Questions - hdbk11010089

DOE-HDBK-1101-96

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 manufacturers' instructions. Thus, contractors may need to be

involved in the reviews, inspections, certifications, and quality assurance work performed by their

subcontractors [Q79].

Questions

75.

Must equipment-specific maintenance procedures be written for every type of mainte-

nance 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 compo-

nents 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.