MAINTENANCE WORK SELECTION/EXECUTION ISSUES | | PLANT INTEGRITY MANAGEMENT

This area of investigation was directed toward addressing the impact of Work Selection/Execution on the Utility Units’ Asset Management Program. Table 3-5 lists the issues addressed and the resultant findings.

MAINTENANCE WORK SELECTION/EXECUTION ISSUES | | PLANT INTEGRITY MANAGEMENT

Inquiry Response
What process is used to review, approve and prioritize maintenance work? Is the process risk based? The process for requesting, planning, and executing work orders is: Operations submits a prioritized work request which goes to the planner for initial planning, checking for spare parts, etc. The preliminary work request is returned to Operation Foreman for approval and scheduling. Once approved the planner then orders materials and finalizes scheduling based on priority. Once the work is scheduled the Maintenance Foreman schedules the work order for execution, assigns personnel to execute the work in accordance with the plan and closes the work order when completed. Completed work orders are supposedly closed on a timely basis. The process for executing work requests is effective in that the planner’s initial plan to determine availability of parts saves the possibility of false work activities, particularly since the availability of spare parts can be an issue.
Is there a planning function for maintenance work and what jobs are planned vs. unplanned? What is the maintenance software used for planning? Is it compatible with the other site functions? How experienced are the personnel using the software? Yes. SAP-PM is used and the individuals using are experienced in it in its use.
Is there a library of standard work plans? How does the mechanic follow the plan and is a check-off procedure used? Only that which is in SAP-PM
Are materials, tools, personnel verified before releasing plans for execution? Planning checks for spare parts as part of their planning process.
What procedure or check is used to ensure all tools and materials are available when execution commences? Maintenance staff in the field checks the work order for any required tools or parts.
What procedure is used to turnover completed work to Operations? Does the procedure include a checklist or sign-off sheet, formal post maintenance testing? The work orders are closed out in accordance with the Maintenance Work Order General Instruction Manual requirements and turned over to operations. The closeout procedure for work orders appears to be effective, especially since there is an index for tracking open work orders.
Is final housekeeping part of the work execution plan? Overall, housekeeping is very good. During the initial unit walk down, no piles of trash or other extraneous debris or abandoned equipment were observed.
What procedure is used to monitor parts usage and ensure adequate materials and replacement parts are available for maintenance? Accomplished through the inventory management module of SAP.
How often has maintenance been delayed because materials and replacement parts were unavailable? What was done to avoid a recurrence? Materials availability is a major issue since the local shop can only store small items. They have .already assessed their needs and collected such items. The availability of larger components is a problem that needs to be addressed.
What priority is given to maintenance requests and work The work prioritization is: 1-emergency work done ASAP, 2-urgent completed in < 48 hrs, 3/4/5- completed in > 48 hours. This work prioritization is justifiable breakdown based on the team’s experience. Experience has shown that further classification of priorities does nothing to enhance work prioritization.
Do all work orders have the necessary information to perform the job or are there times when the job is delayed because of missing information or parts? Yes. No jobs are delayed because of missing information
What is the backlog of WOs by priority code? What are the main causes for the delays Maintenance backlog is about 6 weeks and has a target of 4 to 6 weeks. Backlog is tracked weekly by craft and overall for all the onshore facilities. Most maintenance work is normal maintenance, PM 01 and PM 04, about 99%, with minimal emergency maintenance.

The key finding from the Work Selection/Execution area is summarized as follows:
• The GOSP Utility Units’ work planning and execution is managed and executed with professionalism, a good understanding of the process, and in accordance with established procedure. The process for executing work requests is effective in that the planner’s initial plan to determine availability of parts saves the possibility of false work activities, particularly since the availability of spare parts can be an issue.


 

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