written maintenance procedures [Q75,Q76];
trained process maintenance personnel;
inspection and test procedures;
scheduled inspection, testing, and maintenance of process equipment;
a quality assurance (QA) program to verify that
- for new construction, equipment is suitable for its intended use and is properly installed
according to design specifications and manufacturer's recommendations;
- replacement parts and maintenance materials are suitable for the process application in
which they will be used;
a preventive maintenance program that includes
- pressure vessels and storage tanks;
- piping systems, including valves;
- relief and vent systems and devices;
- emergency shutdown systems;
- controls, such as monitoring devices, sensors, alarms, and interlocks [Q77]; and
- pumps [Q79].
Although the PSM Rule does not specifically require inspectors to be certified, it does require
that qualified personnel be used. In addition, industry standards and guidelines, as well as state
regulations, may require certification as evidence of qualification. All workers performing
quality assurance, maintenance, inspection and testing tasks must be trained in an overview of
the process, the process hazards, and the relevant written maintenance procedures for the
covered process [Q77]. DOE contractors may apply training provisions (Section 2.5) for initial
and refresher maintenance training, documentation, and grandfathering [Q80].
The frequency of inspections, testing, and replacement should be consistent with accepted
standards and codes and manufacturer recommendations. In addition, prior testing, inspection,
and operating records can better determine whether more frequent tests, inspections, or
replacements are needed. These records should also be used to establish testing, inspection, or
replacement frequencies for equipment not covered by codes and standards.
Contractors are responsible for ensuring that installations performed by subcontractors are
consistent with design specifications and manufacturer's instructions. Thus, contractors may
need to be involved in the reviews, inspections, certifications, and quality assurance work
performed by their subcontractors [Q79].
Must equipment-specific maintenance procedures be written for every type of
maintenance activity performed on the equipment? Can generic procedures for
preventive maintenance be used?
DOE contractors may use generic written maintenance procedures for some classes of
components and activities (e.g., lubrication of bearings on a class of rotating machinery).
On the other hand, for some combinations of equipment and activities, unique written
procedures should be developed.