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 Work request

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

Work order (CM or PM) (Maintenance) Job safety analysis Work permit (Maintenance + Safety + Process) (Safety + Process + Maintenance )

Forms

Maintenance Forms - Dr. Attia Gomaa - 2007

Maintenance W/O Contents:

1. 2. 3. 4. 5. 6. 7. Work request (#, requester, description, .. etc.) Dates (start date, finish date, complete date, .. etc), W/O criticality (system/ equipment criticality, W/O priority, .. etc.), Safety condition (work permit #, type: cold, hot, main items, JSA,.. etc ), Last maintenance or Maintenance History (type, description, date, .. etc.) Job plan (main steps, planned duration, actual duration, .. etc.)

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

8.
9.

Tool list (code, description, quantity, planned duration, actual duration, .. etc.)
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: CM MM SM PM PD RP OM Corrective Modification Service Preventive Predictive Repair Work Overhaul

W/O Priority:
P1. Emergency (within 2 hours) P2. Critical (within 24 hours) P3. Normal P4. Overhaul

Op. 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 a safe working environment by providing management control over activities which may have hazardous interactions. 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 Certificates 6. Pressure Test Certificate

Do Not Do Any of These Tasks Without A Permit To Work

Forms
Maintenance Forms - Dr. Attia Gomaa - 2007