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  • Psp-Resak Hti-29 Equipment Testing and Maintenance Procedure

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    Atuk Safiz
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    Equipment Testing & Maintenance Procedure.

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    Psp-resak Hti-29 Equipment Testing and Maintenance Procedure

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    Equipment Testing & Maintenance Procedure.

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    43 visualizações29 páginas

    Psp-Resak Hti-29 Equipment Testing and Maintenance Procedure

    Enviado por

    Atuk Safiz
    Equipment Testing & Maintenance Procedure.

    Direitos autorais:

    © All Rights Reserved
    Baixe no formato PDF ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
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    PROCEDURE NO: 2 PROJECT SPECIFIC PROCEDURE PSP-RESAK HTI-29 HUC REVISION NO. 0 EQUIPMENT TESTING AND MAINTENANCE PROCEDURE FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR DAYANG ENTERPRISE SDN BHD. PCSB PREPARED BY REVIEWED BY APPROVED BY REVIEWED BY | APPROVED ay ney. | are i ‘lige 0 Beles [Hem Or aafee Sean | 20766 | Am qe a3 fou | SOU 7 PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 e AND MAINTENANCE PROCEDURE REVISION NO. 0 HUC PAGE 10F9 ‘TABLE OF CONTENTS SECTION DESCRIPTIO! PAGE 10 PURPOSE 3 20 SCOPE 3 3.0 REFERENCES 3 40 DEFINITIONS 2 5.0 PROCEDURES 5.1 Equipment Maintenance Process Flow Figure [ 4 5.2. Equipment List 4 5.3 Equipment Movement / Locality 4 5.4 Equipment Maintenance Record 4 5.5 Equipment Receiving and Checking 4 5.6 Equipment Maintenance Activity 5 5.7 Equipment Test Run 6 5.8 Pre-Mobilization 6 5.9 Onsite Operations/Checking 7 5.10 Demobilisation of Equipment 7 5.11 New Equipment ia 5.12 Documentation 8 6.0 SPECIAL REQUIREMENTS 8 70 RECORDS 8 PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 AND MAINTENANCE PROCEDURE REVISION NO. 0 HUC PAGE 2 0F9 TABLE OF CONTENTS SECTION — DESCRIPTION PAGE Figure-1; Equipment Maintenance Flow Chart 9 APPENDICES DE-F-06 : Service Request DE-F-61 Pre post Repair Checklist DE-F.62 Equipment Movement and Maintenance Record DE-F-63 Equipment Inspection Report DE-F-74 : Mechanical Log Sheet DE-F-83 Equipment Maintenance Record DE-F-84 ; Equipment List (MovementLocality/Status) DE-F-89 Checklist ~ Portable Air Compressor DE-F-90 Equipment Failure Analysis Report DE-F-91 : Checklist ~ Portable Welding Set DE-F-92: Checklist High Pressure Water/Steam Cleaner DE-F-93: Checklist Portable Engine Driven Water Pump DE-F-94 : Checklist ~ Paint Spraying Equipment DE-F-95 : Checklist ~ Blasting Pot Sample: Equipment Movement Tag Sample Il: Equipment Safety & Technical Inspection PR URE . EQUIPMENT TESTING pane AND MAINTENANCE PROCEDURE REVISION NO. 0 HUC PAGE 3 OF 9 1.0 2.0 3.0 4.0 PURPOSE This procedure describes minimum guideline on equipment maintenance and service for the execution of Petronas Carigali Sdn Bhd (PCSB) ~ Provision of HUC of Carigali Facilities for Year 2007-2010 Projects and to ensure that the accuracy of the measuring and testing equipment is within the allowable tolerance. SCOPE This procedure applies to all DESB Resak HTI Project measuring and testing equipment which require calibration to ensure that their accuracy is within the allowable tolerances. REFERENCES ISO TEC GUIDE 25 1990 - General Requirement for the Competence of Calibration and Testing Laboratories PTS 20.167 (SSB/SSPC Rev 0 - Commissioning Engineering Manual May 83) ANSIINCSI 2540-1-1994 - Calibration Laboratories, Measuring & Test Equipment General Equipment ANSUISO/IEC 17025 - General Equipment for Competent of Testing & Calibration Labor FSP-DESB-16 - Material Control Procedure DEFINITIONS, DESB = Dayang Enterprise Sdn Bhd PCSB - Petronas Carigali Sdn Bhd SR - Service Requisition PTS + Petronas Technical Standard AND MAINTENANCE PROCEDURE PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 REVISION NO. 0 HUC PAGE 4 OF 9 5.0 PROCEDURE 5. 5.2 53. 54 55 Maintenance Process Flow ‘The equipment maintenance process flow is shown in Figure 1. Equipment List ‘The full equipment list will be maintained by the Senior Mechanic Supervisor. Record will be maintained at DESB office. List of all equipment shall be fumished to PCSB representative and ensure all equipment has been inspected and safely tagged. Equipment Movement/Locality The equipment movement between onshore and offshore locations and DESB Warchouse(s) will be recorded in the Equipment Movement list (form DE-E- 84), The record will be updated on weekly basis Equipment Maintenance Record ‘The Equipment Maintenance Record of scheduled servicing for all equipment shall be maintained by the Mechanic Supervisor. (Refer to form DE-F-83). The maintenance record will be updated on fortnightly basis or monthly if there is no change to the record during the fortnightly period. All preventive maintenance work shall be performed in accordance with the manufacturer recommendation specified in the equipment catalogue or the “Owner Manual” for each equipment to optimize the equipment operation and consequently minimize breakdown and downtime, Equipment Receiving and Checking Upon return from offshore or onshore projects, the equipment will be received as follows i) Attached with tag numbers ii) Conduct general equipment inspection and health check AND MAINTENANCE PROCEDURE PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 REVISION NO. 0 HUC PAGE 5 OF 9 5.6 If the equipment is found to be in good condition, after normal servicing, changing of engine oil and cleaning works, the equipment shall be retained in the Warehouse until the next project or assignment. ‘The equipment movement and maintenance record will be updated each time the ‘equipment moved or maintained (See Form DE-F-62). If equipment is found to be not in working condition, it shall be repaired before usage (refer to Figure 1 Equipment Maintenance Flow Chart). Equipment Maintenance Activity a) If major maintenance is required, the equipment shall be sent to the agreed contractor. Prior to the award of the maintenance job, the following will be done = i) The contractor shall carry out check and shall establish scope of work during the inspection, mostly by verbal means. ii) Contractor shall submit a quotation of the maintenance work based on information obtain from (i) above. iii) DESB will review the quotation and subsequently award the job to the successful contractor, by issuing them with a completed SR form. (See form DE-F-06). The contractor shall also be reminded verbally on the repair schedule e.g. proposed date when the equipment should be completed and ready for use by DESB. ‘The equipment move and maintenance record shall be updated accordingly to reflect the repair carried out. (See form DE-F-62). PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 AND MAINTENANCE PROCEDURE, setetshtete totais REVISION NO. 0 HUC PAGE 6 OF 9 57 b) ist of Service Contractors The common list of contractors normally providing the maintenance services shall be kept by the Senior Mechanical Supervisor and copy to the Project Manager. DESB shall note contractor who are specialized in ceriain task e.g, body work or major engine overhaul List of Service Contractor shall be approved by Petronas in accordance with SWEC Code. ©) Minor Maintenance Repair Activity and Servicing Minor repairs and servicing like changing of oil filter, cleaning of engine and painting of the body works shall be done in-house by DESB mechanic, Equipment Test Run A pre-start up inspection shall be conducted on the equipment at the contractor premises after completion of the repair job including other repair works, such as major body repair, etc. and a test run shall be done. ‘The equipment shall be returned to DESB Warehouse upon completion of the test run and a new equipment inspection tag shall be placed on the equipment, The repaired equipment will be stationed at the warehouse, until the next mobilization or use within the company operation: Pre-Mobilization General inspection of all the equipment shall be conducted and test run shall be performed to ensure that the equipment is in a good working condition before mobilization to project site. Equipment safety passport sticker shall be placed on the equipment to indicate status and other movement details prior to shipment. AND MAINTENANCE PROCEDURE PROCEDURE NO, EQUIPMENT TESTING PSP-RESAK HTL-29 REVISION NO. 0 HUC PAGE 7 OF 9 59 5.10 Onsite Maintenance a) b) Minor Maintenance Servicing and Record Keeping Normal equipment servicing or checking shall be conducted from time to time while the equipment is in operations at onshore or offshore locations. Equipment records shall be maintained by the Mechanic/Technician using mechanical log sheet form. (See Form DE-F-74). Major equipment failure or malfunction shall be reported the onshore Mechanic Supervisor. The onsite mechanic shall provide weekly equipments status under his authority to the Mechanic supervisor at the DESB Head Office via telephone or fax, Any inspection findings on the equipment including the proposed repair shall be stated in the equipment inspection report. (See form DE-F-63). This form shall not be used for the normal routine checking, Major Failure and Failure Analysis Any major failure occurred shall be reported by using form DE-F-90. ‘The failure shall be studied and analyzed to identify the cause and to establish ‘measure to prevent future recurrence of such major failure. Demobilisation of Equipment Upon completion of a project, the equipment shall be returned to the onshore base mechanic at the warehouse. The usual equipment inspection / maintenance requirements shall be performed as per equipment maintenance flowchart. Refer in Figure I attached, The equipment list in above Section 5.2 shall be updated accordingly. EQUIPMENT TESTING AND MAINTENANCE PROCEDURE PROCEDURE NO. PSP-RESAK HTI-29 HUC REVISION NO. 0 PAGE 8 OF9 6.0 10 5.11 New Equipment A commissioning test run shall be done on new equipment purchased by DESB. The test run shall be witnessed by the vendor and DESB Senior Mechanical Supervisor. Upon satisfactory test run, a job acceptance form shall be signed by representatives of both parties. The equipment list in above Section 5.2 shall be updated accordingly. 5.12 Documentation All document pertaining to equipment such as the owner manual, Repair/Maintenance Handbook, etc. shall be kept by the Senior Mechanic Supervisor. As for equipment such as welding set, only an in-house test run will be carried out. Documentation shall be kept at DESB office minimum 5 year’s retention period. SPECIAL REQUIREMENTS None RECORDS Figure 1: Equipment Maintenance Flow Chart PROCEDURE NO. EQUIPMENT TESTING PSP-RESAK HTI-29 AND MAINTENANCE PROCEDURE REVISION NO. 0 HUC PAGE 9 OF9 = Receive Equipment rom Site Minor rpc Conduct Genera Taspection Major repair ‘Oban quotation from approved t SWEC Contractor Repairby DESH mechanic q + Award servos + Commence repr work }—___ ¥ Conduct after epi inspecton and test "Fil check and stach equipmest Daily routine check amd tat-upby |» " Giigrs mas "warchouse personnel + Shptoske + Offthore mechanic to cay ot daly routine check 4+ Recon and report on monthly bass ¥ Figure-1: Equipment Maintenance Flow Chart APPPENDICES DAYANG ENTERPRISE SDN BHD NO. SYARIKAT 7721/80 (TEMPATAN 61505-V) Lot 1-07, LEVEL 11, BREM MALL, JALAN KEPONG, ‘52000 KUALA LUMPUR ‘TEL: 03 - 6259 2471 (4 LINES) FAX: 0362592451 WEBSITE : www. Contractor: SERVICE REQUISITION Date: ‘Account SR/KL Code: Require for.- Date Require: Contract No:- Project Ref:- No. ‘SERVICE REQUIREMENT ary AMOUNT Request by: ‘Approved by: Inventory check: ‘Action by: Name’ Dato: CONTRACTOR Rev (FORM : DE-F-61) DAYANG ENTERPRISE SDN. BHD. (61505-vy PRE/POST REPAIR CHECKLIST OF AIR COMPRESSOR & WELDING MACHINE. Equipment Mode! Pre-Repair Inspection Date SNo. Inspected By Tag No. Verified By Pre-Repale 7 Post-Repaie Work Desrinion — Remar a Remarks [dh HicericaPavumatie Sete 1. _ Wiss System. Loose or 2 [starter Mote 3. [Sener swten 4 fRetay 5. [Magnetic Swieh 6 [Altematoe And Charging 7. | uty shutdown Devies Bonen Water ae, Soa = 9. [eauges Engine 4 Fessure Water Temperate [Gompresoro Lerma xbaustTemperatne voter fractomster ir ischarge Presse sett System Pressure star Air Pressure 2 uel Stem 1. |ruetWetersopaatr 2 frvet Finer REV.3 APROt tors a (FORM : DE-F-61) w sion Pre Repl PoseRepale ork Dserptio jess marks nitions Remarks 3. [ et Priming Pump 4 [Fue Hoses and Conestion [| Res Tone inde And Comezton Fue Tank For Din And & lwaee Svein amp &_[hiectormczin i Engine Ot iter 3._|AieCteaner ements 4 [Redinor water tev cop 5. ]Enaine Blower Fan Hee 6 [Atemaor Fan Ben 7. [ngine 01 Cooter nak And East sata 9. [aumer nd Spark Arestoe 10. |eneine Brasher 1 fos Pine 12, [Bewins 13, Joteats 1 |aountngs [oo Comores ir 1 [Compressor it 2 [bess Pines 3. owcooter 4. [oitcooer Fan Ben 5. [owt 6 [Scour Tan/Eemeae 7._ [Ale resure Regu |e Chamer ements Rev. APROI 2o3 ee (FORM: DE-F-61) Work Description = Remarks bird Remarks 9. [ake Diarge Vae Psu Min ae ao Boedown Va [rey vane ad 1p 2. fener 3 [Restor 4. [pee Ranse Sich 5. [pease vatage Conta 6 [ico Recor Hanae 7 [ltincctoy Reo Haale 8 [Caton inate 9, [Restos 10._ [Conroe alam Liss 1i_|eonat Pint Pate 12,_ [save Haw Maer Bod Frame 1. [ste coven 2 [owner Coes 3._ [Top Ant Boom Covers 4 [ose 5 [ovens 6 |Fames >| eons By: aa Vesey Date Due = Rev. AERO: sors sess ssosmerwe sna jaa [aoa vane | moaa NT [moo] San HSS: of womarossa ua yoanoorens| ox ove wsvuints| adOoea FAONVNALNIVIA GNV LNGWAAOW LNaIWaINOa aera aC © (FORM : DE-F-63) Ms DAYANG ENTERPRISE SDN. BHD. (61505-V) EQUIPMENT INSPECTION REPORT - Maintenance EQUIPMENT SINO. F TAG. NO. : DATE : FINDINGS ITEM PROBLEMS, ITEM PROPOSED SOLUTION RECOMMENDATIONS : REMARKS. INSPECTED BY = DATE VERIFIED BY DATE APPROVED BY : DATE : | REV.3 APROT (FORM : DE-F-74) DAYANG ENTERPRISE SDN. BHD. | (61505-V) MECHANICAL LOG SHEET MACHINE MODEL SERIAL NO/TAG NO. LOCATION: ___ DESCRIPTIONS DATE BATTERY ELECTROLYTE LEVEL/TERMINALS RADIATOR COOLANT LEVEL BELT ALTERNATOR BELT BLOWER FAN (AIR-COOLED ENGINE) BELT COOLER FAN BELT ENGINE WATER PUMP ENGINE AIR (MAIN ELEMENT) NGINE AIR (SAFETY ELEMENT) COMPRESSOR AIR (MAIN ELEMENT) [COMPRESSOR AIR (SAFETY ELEMENT) FUELAVATER SEPERATOR ELEMENT PRIMARY FUEL FILTER SECONDARY FUEL FILTER ENGINE OIL LEVEL ENGINE OIL FILTER [COMPRESSOR OIL LEVEL [COMPRESSOR OIL FILTER AIR/OIL SEPERATOR ELEMENT [HOSES (OIL, AIR, INTAKE, ETC) [SERVICE METER READINGS/OPERATING HOURS, TOTAL [CO HRS. BIE ( y= OPERATING HRS REMARK - TEGEND = A Adjustment R Replaced T+ Topp = Checked and found w be satsfictory S = Serviced eg ia the eas of Fuel Water Separator and Main Elements NA [Not Applicable [Nas : = Jobs done or parts used other than ruin checks aro be indicted under “emmiks column. Eg. Switches, Starter/Atemator rept, Carton Brishes replacement ee DUTY MECHANIC: a ee FIELD SUPTISUPERVISOR Zz VERIFIED BY REV. 3 SR APROI Sect DE-F-74/ Mech. Log Sheet pacconrwron drs (6330 C1 1 aS Nu NONE ‘ansuiy_[“SNIONS | “ONOWI [ON TWidag| “S00W ST ‘SuH/SIvG ‘SUH/RLVO 3O1AMSS LXSN ‘3o1nuas snoIAgua Paeg Tuondusssq yeudinby QuOOTY SONVNALNIVI LNSWdINO’ “da ‘Nas asi (a-sosi9) TAdUALNA ONVAVG Ea | (eg-4-30 : WHOS) (ermsiae-owoussey) NoUsTaNOD [SoNaRNOD eq goweg| sea gon & Noa stuoM smnig | 20190N enter | ons uoneu2s0q won GOI SONVNSLNIVN a e ny 18.907] Asid | 907 ]UESAIG 290 + wonduaseq wewdinba (SMLWLS / ALITV9O7/ LNAWSAON ) 1st] LNaWdINDA (a-sosi9) “CHa ‘NGS ASTadaALNT ONVAVG (84-30 : WHOS) e DAYANG ENTERPRISE SDN. BHD. (61505-V) [= oa! EQUIPMENT SAFETY PASSPORT SYSTEM (ESPS) EQUIPMENT CHECKLIST EQUIPMENT/MACHINERY PORTABLE AIR COMPRESSOR MODEL : REG. NO. : * | owner: LOCATION CHECKLIST (Please check and tick in the boxes below) B. X | DEFECTIVE [v_ | AccePTeD [=] MISSINGINOT AVAILABLE BOX ITems REMARKS Engine Condition (oil leak) Engine Cut Off/Shut Down Device Guards (Rotating Parts) Spark Arrestor & Exhaust System Pressure Relief Valves Pressure Gauge Fitting, Coupling and Hoses and Air Vessel Conditions Maintenance's Log (Mechanical Log Sheet) - Lifting Pad Eyes/Tyre Conditions Earthing Others (Please specify) General Remarks : Cc. D. CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE INSPECTED BY : (Name) INSPECTED BY: (Name) SIGNATURE SIGNATURE : z DATE OF INSPECTION = DATE OF INSPECTION : | EXPIRY DATE : REV.0 Rlad JAN'02 DE-F-89/Port.Air Compressor (ESPS) (FORM : DE-F-90) DAYANG ENTERPRISE SDN. BHD. (61505-v) en EQUIPMENT FAILURE ANALYSIS REPORT - Maintenance Dept EQUIPMENT : REPORT DATE: i ‘SINO. : | TAG NO. ‘SMH READING PREVIOUS LOCATION MOBILISATION DATE DEMOBILISATION DATE CURRENT LOCATION PROBLEMS a FINDINGS PROPOSED SOLUTIONS | REMARKS i INSPECTED & REPORTED BY 2 SIGNATURE i REV.0 SR/ad JAN'02 DE-F-90/Equipment Failure Analysis Report _(FORM: DE-F-91) i DAYANG ENTERPRISE SDN. BHD. (61505-V) EQUIPMENT SAFETY PASSPORT SYSTEM (ESPS) EQUIPMENT CHECKLIST EQUIPMENT/MACHINERY PORTABLE WELDING SET & ACCESSORIES MODEL = REG. NO.: A OWNER: LOCATION : 7 | CHECKLIST (Please check and tick in the boxes below) B. X | DEFECTIVE v_] ACCEPTED MISSING/NOT AVAILABLE BOX TEMS REMARKS Engine Condition (oil leak) Engine Cut Off/Shut Down Device Guards (Rotating Parts) ‘Spark Arrestor & Exhaust System Lead Terminal Points 110/240v outlet Socket c/w Weather Protection ELCB (10mA) c/w Weather Protection Earthing Maintenance’s Log (Mechanical Log Sheet) Lifting Pad Eyes/Tyre/Framework Conditions Radiator Condition Others (Please specify) General Remarks : c. D. CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE INSPECTED BY : (Name) INSPECTED BY : (Name) | SIGNATURE : SIGNATURE DATE OF INSPECTION : DATE OF INSPECTION: | EXPIRY DATE : REV.0 SRlad JAN'O2 DE-F-91/PortWeld. set & Accoss. (ESPS) Ps DAYANG ENTERPRISE SDN. BHD. (61505-V) (FORM: DE-F-92) EQUIPMENT SAFETY PASSPORT SYSTEM (ESPS) EQUIPMENT CHECKLIST EQUIPMENT/MACHINERY _HIGH PRESSURE WATER/STEAM CLEANER MODEL: REG. NO. A OWNER LOCATION oa CHECKLIST (Please check and tick in the boxes below) 7 X | DEFECTIVE v_] ACCEPTED = | MISSING/NOT AVAILABLE BOX ITEMS REMARKS Electrical Water Pump/Pneumatic Pump Electrical Fittings and Connections Water Supply Connections and Safety Device High Pressure Hose and Fittings Hand Spray/Steam Gun Burner and Exhaust System Pressure Gauge, Pressure Switch and Safety Valves Fitling/Coupling/Hoses Conditions Others (Please specify) General Remarks : c. D. CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE INSPECTED BY : (Name) INSPECTED BY: (Name) SIGNATURE - ‘SIGNATURE : DATE OF INSPECTION : DATE OF INSPECTION : | EXPIRY DATE REV.0 SRiad JANO2 DE-F-92/Migh Pressure Water/Steam Cleaner (ESPS) (FORM: DE-F-93) DAYANG ENTERPRISE SDN. BHD. (61305-V) ys a EQUIPMENT SAFETY PASSPORT SYSTEM (ESPS) EQUIPMENT CHECKLIST | EQUIPMENT/MACHINERY PORTABLE ENGINE DRIVEN WATER PUMP MODEL REG. NO. A OWNER : LOCATION CHECKLIST (Please check and tick in the boxes below) B. X | DEFECTIVE ACCEPTED - | MISSING/NOT AVAILABLE BOX ITEMS REMARKS Engine Condition (oil leak) Engine Cut Off/Shut Down Device Guards (Rotating Parts) ‘Spark Arrestor & Exhaust System Pressure Gauge/Temperature Gauge Condition Fitting, Coupling and Hoses Conditions Maintenance’s Log (Mechanical Log Sheet) Lifting Pad Eyes/Tyre Conditions Others (Please specify) General Remarks : Cc. D. CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE INSPECTED BY : (Name) INSPECTED BY (Name) SIGNATURE : SIGNATURE DATE OF INSPECTION : DATE OF INSPECTION : | EXPIRY DATE : REV.O SRlad JAN'02 DE-F-93/Port.Engine Driven Water Pump (ESPS) (FORM: DE-F-94) at DAYANG ENTERPRISE SDN. BHD. (61505-V) EQUIPMENT SAFETY PASSPORT SYSTEM (ESPS) EQUIPMENT CHECKLIST EQUIPMENT/MACHINERY PAINT SPRAYING EQUIPMENT MODEL : A. OWNER ] REG. NO. : LOCATION : TA ‘TCO NN EG, ND ART CHECKLIST (Please check and tick in the boxes below) B. X | DEFECTIVE [ ¥ ] ACCEPTED ie MISSING/NOT AVAILABLE BOX ITEMS REMARKS: Hose Condition Hose Connections/Fitting Pressure Gauge Pressure Regulator Spray-Gun Provided Safety Lock for Trigger Provided Earthing Others (Please specify) General Remarks : c. D. CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE INSPECTED BY: (Name) INSPECTED BY : (Name) SIGNATURE : SIGNATURE = DATE OF INSPECTION : DATE OF INSPECTION : | EXPIRY DATE REV.0 SRlad JAN'O2 DE-F-04/Paint Spraying Equip (ESPS) DAYANG ENTERPRISE SDN. BHD. GD (61505-V)

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