff to keep an Ownership and should have a
consciousness that ;
-

Observe Quality Procedures and Work Instructions

Try to develop new Quality Procedures and Work Instructions

Try to update existing Quality Procedures and Work Instructions

5.1 Basic practices

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
Rev. No.
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Section: Reliability Section

Effective Date
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Observing the Quality Procedures and Work Instructions are key success factor to
realize maintenance quality, however we should understand administrative work such
as monitoring, recording and documentation handling.
Following 17 items are common practices to all trades for ensuring quality
maintenance work.
(1) Confirm the Shop / Field maintenance staff understand outline of failure condition
and
focal point of repair before the repair is started. Recommend that Shop/Field
maintenance should check the abnormal condition of equipment in operation. If
possible, ask Operation Section to re-start equipment to check abnormal condition.
(2) Confirm that Shop / Field Maintenance has manuals and drawings provided by
vendor,
right tools for disassembling / repair / assembling before work starts. If Shop / Field
Maintenance do not have these documents and tools, stop the maintenance work.
(3) Confirm the hold points for planned maintenance work based on procedures /
check
lists were recognized by related staff before work starts.
(4) Confirm information channel on request for check of hold points were established
and
shared between related staff.
(5) Confirm that maintenance / repair work is executed based on procedures, vendor
manuals, and appropriate tools are used.
(6) Confirm that procedure for handling of removed parts are established. If it has not
been established, recommend establishment as quickly as possible.
(7) The hints of procedure for handling of removal parts are as follows
- Removed parts are recorded and put these parts on the clean table of floor in
order (do not put in the box randomly)
- Removed parts are checked and if damaged replaced with new one and put the
same place (on the table or floor)
- After assembling, the table and floor are checked and confirmed no parts are left.
(8) If some incorrect information or inconsistencies are found in above maintenance
or repair procedures, QA/QC Sr. Supervisor sends notification for corrective action
to developer of procedures (The maintenance / repair procedures are mainly
developed by TSU).

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
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(9) Implement witnesses on repair work by Maintenance shop / Field Maintenance as


needed.
(10) Conduct witness at hold point (including each test) fixed before work starts.
(11) The maintenance work can be proceeded with QA/QC endorse and sign on each
hold point.
(12)

After maintenance was completed and equipment was assembled, confirm the
check of tolerance between specification and equipment were implemented and
recorded.

(13) Conduct visual check and measurement at actual equipment or parts as sampling
check.
(14)

Confirm leak test is planned based on maintenance procedure and line-up


(pressurized portion, plugging, opening, etc.) is checked using drawings.

(15) Confirm repair report (including replacement of parts) and measurement records
developed by Shop / Field Maintenance and endorse these with sign.
(16) Recommend application of MOC to TSU if as-is repair is considered to be difficult
to keep equipment quality.
(17) Special considerations on field maintenance are as follows
- Check original position of equipment to be repaired and confirm that the
equipment
is returned to its original position.
-

Check each records on dimension measurement implemented by Field


maintenance
before removal and confirm after reinstallation that these dimensions meet the
specifications.

Observe installation of key equipment or equipment which has some difficulties to


keep
continuous operation and conduct checks if necessary.

Provide key points for installation and assist development of installation


procedures of
equipment which have some difficulties to keep continuous operation.

In case of big equipment, confirm documents for condition of foundation and


setting bolts checked by Field maintenance and these are sound.

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Effective Date
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6. Quality Monitoring and Improvement (ISO 9001 Section 8.2)


6.1 General Procedures
The Quality Monitoring is planned and implemented to analyze the maintenance
activities, and make recommendations for improvements. In addition, it is implemented
to adopt a constructive approach to achieving improvements in the Quality
Management System.
The audit schedule is prepared by Chairperson of Quality Committee, and
reviewed /approved by the Owner of Quality Committee. The monitoring schedule is
issued at the start of the year.
The monitoring is planned and implemented based on existing maintenance
procedures PM-MN-REL-P-004 and 402. The key monitoring items for shop and field
maintenance are :
- Performance of maintenance shop staff & contractors
- Preparation of work procedures, drawings, vendor manuals
- Application status of above documents
- Development status of repair records and its qualities
- Status of endorse or approval to repair records

And Key monitoring items for preventive maintenance are :


- Implemented based on planned schedule
- Check list for items to be implemented is in place
- Consistency between check list and actual equipment (e.g. described check
pressure but no pressure gauge at actual equipment)
- Status of endorse or approval to implementation records
- Document (implementation records) check for completed PM
- Intensity of work load (prevent many job / small resource)

Results of Quality Monitoring are documented in predefined form by monitoring


team and kept minimum of five (5) years in Reliability share folder. The monitoring
report is sent to monitored organization after approval of Reliability Section Head.
6.2 Intended Activities for Quality Monitoring

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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The intended activities for monitoring are shop maintenance, filed maintenance, and
Preventive maintenance.
The intended organization does not need to prepare anything special against
Quality Monitoring because it checks as is condition, however should provide any
documents or evidences on demand from auditors. Any fake paperwork on records or
ad hoc excuses are prohibited.
6.3 Follow-up of Quality Monitoring
The Chairperson of Quality Committee is responsible for ensuring follow-up of
actions arising from Quality Monitoring. Results of Quality Monitoring are documented
in predefined form by monitoring team and sent to intended organization after approval
of Chairperson of Quality Committee. The document for results are kept minimum of
five (5) years in the PC share folder for Quality Committee.
The intended organization should develop implementation plan for corrective action
and should report progress of implementation to Quality Committee. The intended
organization reviews implementation status / progress of corrective action and
indicates adequate action in the Section. The implementation plan and progress should
be kept at least five (5) years in the intended organization.

7. Rework Management (ISO 9001 Section 8.2, 8.3, 8.4)


Elimination of Rework is one of most important part to realize maintenance quality. It
affect not only equipment reliability but also motivation of concerned people. How to
eliminate rework should be discussed from aspect of Personnel factors (knowledge, skill,
and consciousness, etc.), Organizational factors (procedures, resources, tools, work
environment, etc.)
In PRC, Rework is defined as :

The incident a repaired or maintained equipment failed within 15 days from


the date of commissioning due to the same cause of the last failure, whether
repair was done via T&I, Work Order, Minor Ticket, contractor, or anything
else.

The definition of Rework is reviewed annually in Quality Committee and updated if


necessary.
7.1 Actions for Rework

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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If incident considered as Rework was observed, it is informed through the


supervisor for Operation Unit who is responsible for work order. The
investigation of Rework is conducted and completed by the Unit QC staff
and shop or field maintenance staff. If it is caused by technical matters, TSU
staff join the investigation team. Recovery work for rework should be
handled as an Emergency work
As a result of investigation, if revision of existing maintenance procedures or check
lists was required, QA/QC Senior Supervisor informs in detail to TSU Senior
Supervisor and ask revision of concerned procedure / check list. TSU should expand
this revision to same type equipment.
QA/QC Unit records outline of rework in the list and reports it including probable root
cause using format of QA/QC report. The rework is reported to Quality Committee and
reviewed validity of root cause and corrective actions.
7.2 Analysis of Rework
# of rework should be 0, however set less than 2% of total # of repair work as
implementation target. Analyzed data (# and % of rework by each categories such as
root cause) are reported as Quality KPI in the monthly report of Reliability Section.
Quality KPI should be reflected to continuous improvement and corrective action
should be taken.

8. Documents and Formats


In order to sustain the Maintenance Quality Management System, a lot of formats for
document are used. The documentations concerned to this manual are as follows.
-

Maintenance Quality Procedures


: PR-MN-REL-P-XXX

Maintenance Work Instructions for equipment repair / maintenance


: PR-MN-REL-WI-XXX, PR-MN-FMN-WI-XXX, PR-MN-SMN-WI-XXX)

Check Lists for shop / field Maintenance


: Included above Procedures or Instructions as attachments

Records
: Developed by each activities such as repair results or condition monitoring

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
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The list for Maintenance Quality Procedure, Work Instructions and Records are
shown in Attachment-1, 2, 3 respectively.
These documents are reviewed and updated or deleted by Maintenance Quality
Committee and new documents are developed and register as needed under approval
of Maintenance Quality Committee.
Attachment -1 List for Maintenance Procedures
No.

Document No.

Document Title

PR/MND/REL/P-001

Reliability Section Procedure

PR/MND/REL/P-003

Electrical Criticality Classification Guideline

PR/MND/REL/P-004

Preventive Maintenance Program Procedure

PR/MND/REL/P-005

Maintenance Quality Program

PR/MND/REL/P-401

Critical Machinery Change Over Guideline

PR/MND/REL/P-402

Reliability Audit Guidelines

PR/MND/REL/P-403

General Condition Monitoring Guidelines

PR/MND/REL/P-404

Lubrication Guidelines

PR/MND/REL/P-405

Machinery Changeover Guideline-Monomer

10

PR/MND/REL/P-406

Machinery Changeover Guideline-Refinery

11

PR/MND/REL/P-407

Machinery Changeover Guideline-U&OM

12

PR/MND/REL/P-903

Reliability Work Flow Guidelines

13

PR/MND/REL/P-904

Preventive Maintenance Guidelines

14

PR/MND/REL/P-905

Equipment Bad Actor Management & Elimination Program


Guideline

15

PR/MND/REL/P-906

Reliability Quality Control Procedure

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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16

PR/MND/REL/P-907

Rotating Machines Structured Operator Rounds Guidelines

17

PR/MND/REL/P-910

Equipment Integrity Failure Investigation Procedure

Attachment - 2

List for Work Instructions (1/2)

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
Document No.
Rev. No.
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Attachment - 2

Section: Reliability Section

Effective Date
., 2015

List for Work Instructions (2/2)

Page No.
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Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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Rev. No.
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Attachment - 3

Section: Reliability Section

Effective Date
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List for Records

No

Record No.

Record Title

PR/MND/REL/F-060

API Plan 53 B Buffer Fluid Filling Checklist

PR/MND/REL /F-061

Centrifugal Compressor Round Checklist

PR/MND/REL /F-062

Centrifugal Pump Round Checklist

PR/MND/REL /F-063

Condition Monitoring Report

PR/MND/REL /F-098

Failure Analysis Report

PR/MND/REL /F-099

Machinery Reliability Review/Audit Check List for


Compressor & Turbines

Procedure Title:

Maintenance Quality Program


Department: Maintenance Department (MND)
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PR/MND/REL /F-100

Machinery Reliability Review/Audit Check List for Pumps

PR/MND/REL /F-101

SAP Equipment Master Database Request

PR/MND/REL /F-107

Protection Relays Resetting Schedule

10

PR/MND/REL /F-108

QC Performance Audit Report

11

PR/MND/REL /F-109

Reciprocating Compressor Rounds Checklist

13

PR/MND/REL /F-110

Section Letter

14

PR/MND/REL /F-111

Vibration Check Request

15

PR/MND/REL /F-112

Recommendation Closure Certificate

16

PR/MND/REL /F-113

Temperature Trip Report

17

PR/MND/REL /F-114

Trip Investigation Report

18

PR/MND/REL /F-115

Close Out Sheet Form

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