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Preventative Maintenance Operating Procedures

PREVENTATIVE MAINTENANCE
OPERATINGPROCEDURES

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Preventative Maintenance Operating Procedures

TABLEOF CONTENTS
1.0 PreventativeMaintenanceProgram.....................................................................3
1.1
1.2
1.3

FastInspectionofToolFIT.........................................................................................3
ToolsReviewandInspectionMonthlyTRIM.............................................................3
QuarterCheckQCheck...........................................................................................4

1.3.1 ToolFloodedorFishedConsiderations............................................................................4

1.4
1.5
1.6

Temperaturetestwithoven....................................................................................4
EngineerAcceptanceProcedureEAP(Passed).........................................................5
ToolTags......................................................................................................................6

1.6.1 RedTag..............................................................................................................................6
1.6.2 YellowTag..........................................................................................................................6
1.6.3 GreenTag..........................................................................................................................7

LISTOF ILLUSTRATIONS

Figure1: RedTag..............................................................................................................................................5
Figure2: YellowTag.........................................................................................................................................5
Figure3: GreenTag...........................................................................................................................................6

LISTOF TABLES

Table1:PreventativemaintenanceProceduresSummary.................................................................................3

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Preventative Maintenance Operating Procedures

1.0

PreventativeMaintenanceProgram
ThepurposeofthePreventativemaintenanceprogramissimplytoreducelosttimefailuresand
improveourKeyPerformanceIndicators.Historicalstatisticsshowthatitispossibletoeliminate
upto60%oflosttimefailureswitheffectiveandontimetoolmaintenance.

Properimplementationofthisprogramisvitaltocompetitivepositionintheindustry.

Table1summarizesthecomponentsofthePreventativemaintenanceprogram.Thesections
thatfollowprovideamorethoroughexplanationofeachcomponent.

Table 1:PreventativemaintenanceProceduresSummary

Name
FastInspectionofTool
ToolReview&Inspection
Monthly

Acronym
FIT
TRIM

QuarterCheck

HighTemp/PressureTest

Engineer
AcceptanceProcedure
Calibration

QCheck

Oventest

EAP
(PASSED)

CAL

Performedby
FieldCrew

Frequency
Before/aftereveryjob.

Field/Mainte Monthly.
nanceCrew
After every labrepair;andona fixed
Maintenance basisthatisdeterminedbyusage.
Technicians Maintenancerequestsareauto
generatedbyFixNet.
Maintenance After every labrepair;andona fixed
Incharge(by basisthatisdeterminedbyusage.
FSMorder) Maintenancerequestsareauto
generatedbyFixNET.
Field
Engineer/
Supervisor

Performedwheneveranengineer /
Supervisoracceptsatoolforuseona
fieldunit.

FieldEngineer Regardingtotoolscalibrationexpiration
periodwroteintheirmanuals.

1.1

FastInspectionofToolFIT

FITmustbeconductedbythefieldcrew,oneveryloggingtooldeployed,beforeandaftereachjob.
FITinvolvebasicvisualinspectionsandgeneralcleaningandservicingoffieldtools. The
requirementsvaryfromtooltotool,butinallcases,thechecksaredesignedtoensurethetoolsare
inproperworkingorderbeforetheyareusedorstored.

Fieldengineers/supervisorsareresponsibletoensurethefieldcrewperformingtheFITisdoingso
inasafeandcomprehensivemanner.

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Preventative Maintenance Operating Procedures

1.2

ToolsReview&inspectionMonthlyTRIM

TRIMmustbeperformedbythefieldcrewonalldevicesassignedtotheirfieldunitonamonthly
basis.TRIMtypicallyinvolveelectricalpintopincontinuityandleakagecheckstoverifythe
electricalintegrityofthedevice. Theymayalsoincludemoreinvolvedinspectionandservicethen
theFIT.

Fieldengineers/supervisorsareresponsibletoensurethefieldcrewperformingtheTRIMisdoing
soinasafeandcomprehensivemanner.

1.3

QuarterCheckQCheck
TheQCheckisperformedbyfieldtechniciansonaperiodicbasisasapartofthescheduled
maintenanceprogrammanagedbytheFixNETdatabase.

ThelengthofthescheduledintervalbetweenQChecksisdeterminedbytimeorbytoolusageandis
typicallybetween6and24months. TheintervalisresetaftereveryQCheckisperformed. The
frequencyatwhichtheQCheckissetinFixNET,isdeterminedbyMaintenanceGroup.Various
locationsareabletorecommendnewQCheckrulesinFixNETiftheywishtoQCheckmore
frequently,forinstanceiftheyperformahighvolumeofworkorareexposedregularlytohigh
workingtemperaturesandpressures.

TheFunctionalTestSectionoftheQCheckisalsoperformedaftereverytoolrepairand
modification. TheQCheckscheduledmaintenanceintervalisnotresetifjustaFunctionTestis
performed.

OncetheQCheckhasbeensuccessfullycompleted,thetoolsshouldbeyellowtaggedandreleased
tooperationalpersonnel,whomustconductanEAPpriortoacceptingitforfielduse.AftertheEAP
testhasbeensuccessfullycompleted,thetoolcanbefittedwithagreentagandassignedtoafield
unitorplacedinstorageontheactivetoolshoprack.

1.3.1

ToolFloodedorFishedConsiderations
1) TheQCheckisonlytheminimumrequirementafteratoolhasbeenfloodedorfished.Thereisa
verygoodchancethatextensiveworkwillneedtobeperformed.Itemsthatmaynotbeobvious
duringanormalQCheckmayneedtobeexaminedcarefullyduetothisevent.
2) Carefullyevaluatetheextentofthedamage.Trytodeterminetheoriginoftheflood.The
sourcemaynotbeobviousandmaybedifficulttofind.ConsultwithyourManagerand
determineifyouarecapableofrepairingthetool.
3) ContactToolManufacturerSupportforassistance.Reportwithadequateinformationand
photosforrecommendationsoranappropriatecourseofaction.
4) Toensurethatalloftheproblemshavebeenaddressed,itmaybebeneficialtoreturnthe
tooltotheRepairfacilityifthedamageisbeyondyourabilities.

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1.4

Temperaturetestwithoven

TheLabtestprocedurewithoventestisusedinplaceofthestandardlabtestprocedurefortools
usedindistrictsthatexperiencehighoperatingtemperaturesand/orpressures.

OncetheOventesthasbeensuccessfullycompleted,thetoolshouldbeyellowtaggedandreleased
tooperationalpersonnel,whomustconductfunctiontestpriortoacceptingitforfielduse.Afterthe
Functiontesthasbeensuccessfullycompleted,thetoolcanbefittedwithagreentagandassigned
toafieldunitorplacedinstorageontheactivetoolshoprack.

1.5

EngineerAcceptanceProcedureEAP

Engineeracceptanceproceduresmustbeperformedontoolsbyfieldengineers/supervisorsbefore
theycanacceptedforuseonafieldunit. Thisincludesrepairedtools,newtools,modifiedtools
andtoolstransferredfromothertrucksordistrictsandtoolsthathavebeenTRIMcheckedand
placedontherackforstorage.
EngineersalsohavetocheckthelastcalibrationdateofthetooltoconductEAP,itcanbedoneby
checkingFixNetStatusofthetoolorToolHistory.Incaseofcalibrationexpiration,engineermust
calibratethetoolASAPorshouldyellowtagittoletotherengineersknowitsoutofcalibration.

1.6

Tool Tags

1.6.1

RedTag
ARED tagindicatesatool/equipmentfailureanditshouldbeaccompaniedbyaRepairRequest.
AfailedtoolshouldalwaysbeRED taggedbeforeitcomesbacktobase. EachRED tagshould
includethefollowinginformation:

Figure1:Red Tag

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1.6.2

YellowTag
AYELLOW tagsignifiesthetoolhasbeenrepairedbythetechnicalstaff,checkedwithQCheck
andneedstobeevaluatedbyanEAP.EachYELLOW tagshouldincludethefollowing
information:

Figure2:YellowTag

1.6.3

GreenTag
ToolsevaluatedbyanengineerandcheckedwithanEngineerAcceptanceProcedure(EAP)are
taggedwithaGREEN tag.AGREEN tagindicatesatoolisreadyforajob.Alltoolsshouldbe
GREEN taggedbeforegoingoutonajob.EachGREEN tagshouldincludethefollowing
information:

Figure3:GreenTag

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