Core Unit 1 - Carrying Out Planned Maintenance v2

ECITB Level 3 International Diploma in
Engineering Maintenance – Core Unit

Session 1. Carrying Out Planned Maintenance
Core Module includes
Units
1. Carry out Planned Maintenance
2. Establish that a Maintenance Activity is Suitable
3. Diagnosing Faults
4. Determining the Feasibility of Carrying out Repairs
5. Testing Equipment and Analysing the Results
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Unit 1: IDCTCPM
Carry out Planned Maintenance
LO: Explain the tools, terminology, techniques and practices to carry out planned
maintenance procedures on plant and equipment
1.1 Explain the principles of scheduled maintenance
1.2 Describe maintenance schedules and specifications and demonstrate how to

interpret them
1.3 The techniques necessary to carry out plant maintenance procedures
1.4 Describe the procedures used to report on maintenance activities
1.5 Describe maintenance authorisation procedures and limits of responsibility and

authority
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Unit 1: IDCTCPM
1.1 Explain the principles of scheduled maintenance
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Explain the principles of scheduled maintenance
Plant and Equipment
No components, plant or equipment, are designed to last indefinitely

however, overtime will wear out
In addition to wearing out equipment could break, fail or sustain damage

and there are numerous causes of failure that can occur, these can
include:
• Age – Metals and plastic fatigues and weakens with age

• Wear – Caused by components moving against each other (friction)
• Vibration – Causes stress cracking
• Corrosion – Weakens metals through excessive build ups of rust,
oxidisation etc.)
• Environment – Heat, damp, corrosive atmospheres
• Lack of Maintenance
• And many others
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Types of Maintenance
Routine Maintenance:
Is maintenance that is carried out to prevent breakdown of

plant or equipment. It involves tasks such as lubricating,
cleaning and adjustment and tends to carried out regularly i.e.
every day or every week.
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Condition Monitoring:
• Is the monitoring of plant and equipment, and its operation in order

to recognise that a breakdown could be imminent, and so a
maintenance activity could be planned and could avoid an
equipment breakdown and subsequent loss of ‘downtime’.
• Condition monitoring can include vibration monitoring, temperature
monitoring and other measurement checks.
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Servicing:
Servicing of machinery is normally carried out on a

planned regular basis, the frequency of which can vary
depending upon numerous factors, including
manufacturers recommendations and / or other factors:
• Involves changing numerous components or oils,

these include oil, air, fuel filters and could include
yearly seal changes and / or bearing changes
• Only suitably skilled and qualified trades people

will undertake these activities
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What is Preventive Maintenance?
The care and servicing by operatives for the purpose of

maintaining equipment and facilities in satisfactory
operating condition by providing for systematic
inspection, detection, and correction of incipient failures
either before they occur or before they develop into major
defects.
Maintenance activities include:
• Tests
• Measurements
• Adjustments
• Parts replacement
• Cleaning
• Independent Verification (ICP)
Performed specifically to prevent faults and breakdowns occurring - leading to outage and loss of production
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Good Maintenance Scheduling and Planning:
You can avoid many engine problems and save money on Best Practice and basic principles within the
parts and repairs if you follow a regular maintenance Motor Industry.
schedule.
Make good maintenance a habit when your engine is new, and

always consult your operator's manual for special guidelines
for your make and model.
Service the engine more frequently if you use it heavily or

under dusty or dirty conditions
Therefore, makes good sense and best

practice to employ and convert these basic
principles into the oil and gas industry
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Maintenance Schedule Motor Industry V Petrochemical Industry
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Maintenance Schedule - Date / Time:
Maintenance scheduling can be based

on a number of factors these could
include:
• Hours
• Days
• Weeks
• Months
Other major factors to consider include:

• Operational Readiness
• Operations and Maintenance Safety
• Production & Maintenance Cycles
• Safety Critical Elements
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Reliability Centred Maintenance:
Is a process to ensure that process systems plant and equipment

continue to do what their users require in their present operating
state. An engineering framework that enables organisations to
establish a complete maintenance regime will include:
• Frequency, Type and Activity

• Cost against Maintenance
• Reliability (What is the item supposed to do?)
• Systematic Tasks
• Unplanned Breakdowns
• Over Servicing ensures low level of unplanned breakdowns
however, leading to excessive cost
• Impact on reputation and quality
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Determination of Asset Life:
Components, plant or pieces of equipment will not last indefinitely,

therefore organisations plan on-going operations around the ‘life
cycle’, of plant and equipment.
Factors involved in determining the useful life of a asset include the

age of the asset when purchased, how frequently the asset is
used and the environmental conditions
Other factors to consider include

• Maintenance Records
• Usage Allowance and Records
• Repair Analysis
• Integrity Records
• Breakdowns Data
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Extensions:
Sometimes equipment may be required to run beyond its planned

end date, there are many reasons for this i.e. Unavailable, long
lead in times, but where this occurs, it usually requires:
• Higher maintenance activities

• Increased labour cost
• Closer monitoring
• Further planning
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• Maintenance Scheduled
• Reliability Centred Maintenance
• Determining of Asset Life
• Recording Usage
• Extensions
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Unit 1: IDCTCPM
1.2 Describe maintenance schedules and specifications and demonstrate how to

interpret them
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Describe maintenance schedules and specifications and
demonstrate how to interpret them
Maintenance Manuals:
There are numerous types of manuals and guidance documents

available, and names vary from site to site, organisation to
organisation and across differing disciplines, for example.
• Workshop Manuals
• Manufactures Manuals
• Maintenance Manuals
• Guide Sheets
• Method Statements
Manuals provide detailed information about the component, equipment, plant, vehicle
etc., this includes the various specifications, capacities and tolerances, the correct
procedures to remove, dismantling, reassemble and refit components, plant or pieces of
equipment.
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Maintenance Schedules:
The servicing and maintenance schedules are initially

recommended by manufacturers of components, plant, pieces of
equipment or vehicles etc.
However manufacturers guides are usually only the starting point
we need to considering:
• Frequency and type of servicing
• Internal & External Factors
• Distance Travelled and Timescales
• Geographical Location
• Environment
Maintenance schedules will also be determined by the organisation

and its production requirements, type of plant and those Safety
Critical Elements/Components within
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Safety Critical Elements/Component are defined as:

Such parts of the asset or installation and such of its plant (including
computer programmes) or any part thereof: -
The failure of which could cause or contribute substantially to: or
A purpose of which is to prevent, or limit the effect of, a major accident.
• SCEs must perform to clearly defined performance standards

• By physical testing be shown to do so (verification)
• Verification Scheme administered by independent person
• You must be alert to defects/deficiencies in plant, equipment,
processes or procedures.
• Proactively report to appropriate supervisor
• Implement the principles of the Safety Observation System
Emergency Shut -off Valves
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The Safety Critical Elements / Components Exercise
List the Safety Critical

Components of the Mini
What is their Function
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Parts Catalogues:
• Consideration of what parts and consumables should be
held in stock is vital and while parts catalogues still
exist, most organisations now use electronic systems to
record the input and output of all stock items.
• This enables the business to more easily monitor what

is in stock and its capital value, in addition what is
being used quickly and what is ‘on the shelf’, this
enables the business to better control costs and
expenditure.
• All business try to find an acceptable balance between what

is held in stock and how much financial capital (monies) is
available, for example
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Modifications:
• Existing plant and equipment may need to be modified within its planned
operating life.
• Modifications can vary from simply updating a particular component to a newer

but different version, through to major modifications requiring some structural
changes as operating problems may have emerged from the original design
and installation.
• The modifications will normally be scheduled into the servicing and

maintenance schedules OR Shutdowns, but, depending on circumstance,
may require a more immediate action.
• Organisation will implement a Change Management Process and Series of

Procedures to make any alterations to As Built, submitting RED LINE
Drawings from original P&ID’s
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Company Performance Standards:
• All on site component, equipment, plant and vehicles (assets), have

performance standards in place.
• These are used to enable the actual performance to be measured

against the planned performance, where differences emerge or occur,
this would initiate a process to identify the root cause(s) of where the
differences were occurring, why, and then enable consideration of
what could be done to correct.
• Performance Standards are also subject to Independent Verification

by an Independent Competence Person and forms an integral part
of the Written Scheme of Examination
Basically does the System or piece of Equipment perform to what it

states in the Performance Standard?
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• Maintenance Manuals
• Maintenance Schedules
• Parts Catalogues
• Modifications Lists
• Repair Information
• Company Performance Standards
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Unit 1: IDCTCPM
1.3 Describe the techniques necessary to carry out plant maintenance procedures
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Describe the techniques necessary to carry out planned
maintenance procedures to plant and equipment
Numerous techniques will be used when carrying out

maintenance activities such as:
• Breaking containment - flanges and joints, using ring

spanners, cold chisel and hammer to ease open joint.
• Using screwdriver to release electrical wires from

connections, clips and housings.
• Dismantling instrument control valves and components using

open ended spanners
• Wrenches for dismantling pipework
• Carrying out correct procedures to Isolate source of energy.
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Isolation Techniques and Procedures
Prior to inspecting, cleaning, repairing or maintaining

power driven machinery where persons may be
exposed to:
• Dangerous moving parts.

• Electric shock.
Plant “lock-off” isolation procedures must be strictly

complied with.
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Stripping Down:
Some components, plant or pieces of equipment, as part of the

scheduled maintenance process (or service) can be quickly (or
easily) ‘stripped down’ to enable component condition to be
checked for wear, corrosion, pitting and also its general condition
etc. these include:
• Bearings
• Brake linings
• Brush packs in electrical motors
• Clutch linings
• Drive belts or chains
• Pumps, valves and compressors
• Electrical and Instrumentation components
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Component Condition and Cleaning:
Many components, plant or pieces of equipment, when in use, can be effected by emissions from the
surrounding site, or from the environment, for example:
• Corrosion or become dirty through emission leaks, dust, oils, greases (or other products)
Before being dismantled, these items must be thoroughly cleaned, and in some instances, the cleaning may
require the involvement of specialist cleaning companies as some products can be harmful to people and to the
environment etc.
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Unclean / Dirty:
Plant, vehicles, equipment can become dirty (or contaminated) via

numerous other means, these could include:
• Dust
• Oil
• Grease
• Sand
• Mud
• Product emission leaks
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Checking, examining and inspecting for:
As components, plant or pieces of equipment are dismantled, its

very important that the parts are checked, examined and
inspected for: Wear
• Making visual inspection

• Taking measurements and precession measuring
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Checking, examining and inspecting for:
In addition to visually checking and taking measurements as mentioned

previously, maintenance technicians will check: -
inspected for: Damage
• Housing damage (cracks, breaks, bent out of original shape)

• Colour of oil / grease on draining (or removing) and are there
signs of contamination, metal particles or does oil feel ‘gritty’
• Paintwork (chafing, deep scratches, bright steel showing (could
be loose on mountings),
• High operational resistance when turning drive shafts / gears
(i.e. NOT running freely)
• Chips / damage on components - Gear teeth, Dog clutches,
Synchromesh mechanisms, bearings
• Signs of excessive temperatures (colour of metals, melting)
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Precision Measuring:
• As previously discussed, when using precision measuring equipment

(tools), these would always be used in conjunction with
manufacturers technical data (specifications).
• In addition, historical readings (where available) should be

considered as measurements may have been made over a period of
time (known as historical data), which can identify levels (or degrees)
of wear over given time frames.
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Repairs, Modifications, Aligning, Adjusting Settings

and Hand Fitting:
• Many items of equipment can be restored to a good and

serviceable condition by repairing the damage, or by
making adjustments, or making modifications or re-
aligning to a component.
• However, some components, or pieces of equipment are

classed as being ‘consumable’, these include items such
as oil seals, gaskets, bearings, brake pads, drive belt,
etc., where this is the case, then ‘like for like’ replacement
is usually undertaken, and in many instances, resolves the
problem without the need for the full component being
replaced
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Component Replacement:
• In some cases a repair may not be possible, but a

replacement of a consumable item (such as an oil seal,
bearing, drive belt) could resolve the problem
• A replacement of a bigger part such as an engines

water, oil or fuel pump may resolve the problem and
avoid the need for a more costly engine (or component,
plant or piece of equipment)
• Once again techniques and process required include:

Isolation, dismantle, repair or replace, reassemble,
install, make secure, test and commission, handover
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Recording Readings, Resetting Measuring

Devices and Testing:
• Important that readings of measurements are recorded

• Used as historical data and part of investigation
• Calibration of precision tools – give true readings
• Check against performance standards
• Required for independent verification
Plus certain pieces of equipment / systems once installed

or upgraded will then be subject to soundness test and
certification, test carried out using hydrostatic a pneumatic
methods and techniques
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Visual:
• Although the point of visual (or safety inspections) has

been covered previously, a visual (or safety) inspection
can often be a quick method of establishing the
condition or operational performance of components,
plant, vehicle or piece of equipment, from which
decisions can be made as to which further actions (if
any) are needed
• The use of P&ID’s and specifications may be useful

when carrying out these visual checks and techniques
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Compliance:
• Does the components, plant or pieces of equipment

meet the manufacturers or site specification, does it
meet the Independent Verification requirements? - if not
then further investigations are required, if ok, then the
compliance exercise and readings must be recorded
and the component, plant or piece of equipment can be
re-assembled
• The use of P&ID’s and specifications may be useful

when carrying out these compliance checks and
techniques
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Testing and Compliance Checks:
What are some common

forms of stored energy?
• Electricity.
• Hydraulics.
• Pneumatics.
• Mechanical – fly wheel.
• Springs.
Work on stored energy sources by competent persons only.
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• Stripping Down
• Cleaning
• Checking, Examining and Inspecting
• Precision Measuring
• Repairs
• Component Replacement
• Modifications
• Hand Fitting
• Aligning Components
• Adjusting Settings
• Resetting Measuring Devices
• Recording Readings
• Tests
• Compliance
• Visual
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Unit 1: IDCTCPM
1.4 Describe the procedures used to report on maintenance activities
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Describe the procedures used to report on
maintenance activities
Maintenance Records:
Why is it important to keep maintenance records?
A: enables the site management and coordination teams to establish:
• What maintenance activities have been carried out

• What parts were used during each activity
• Who carried out these activities
• When were these carried out
• Is the components, plant and equipment reaching the end of its
planned operating life cycle
• Should a repair or replacement be scheduled to undertaken - or
undertaken if its an unplanned breakdown.
• Helps formulate the planned maintenance schedule
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Required Documents:
What types of documentation do you think is required?

• Risk Assessment of the tasks to be completed
• Permit to Work
• Method Statements
• P&ID’s & Engineering Drawings
• Manufacturers Specifications
• Standard Operating Procedures
• Job Sheets / Card
• Isolation Certificate
• Test Report / Certificate
• Approval Records (Verification Reports)
• COSHH Data information
• PPE Information
• Tools & Equipment etc
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Storage Requirements of Documentation:
SYSTEMS, APPLICATIONS AND PRODUCTS IN DATA

PROCESSING (SAP)
SAP is computer software that can be used to manage an entire
company. It can be used by many individuals, in many locations
and in many currencies and languages, to manage a variety of
business activities.
MAXIMO ASSET MANAGEMENT ESSENTIALS

Maximo is another electronic tool, designed to help small and
midsized organizations manage their operational assets more
efficiently and effectively, throughout the complete asset lifecycle
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Storage Requirements of
Documentation:
Accident / Near Miss Records –In the

UK these must be kept for at least 3 years
from date of accident Source UK Health
and Safety Executive (HSE)
Health Record’ MUST be kept

for all employees under health
surveillance, the records are important
because they allow links to be made
between exposure and any health effects
Source: The Costs of Accidents

– Harsco Infrastructure/ CITB
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Personnel Records (Files):

The personal records (files) of suitably qualified and experienced
staff, and should contain the following information on all full & part
time staff, all contractors and all sub-contractors:
• A Curriculum Vitae (CV)

• Interview records
• References (from previous employers)
• Copies of occupationally relevant certificates
• View the driving licence and record the categories of vehicle /
plant qualified to drive
• The staff appraisal(s) and the performance targets set (and
achieved)
• Disciplinary Records (If applicable)
• Other Next of kin
Contact details of own doctor
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How do you establish the competence of your work team and keep track of who has what skills ?
Organisations must maintain Training and Competence Matrix
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Defect Reports:
• These are documents that sites (employers) use, and contain
information of problems that have been identified by own staff
personnel, or contractors (or other third parties)
• Specifically in regard to defects observed, whether these were

by visual inspection, safety check, or other means and were
identified as being a potential threat, risk or hazard that could
result in an unplanned breakdown or failure of a piece of plant,
vehicles, components or pieces of equipment, or a danger to
health.
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Test & Verification Reports:

Are documents that contain the results of any type of test where
equipment, meters or instruments are used to measure:
• Electrical – amps, ohms (resistance) or voltage

• Flow rate
• Noise
• Pressure
• Temperature
• Vacuum
• Vibration
• Condition
• Welding Reports etc
The results may be part of an independent verification exercise and
will be compared to the technical data from site or manufacturers
manuals, or compared to historical data for same (or similar)
equipment etc.
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Job Sheets / Cards:

• Are instructions to undertake some type of work
activity, job sheets are also called by other names,
for example - job cards, work instructions or method
statements.
• Can be issued over differing timescales, but are

usually issued on a daily or weekly basis.
• Contain the required activities to be undertaken in

some type of prioritised order.
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Approval (or certification) Records:

These are documents that are used to confirm that components, plant and
equipment are safe, and / or have been passed as being serviceable and
approved for use. Some examples of approval records include:
• Vendor and Licenser certificates

• Safety inspection certificates,
• Lifting equipment certificates
• Scaffold ‘scaff’ tags
• Ministry of Transport certificates (for vehicles and trailers).
• Pressure test certificates (mobile / static vessels and tanks)
• Tank wash certificates (when static or mobile tanks have been
cleaned).
• Portable Appliance Testing (PAT) records.
• Waste electrical and electronic equipment (WEEE).
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What is a Permit To Work system? A permit-to-work system is a formal

recorded process used to control work
which is identified as potentially hazardous.
What determines if a PTW is required?
The safety policy and risk assessment

Typically what sort of activities require a determines if a permit to work is required.
PTW?
PTW controlled activities typically include:

working with electricity, confined spaces,
hot work, excavations, hazardous /
explosive, pressure testing.
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Permit to Work:
Are safety critical documents that control the movement of
personnel, tools, materials and equipment into (or out of) controlled
or hazardous areas on any industrial site or employer location
Staff before going into a ‘controlled area’, MUST request a Permit to

Work, and MUST wait until they receive written confirmation that an
approval has been given, similarly staff when leaving the controlled
area (or on completion of the task) MUST also report to the permit
issuer to become ‘signed off’.
Ensures that the employer (or site) know who and what is on site,
where and at what time undertaking which activity.
Permits are also defined by categories (HML) for example Hot or

Electrical or Breaking Containment will require a Higher level of
permit
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Risk Assessments:
What is the difference between Hazard and Risk?
HAZARD is defined as “a
physical situation with a RISK is defined as
potential for human “how great the chance
injury, damage to that someone or thing
property, damage to the will be harmed by the
environment or some hazard”
combination of these”
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Risk Assessments:
In many countries it is a legal requirement for every employer and
self-employed person to make an assessment of the health and
safety risks arising out of their work. The purpose of
the assessment is to identify what needs to be done to control health
and safety risks.
• Hierarchy of risk control should be considered

a. Elimination
b. Substitution
c. Engineering controls
d. Checking work methods
e. Reduce (or limit) time exposure
f. Good housekeeping
g. Introduce safe systems of work
h. Training and information
i. Personal Protective Equipment
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Risk ratings in the matrix – likelihood of an event x severity of injury
Quantitative Risk Assessments No injury Minor Inj. Mod Inj. Major Inj. Fatality
1 2 3 4 5
Almost certain 5 5 10 15 20 25
Likelihood Likely 4 4 8 12 16 20
Possible 3 3 6 9 12 15
Unlikely 2 2 4 6 8 10
Rare 1 1 2 3 4 5
Severity
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Risk Assessment Activity: Working on Ladders
Using the 5 x 5 risk matrix rate the likelihood of

something going wrong and the severity or
consequences of the event.
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Risk assessment form
Detail of task: Working at Height on Ladders Assessed by:
INITIAL RISK
RESIDUAL RISK
RATING
ACTIVITY AND ASSOCIATED
LXS=T LXS=T
HAZARD AND RISKS RISK CONTROLS
IDENTIFIED
L S T L S T
LIST THE HAZARD LIST HOW HAZARD RISK

WILL BE REDUCED
RISK ASSESSED BY DATE

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• Stripping Down
• Maintenance Records
• Required Documentation
• Storage Requirements of Documentation
• Personnel Records
• Defect Records
• Test Reports
• Job Sheet / Cards
• Approval Records
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Unit 1: IDCTCPM
1.5 Describe maintenance authorisation procedures and limits of responsibility and

authority
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Describe maintenance authorisation procedures and
limits of responsibility and authority
The Law and Authorisation Records:
In the UK, all companies (employers) have legal responsibilities, as do all

employees and other personnel including contractors and sub-
contractors, each must comply with the law (or regulations derived from
it).
A brief overview is provided below as to what the law is, how it applies,
and the implications to ‘authorisation’.
• Statute Law – Created by UK Government in Parliament (i.e. Acts of Parliament’ or ‘Regulations’)

• Case law – Created through judgements made by (or within) ‘courts of law’ over many years
• Criminal Law – Case(s) brought by the Government i.e. Police, Customs and Excise, The HSE etc
• Civil Law – Cases brought by individuals (against individuals) as everyone owes everyone else a ‘duty of
care’
• What is the law in your country, remember if you are working in a different country, the law may
change
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Authorisation Records:
Were covered in a previous slides, but would
include
• Job Sheets and / or Job Description
• Risk Assessments
• Permits to Work
• Breaking Containment
• Approval to work records
• Isolation Certs
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Types of Tasks that Require Authorisation:

There is a wide range of tasks, situations or environments that
would require authorisation, these include: -
• Entry into ‘secured’ or ‘sensitive’ areas’

• Entry into confined space areas
• Entry to and working in hazardous areas (or sites) i.e.
Chemical - Toxic or flammable
Electrical - High voltage or current flow
Biological - Hospitals, pharmaceutical sites, drainage,
Radiation - Nuclear power stations, hospital x-ray
wards, armed forces
Magnetism - Research facilities, Hospitals (Scanners)
• Lifting of loads
• Entry into areas that produce foodstuffs etc.,
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Demonstrate Competence
Skill
S
Knowledge
K
Attitude Skilled & Competent
A Workforce
T Training
E Experience
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Demonstrate Competence:
Further example of a competent person is somebody who has been
trained, or who has significant experience and has been assessed
successfully against an agreed standard.
For example, the UK has many Nationally agreed standards and these
are contained within vocational qualifications.
Other acceptable methods include

• Undertaking and passing skills (or trade) tests
• Undertaking relevant knowledge qualifications, that are assessed
by examination or assignment
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Who can authorise people and tasks that require authorisation:
• As the employer and all those in the management chain have

legal responsibilities, it is important that they are fully aware
as ‘action can and has been taken against companies and
individuals within companies where death, injury or damage
occurred
• Tutor to explain the Plan, Do, Check Act model, which
suggests that employers consider both ‘proactive’ and where
required ‘reactive’ monitoring
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Who can authorise people and tasks that require authorisation:
Proactive Monitoring
Is checking what has been done in line with
established standards and this involves implementing
safety Inspections, a safety committee and a health &
safety file.
Reactive Monitoring
Occurs after something has gone wrong for example
and accident / incident or near miss. This includes
analysing past statistical data and comparing to
present in regard to injures / health and arranging and
where required delivering additional training to staff
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Who can Authorise People:
• Facilities Refinery Manager / OIM

• Area Authority (Production / Maintenance Supervisor)
• Lead Technician
• Area Technician (Maintenance Technician)
• Performing Authority
• Isolation Authority (IAEH and IAEL)
• Electrical Isolation Authority
• Isolation Verifier
Research Activity
Describe their Roles and Authorisation
Responsibilities
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How to obtain authorisation:
All sites have a line of authority, a typical examples include:

• The Client
• Domestic Client
• Principle Designer
• Designers
• Principle Contractor
• Contractors
• Employees
Majority of activities performed on site come under a SSoW

i.e. Permit to Work, therefore maintenance personnel wishing
to carry out day-to-day activities would have to apply and
obtain the relevant PTW
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• Authorisation Records
• The Types of Tasks that Require Authorisation
• Demonstration of Competence
• Who Can Authorise People
• How to Attain Authorisation
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Unit 1: IDCTCPM
ecitb.org.uk 72

Core Unit 1 - Carrying Out Planned Maintenance v2

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ECITB Level 3 International Diploma in

Engineering Maintenance – Core Unit

1. Carry out Planned Maintenance

2. Establish that a Maintenance Activity is Suitable

4. Determining the Feasibility of Carrying out Repairs

5. Testing Equipment and Analysing the Results

1.1 Explain the principles of scheduled maintenance

1.2 Describe maintenance schedules and specifications and demonstrate how to

1.3 The techniques necessary to carry out plant maintenance procedures

1.4 Describe the procedures used to report on maintenance activities

1.5 Describe maintenance authorisation procedures and limits of responsibility and

1.1 Explain the principles of scheduled maintenance

Plant and Equipment

No components, plant or equipment, are designed to last indefinitely

In addition to wearing out equipment could break, fail or sustain damage

• Age – Metals and plastic fatigues and weakens with age

Is maintenance that is carried out to prevent breakdown of

• Is the monitoring of plant and equipment, and its operation in order

Servicing of machinery is normally carried out on a

• Involves changing numerous components or oils,

• Only suitably skilled and qualified trades people

What is Preventive Maintenance?

The care and servicing by operatives for the purpose of

Good Maintenance Scheduling and Planning:

Make good maintenance a habit when your engine is new, and

Service the engine more frequently if you use it heavily or

Therefore, makes good sense and best

Maintenance Schedule Motor Industry V Petrochemical Industry

Maintenance Schedule - Date / Time:

Maintenance scheduling can be based

Other major factors to consider include:

Reliability Centred Maintenance:

Is a process to ensure that process systems plant and equipment

• Frequency, Type and Activity

Determination of Asset Life:

Components, plant or pieces of equipment will not last indefinitely,

Factors involved in determining the useful life of a asset include the

Other factors to consider include

Sometimes equipment may be required to run beyond its planned

• Higher maintenance activities

1.2 Describe maintenance schedules and specifications and demonstrate how to

There are numerous types of manuals and guidance documents

The servicing and maintenance schedules are initially

Maintenance schedules will also be determined by the organisation

Safety Critical Elements/Component are defined as:

• SCEs must perform to clearly defined performance standards

The Safety Critical Elements / Components Exercise

List the Safety Critical

What is their Function

• This enables the business to more easily monitor what

• All business try to find an acceptable balance between what

• Modifications can vary from simply updating a particular component to a newer

• The modifications will normally be scheduled into the servicing and

• Organisation will implement a Change Management Process and Series of

Company Performance Standards:

• All on site component, equipment, plant and vehicles (assets), have

• These are used to enable the actual performance to be measured

• Performance Standards are also subject to Independent Verification

Basically does the System or piece of Equipment perform to what it

Numerous techniques will be used when carrying out

• Breaking containment - flanges and joints, using ring

• Using screwdriver to release electrical wires from