ICS Control Container Preservation, Storage and Maintenance
ICS Control Container Preservation, Storage and Maintenance Document type
Doc.no :
PSM-0000021042
Final Documentation
Page
1 of 22
:
Status
Change no.
Date
Version
Revision
Released Version
500000009665
27.08.2002
00
-
This document is the property of FMC Kongsberg Subsea AS and is not to be reproduced or disclosed to any party without the written consent of FMC Kongsberg Subsea AS. ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy
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TABLE OF CONTENTS Section 1.
Page
INTRODUCTION ....................................................................................................... 5 1.1
PURPOSE OF MANUAL.................................................................................. 5
1.2
SYMBOLS AND CONVENTIONS .................................................................. 5
1.3
SAFETY NOTES ............................................................................................... 5 1.3.1 Mechanical.............................................................................................. 6 1.3.2 Electrical................................................................................................. 6 1.3.3 Hydraulic ................................................................................................ 6
2.
3.
1.4
ABBREVIATIONS............................................................................................ 6
1.5
REFERENCE DOCUMENTS ........................................................................... 7
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS................................................. 8
1.7
CONSUMABLES .............................................................................................. 8
1.8
DEFINITIONS ................................................................................................... 8
PRESERVATION AND STORAGE .......................................................................... 9 2.1
PRESERVATION .............................................................................................. 9
2.2
STORAGE.......................................................................................................... 9
2.3
REPLACEMENT / REPAIR.............................................................................. 9
2.4
FAULTFINDING............................................................................................... 9
TESTING..................................................................................................................... 10 3.1
4.
TEST DETAILS................................................................................................. 10
EQUIPMENT MAINTENANCE CHECKLIST ......................................................... 11 4.1
MAINTENANCE CHECKLIST........................................................................ 12 4.1.1 Basic Tasks ............................................................................................. 13 4.1.2 Mobilisation............................................................................................ 16 4.1.3 De-mobilisation ...................................................................................... 17 4.1.4 Periodic Maintenance ............................................................................. 18 4.1.5 Mandatory Maintenance ......................................................................... 19 4.1.6 In Storage Maintenance .......................................................................... 20 4.1.7 Incoming Goods Inspection and Test ..................................................... 21
5.
ATTACHMENTS........................................................................................................ 22
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FIGURES Page Figure 1 ICS CONTROL CONTAINER Main Components................................................4 TABLES Page Table 1 Storage Conditions ..................................................................................................9
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Figure 1 ICS CONTROL CONTAINER , Main Components
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1. INTRODUCTION This manual is for the following equipment supplied by FMC Kongsberg Subsea AS (FKS): ·
ICS Control Container
There may be project specific variations to the standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File, which this PSM normally is part of.
1.1 PURPOSE OF MANUAL This manual provides the service personnel with the necessary information to perform routine preventive maintenance. Where relevant, a guide to fault finding is included together with instructions for repair. The manual is intended used by competent, trained personnel.
1.2 SYMBOLS AND CONVENTIONS The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS. Text set off in this manner provides warning notice that failure to follow these directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment. Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
1.3 SAFETY NOTES FKS’s and the Customer’s Health and Safety System must be adhered to at all times.
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Mechanical
N/A 1.3.2
Electrical
Isolate the power supply at source before working on electrical equipment. Allow sufficient time for the internal components to cool before opening Junction Boxes. Do not switch on power supplies until all electrical isolation permits have been withdrawn. Never attempt to bypass or override control functions using temporary leads.
1.3.3
Hydraulic
N/A 1.4 ABBREVIATIONS The following abbreviations are used in this manual: Abbreviation
Description
DnV
Det norske Veritas
Dunf.
Dunfermline
FKS
FMC Kongsberg Subsea AS
Kbg.
Kongsberg
MF
Maintenance File
MMT
Material Movement Ticket
MSDS
Material Safety Data Sheet
N/A
Not Applicable
NDT
Non Destructive Testing
P/N
Part Number (Previous denotation of Material Number)
QN
Quality Notification
QS
Quality System
RH
Relative Humidity
WO
Work Order
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1.5 REFERENCE DOCUMENTS This manual is supplied as a part of a ICS Control Container Maintenance File (MF). All relevant reference documents will be compiled in this MF. Always use the latest revision of any documents.
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1.6 TEST EQUIPMENT AND SPECIFIC TOOLS N/A 1.7 CONSUMABLES Equipment
FKS Material No
Quantity
Marston Bentley Oceanic HW540 Control Fluid.
N/A
As required.
Marston Bentley Oceanic EPF Hydraulic Equipment Preservation Fluid.
N/A
As required.
Light Solvent
N/A
As required.
Silica Gel
N/A
As required
Tectyl 5504W
N/A
As required.
1.8 DEFINITIONS Basic Tasks
All scenarios, including after use / before transport / shipping, etc.
Mobilisation
When preparing for use offshore.
De-mobilisation
When preparing for storage after use offshore.
Periodic Maintenance
When performing light preventive maintenance at fixed intervals or number of runs / runtime.
Mandatory Maintenance
When performing extensive preventive maintenance included strip-down and recertification at fixed intervals or numbers of runs / runtime.
In Storage Maintenance
When the equipment is in storage
Incoming Goods Inspection
When the equipment is received (First Time Received).
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2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation process is to protect the equipment against accidents normally encountered during handling, transportation and storage. Preservation is to be carried out in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The ICS Control Container must be preserved in order to provide protection from rain, snow, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document. Table 1 Storage Conditions Item
Condition
Storage area:
Indoors
Storage temperature:
- 30°C to + 50°C
Maximum air humidity:
95% RH
Do not de-preserve until just prior to use.
2.3 REPLACEMENT / REPAIR In general, any repair is limited to direct replacement of damaged or broken components with new or reconditioned parts. Damaged components must be returned to FKS for inspection or possible rework. If considered necessary, test the ICS Control Container after repair. 2.4 FAULTFINDING Before troubleshooting is started, observe the given security regulations and proceed according to these. Make a thorough check before further work is started. Start with the most simple action.
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3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Maintenance Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FKS Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS N/A
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4. EQUIPMENT MAINTENANCE CHECKLIST The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the company's Service System.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.
4)
Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.
Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A). In a service system where a task is given a specified number (individual Service Order Number), the .PDF file name must include the identity (number) of this Service Order.
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MAINTENANCE CHECKLIST
Scan to PDF format after signing, file document on address NOT No: Product Name:
ICS Control Container
Maintenance Type: Mobilisation: Periodic Maintenance:
De-mobilisation:
In Storage Maintenance:
Mandatory Maintenance:
Incoming Goods Inspection:
FMC's (Dunf./Kbg.) Material No.: Supplier Material No.:
Serial No.: Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Log No.
Category: Prioritised
Periodic Maintenance: Every 6 months
Mandatory Maintenance: Every 12 months
In Storage Maintenance Every 6 months
REFERENCED DOCUMENTS Assembly Drawing No.:
MAINTENANCE PROGRAM Activity
Description
Mobilisation
Equipment to be checked in accordance with Section 4.1.2.
De-mobilisation
Equipment to be checked in accordance with Section 4.1.3.
Periodic Maintenance
Equipment to be checked in accordance with Section 4.1.4.
Mandatory Maintenance / Complete Overhauling
Date/sign
Remarks
Equipment to be checked in accordance with Section 4.1.5.
In Storage Maintenance
Equipment to be checked in accordance with Section 4.1.6.
Incoming Goods Inspection
Equipment to be inspected in accordance with Section 4.1.7
Signature of personnel responsible:
Date:
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Basic Tasks
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting Points and Lifting Components. (Including lifting-subs, etc., if any) prior to lifting.
1.5
Check the validity of applicable certificates. If the certificates are not valid, initiate a re-certification of ICS Control Container to be performed by third party in accordance with DnV 2.7-1 or applicable local regulations.
1.6
Check the relevant local Health, Environment and Safety Data Sheet / Requirements. Return waste must be marked in accordance with local regulations.
1.7
Wash down the equipment. If necessary, wash down with fresh water to remove all traces of salt. Remove excess water using compressed air. Refer to FKS Document PRD-0000021584 or valid procedure for washing instructions.
1.8
Remove possible non-painted surface protection.
1.9
Check for damage and corrosion.
1.10
Check and update surface treatment.
1.11
Update preservation if needed.
1.12
Check for proper fastening of mounted components.
1.13
Check/tighten bolt connections (spot check). Refer to FKS Document PRD-0000021662 for bolt tightening instructions.
1.14
Check movable parts. "Move up/down" and lubricate/grease if needed.
Date/Sign.
Remarks
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Description Inspect electrical components (control panels / junction boxes), cables and contacts / connection points. Change silica gel where required. Inspect for damage or unfixed (loose) items. Verify that protection caps are installed where required.
1.16
Silica Gel shall be placed inside MCU, MCP and inside the VDU`s & printer protection boxes. Ensure a label is attached outside the equipment stating that Silica Gel is inside and the date it was installed. Change silica gel where required.
1.17
Inspect Control Units, Consoles, Computers, etc. Check for damage or unfixed items. Clean up (vacuum clean) and wipe off if necessary. Change silica gel where required.
1.18
Silica Gel shall also be installed inside all junction boxes, ensure a label is attached outside the equipment stating that Silica Gel is inside and the date it was installed. Change silica gel where required.
1.19
Perform control of EX-equipment.
1.20
Check surface treatment and markings. Repair if necessary.
2.0 2.1
PRODUCT SPECIFIC CHECKS Vacuum clean the fan in/outlet.
2.2
Check that the electrical termination points inside the junction boxes are tight.
2.3
Inspect the Exd enclousure flame paths.
3.1
ASSEMBLE/DISASSEMBLE N/A
3.0 4.0 4.1 5.0 5.1 6.0 6.1 6.2
TESTING Test according to documentation listed in MF, chapter 4. QS CHECKOUT Punch out by QS PRESERVATION The MCU, MCP, VDU`s and the Printer shall be stored in a dry and cleaned tempered area. The fire dampers shall be protected/blinded using the provided protection covers.
Date/Sign.
Remarks
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Description All cable entries, hatches and other open sections shall be covered to prevent contamination to enter during storage. Ensure that the jumpers are cleaned and covers are fitted to each end of the jumpers.
Date/Sign.
Remarks
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Mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A.
4.1
TESTING Test according to documentation listed in MF, chapter 4.
5.1
QS CHECKOUT Perform the QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
5.0
6.0 6.1
PRESERVATION N/A
Date/Sign.
Remarks
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De-mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1 5.0
Test according to documentation listed in MF, chapter 4.
5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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Periodic Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test according to documentation listed in MF, chapter 4.
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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Mandatory Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 1.1
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0.
2.0
PRODUCT SPECIFIC CHECKS Initiate a re-certification of ICS Control Container to be performed by third party in accordance with DnV 2.7-1, or local regulations
2.1
2.2
Check welds yearly in accordance with API or other relevant standard by NDT.
2.3
Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0.
3.0 3.1 4.0
ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test according to documentation listed in MF, chapter 4.
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0 (if applicable).
6.0
Date/Sign.
Remarks
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In Storage Maintenance
Scan to PDF format after signing, file document on address REP No: Item 1)
Description
2)
Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0
3)
Preserve in accordance with Section 4.1.1/6.0
Perform basic tasks in accordance with information provided in Section 4.1.1/1.0
Date/Sign.
Remarks
FMC Kongsberg Subsea AS Version : 4.1.7
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Incoming Goods Inspection and Test
Scan to PDF format after signing, file document on address REP No: EQUIPMENT NAME:
ICS CONTROL CONTAINER
MATERIAL NO.
QTY / SERIAL NO.
MMT NO./ DELIVERY NOTE SUPPLIER: INSPECTION ACTIVITIES Item
Description
1.0
TRANSPORTATION
Checked
1.1
Unpacking of Equipment.
1.2
Transportation Damage.
1.3
Consignment Note Signed.
1.4
Correct Quantity of Received Materials.
2.0
N/A
QN Ref
VISUAL INSPECTION 2.1
Equipment Marking.
2.2
Lifting Gear Identification.
3.0
DOCUMENTATION 3.1
Dispatch Dossier.
3.2
Lifting Certificates.
3.3
Material Safety Data Sheet (MSDS).
3.4
Punch List.
OUTSTANDING ITEMS TRANSPORT DAMAGE
DESCRIPTION:
INSPECTION SITE:
SIGNATURE:
DATE:
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5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT Fill in the following data if applicable: ·
Equipment Name.
·
FKS Material Number.
·
Reference Document (this is the number of the current PSM manual).
·
Reference Drawing Number(s).
CORRECTIVE MAINTENANCE REPORT Scan to PDF format after signing, file document on address REP No: Equipment Name:
ICS CONTROL CONTAINER
FKS Material Number: Fault Reference Document: Reference Drawing Number(s): Task Description
Date
Comments
Parts Used
Date
Comments
Discipline
Man-hours:
Name:
Signature:
Doc.no :
PSM-0000021042
Final Documentation
Page
1 of 22
:
Status
Change no.
Date
Version
Revision
Released Version
500000009665
27.08.2002
00
-
This document is the property of FMC Kongsberg Subsea AS and is not to be reproduced or disclosed to any party without the written consent of FMC Kongsberg Subsea AS. ELECTRONIC ORIGINAL User is responsible for verification of released revision status on document copy
FMC Kongsberg Subsea AS Version :
00
Revision :
-
Doc.no.:
PSM-0000021042
Page no. :
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TABLE OF CONTENTS Section 1.
Page
INTRODUCTION ....................................................................................................... 5 1.1
PURPOSE OF MANUAL.................................................................................. 5
1.2
SYMBOLS AND CONVENTIONS .................................................................. 5
1.3
SAFETY NOTES ............................................................................................... 5 1.3.1 Mechanical.............................................................................................. 6 1.3.2 Electrical................................................................................................. 6 1.3.3 Hydraulic ................................................................................................ 6
2.
3.
1.4
ABBREVIATIONS............................................................................................ 6
1.5
REFERENCE DOCUMENTS ........................................................................... 7
1.6
TEST EQUIPMENT AND SPECIFIC TOOLS................................................. 8
1.7
CONSUMABLES .............................................................................................. 8
1.8
DEFINITIONS ................................................................................................... 8
PRESERVATION AND STORAGE .......................................................................... 9 2.1
PRESERVATION .............................................................................................. 9
2.2
STORAGE.......................................................................................................... 9
2.3
REPLACEMENT / REPAIR.............................................................................. 9
2.4
FAULTFINDING............................................................................................... 9
TESTING..................................................................................................................... 10 3.1
4.
TEST DETAILS................................................................................................. 10
EQUIPMENT MAINTENANCE CHECKLIST ......................................................... 11 4.1
MAINTENANCE CHECKLIST........................................................................ 12 4.1.1 Basic Tasks ............................................................................................. 13 4.1.2 Mobilisation............................................................................................ 16 4.1.3 De-mobilisation ...................................................................................... 17 4.1.4 Periodic Maintenance ............................................................................. 18 4.1.5 Mandatory Maintenance ......................................................................... 19 4.1.6 In Storage Maintenance .......................................................................... 20 4.1.7 Incoming Goods Inspection and Test ..................................................... 21
5.
ATTACHMENTS........................................................................................................ 22
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FIGURES Page Figure 1 ICS CONTROL CONTAINER Main Components................................................4 TABLES Page Table 1 Storage Conditions ..................................................................................................9
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Figure 1 ICS CONTROL CONTAINER , Main Components
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1. INTRODUCTION This manual is for the following equipment supplied by FMC Kongsberg Subsea AS (FKS): ·
ICS Control Container
There may be project specific variations to the standard components. However, the preservation, storage and maintenance instructions are identical for all components. For project specific details, please refer to the Maintenance File, which this PSM normally is part of.
1.1 PURPOSE OF MANUAL This manual provides the service personnel with the necessary information to perform routine preventive maintenance. Where relevant, a guide to fault finding is included together with instructions for repair. The manual is intended used by competent, trained personnel.
1.2 SYMBOLS AND CONVENTIONS The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS. Text set off in this manner provides warning notice that failure to follow these directions in this WARNING can result in bodily harm or loss of life and/or extensive damage to equipment. Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment. Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.
1.3 SAFETY NOTES FKS’s and the Customer’s Health and Safety System must be adhered to at all times.
FMC Kongsberg Subsea AS Version :
00
Revision : 1.3.1
-
Doc.no.:
PSM-0000021042
Page no. :
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Mechanical
N/A 1.3.2
Electrical
Isolate the power supply at source before working on electrical equipment. Allow sufficient time for the internal components to cool before opening Junction Boxes. Do not switch on power supplies until all electrical isolation permits have been withdrawn. Never attempt to bypass or override control functions using temporary leads.
1.3.3
Hydraulic
N/A 1.4 ABBREVIATIONS The following abbreviations are used in this manual: Abbreviation
Description
DnV
Det norske Veritas
Dunf.
Dunfermline
FKS
FMC Kongsberg Subsea AS
Kbg.
Kongsberg
MF
Maintenance File
MMT
Material Movement Ticket
MSDS
Material Safety Data Sheet
N/A
Not Applicable
NDT
Non Destructive Testing
P/N
Part Number (Previous denotation of Material Number)
QN
Quality Notification
QS
Quality System
RH
Relative Humidity
WO
Work Order
FMC Kongsberg Subsea AS Version :
00
Revision :
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Doc.no.:
PSM-0000021042
Page no. :
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1.5 REFERENCE DOCUMENTS This manual is supplied as a part of a ICS Control Container Maintenance File (MF). All relevant reference documents will be compiled in this MF. Always use the latest revision of any documents.
FMC Kongsberg Subsea AS Version :
00
Revision :
-
Doc.no.:
PSM-0000021042
Page no. :
8 of 22
1.6 TEST EQUIPMENT AND SPECIFIC TOOLS N/A 1.7 CONSUMABLES Equipment
FKS Material No
Quantity
Marston Bentley Oceanic HW540 Control Fluid.
N/A
As required.
Marston Bentley Oceanic EPF Hydraulic Equipment Preservation Fluid.
N/A
As required.
Light Solvent
N/A
As required.
Silica Gel
N/A
As required
Tectyl 5504W
N/A
As required.
1.8 DEFINITIONS Basic Tasks
All scenarios, including after use / before transport / shipping, etc.
Mobilisation
When preparing for use offshore.
De-mobilisation
When preparing for storage after use offshore.
Periodic Maintenance
When performing light preventive maintenance at fixed intervals or number of runs / runtime.
Mandatory Maintenance
When performing extensive preventive maintenance included strip-down and recertification at fixed intervals or numbers of runs / runtime.
In Storage Maintenance
When the equipment is in storage
Incoming Goods Inspection
When the equipment is received (First Time Received).
FMC Kongsberg Subsea AS Version :
00
Revision :
-
Doc.no.:
PSM-0000021042
Page no. :
9 of 22
2. PRESERVATION AND STORAGE 2.1 PRESERVATION The purpose of the preservation process is to protect the equipment against accidents normally encountered during handling, transportation and storage. Preservation is to be carried out in accordance with the instructions given in Section 4 of this document.
2.2 STORAGE The ICS Control Container must be preserved in order to provide protection from rain, snow, ice, dust, solar radiation or sand in accordance with instructions given in Section 4 of this document. Table 1 Storage Conditions Item
Condition
Storage area:
Indoors
Storage temperature:
- 30°C to + 50°C
Maximum air humidity:
95% RH
Do not de-preserve until just prior to use.
2.3 REPLACEMENT / REPAIR In general, any repair is limited to direct replacement of damaged or broken components with new or reconditioned parts. Damaged components must be returned to FKS for inspection or possible rework. If considered necessary, test the ICS Control Container after repair. 2.4 FAULTFINDING Before troubleshooting is started, observe the given security regulations and proceed according to these. Make a thorough check before further work is started. Start with the most simple action.
FMC Kongsberg Subsea AS Version :
00
Revision :
-
Doc.no.:
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3. TESTING Testing of the equipment is to be performed in accordance with the Equipment Maintenance Checklist, refer to Section 4. Extended testing due to repair of the equipment is to be clarified with FKS Quality System (QS)/Project prior to testing.
3.1 TEST DETAILS N/A
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4. EQUIPMENT MAINTENANCE CHECKLIST The Equipment Maintenance Checklists are always to be signed out as follows: 1)
Allocate a REP number to the Checklist in the company's Service System.
2)
Fill in the General Checklist (mandatory).
3)
Fill in the Checklist that is relevant to the maintenance activity (Mobilisation, De-mobilisation, etc.). See Chapter 1.8 for information.
4)
Once filled in and signed out, scan the Checklists and create a PDF file using the REP number as filename.
Any task in the individual checklists that is not relevant is to be marked as Not Applicable (N/A). In a service system where a task is given a specified number (individual Service Order Number), the .PDF file name must include the identity (number) of this Service Order.
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MAINTENANCE CHECKLIST
Scan to PDF format after signing, file document on address NOT No: Product Name:
ICS Control Container
Maintenance Type: Mobilisation: Periodic Maintenance:
De-mobilisation:
In Storage Maintenance:
Mandatory Maintenance:
Incoming Goods Inspection:
FMC's (Dunf./Kbg.) Material No.: Supplier Material No.:
Serial No.: Supplier Serial No.:
GENERAL Date Received:
Date Shipped:
Log No.
Category: Prioritised
Periodic Maintenance: Every 6 months
Mandatory Maintenance: Every 12 months
In Storage Maintenance Every 6 months
REFERENCED DOCUMENTS Assembly Drawing No.:
MAINTENANCE PROGRAM Activity
Description
Mobilisation
Equipment to be checked in accordance with Section 4.1.2.
De-mobilisation
Equipment to be checked in accordance with Section 4.1.3.
Periodic Maintenance
Equipment to be checked in accordance with Section 4.1.4.
Mandatory Maintenance / Complete Overhauling
Date/sign
Remarks
Equipment to be checked in accordance with Section 4.1.5.
In Storage Maintenance
Equipment to be checked in accordance with Section 4.1.6.
Incoming Goods Inspection
Equipment to be inspected in accordance with Section 4.1.7
Signature of personnel responsible:
Date:
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Basic Tasks
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 1.2
Description GENERAL Check Work Order (WO). Check if there are any Quality Notifications (QNs) on the equipment. If approved by Client, repair accordingly.
1.3
Check if there are any Service Alerts for the equipment.
1.4
Check all Lifting Points and Lifting Components. (Including lifting-subs, etc., if any) prior to lifting.
1.5
Check the validity of applicable certificates. If the certificates are not valid, initiate a re-certification of ICS Control Container to be performed by third party in accordance with DnV 2.7-1 or applicable local regulations.
1.6
Check the relevant local Health, Environment and Safety Data Sheet / Requirements. Return waste must be marked in accordance with local regulations.
1.7
Wash down the equipment. If necessary, wash down with fresh water to remove all traces of salt. Remove excess water using compressed air. Refer to FKS Document PRD-0000021584 or valid procedure for washing instructions.
1.8
Remove possible non-painted surface protection.
1.9
Check for damage and corrosion.
1.10
Check and update surface treatment.
1.11
Update preservation if needed.
1.12
Check for proper fastening of mounted components.
1.13
Check/tighten bolt connections (spot check). Refer to FKS Document PRD-0000021662 for bolt tightening instructions.
1.14
Check movable parts. "Move up/down" and lubricate/grease if needed.
Date/Sign.
Remarks
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Description Inspect electrical components (control panels / junction boxes), cables and contacts / connection points. Change silica gel where required. Inspect for damage or unfixed (loose) items. Verify that protection caps are installed where required.
1.16
Silica Gel shall be placed inside MCU, MCP and inside the VDU`s & printer protection boxes. Ensure a label is attached outside the equipment stating that Silica Gel is inside and the date it was installed. Change silica gel where required.
1.17
Inspect Control Units, Consoles, Computers, etc. Check for damage or unfixed items. Clean up (vacuum clean) and wipe off if necessary. Change silica gel where required.
1.18
Silica Gel shall also be installed inside all junction boxes, ensure a label is attached outside the equipment stating that Silica Gel is inside and the date it was installed. Change silica gel where required.
1.19
Perform control of EX-equipment.
1.20
Check surface treatment and markings. Repair if necessary.
2.0 2.1
PRODUCT SPECIFIC CHECKS Vacuum clean the fan in/outlet.
2.2
Check that the electrical termination points inside the junction boxes are tight.
2.3
Inspect the Exd enclousure flame paths.
3.1
ASSEMBLE/DISASSEMBLE N/A
3.0 4.0 4.1 5.0 5.1 6.0 6.1 6.2
TESTING Test according to documentation listed in MF, chapter 4. QS CHECKOUT Punch out by QS PRESERVATION The MCU, MCP, VDU`s and the Printer shall be stored in a dry and cleaned tempered area. The fire dampers shall be protected/blinded using the provided protection covers.
Date/Sign.
Remarks
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Description All cable entries, hatches and other open sections shall be covered to prevent contamination to enter during storage. Ensure that the jumpers are cleaned and covers are fitted to each end of the jumpers.
Date/Sign.
Remarks
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Mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with the information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A.
4.1
TESTING Test according to documentation listed in MF, chapter 4.
5.1
QS CHECKOUT Perform the QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
5.0
6.0 6.1
PRESERVATION N/A
Date/Sign.
Remarks
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De-mobilisation
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.1 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1 5.0
Test according to documentation listed in MF, chapter 4.
5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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Periodic Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 2.0 2.1 3.0 3.1 4.0
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0. PRODUCT SPECIFIC CHECKS Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0. ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test according to documentation listed in MF, chapter 4.
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0.
6.0
Date/Sign.
Remarks
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Mandatory Maintenance
Scan to PDF format after signing, file document on address REP No: Step 1.0 1.2 1.1
Description GENERAL Perform general checks in accordance with information provided in Section 4.1.1 / 1.0.
2.0
PRODUCT SPECIFIC CHECKS Initiate a re-certification of ICS Control Container to be performed by third party in accordance with DnV 2.7-1, or local regulations
2.1
2.2
Check welds yearly in accordance with API or other relevant standard by NDT.
2.3
Perform product specific checks in accordance with the information provided in Section 4.1.1 / 2.0.
3.0 3.1 4.0
ASSEMBLE / DISASSEMBLE N/A TESTING
4.1
Test according to documentation listed in MF, chapter 4.
4.2
If any extended testing is necessary due to repair of the equipment, get in touch with FKS QS/Project for detailed instructions.
5.0 5.1
QS CHECKOUT Perform QS checkout in accordance with information provided in Section 4.1.1 / 5.0.
6.1
PRESERVATION Preserve equipment in accordance with information provided in Section 4.1.1 / 6.0 (if applicable).
6.0
Date/Sign.
Remarks
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In Storage Maintenance
Scan to PDF format after signing, file document on address REP No: Item 1)
Description
2)
Perform product specific checks in accordance with the information provided in Section 4.1.1/2.0
3)
Preserve in accordance with Section 4.1.1/6.0
Perform basic tasks in accordance with information provided in Section 4.1.1/1.0
Date/Sign.
Remarks
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Incoming Goods Inspection and Test
Scan to PDF format after signing, file document on address REP No: EQUIPMENT NAME:
ICS CONTROL CONTAINER
MATERIAL NO.
QTY / SERIAL NO.
MMT NO./ DELIVERY NOTE SUPPLIER: INSPECTION ACTIVITIES Item
Description
1.0
TRANSPORTATION
Checked
1.1
Unpacking of Equipment.
1.2
Transportation Damage.
1.3
Consignment Note Signed.
1.4
Correct Quantity of Received Materials.
2.0
N/A
QN Ref
VISUAL INSPECTION 2.1
Equipment Marking.
2.2
Lifting Gear Identification.
3.0
DOCUMENTATION 3.1
Dispatch Dossier.
3.2
Lifting Certificates.
3.3
Material Safety Data Sheet (MSDS).
3.4
Punch List.
OUTSTANDING ITEMS TRANSPORT DAMAGE
DESCRIPTION:
INSPECTION SITE:
SIGNATURE:
DATE:
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5. ATTACHMENTS CORRECTIVE MAINTENANCE REPORT Fill in the following data if applicable: ·
Equipment Name.
·
FKS Material Number.
·
Reference Document (this is the number of the current PSM manual).
·
Reference Drawing Number(s).
CORRECTIVE MAINTENANCE REPORT Scan to PDF format after signing, file document on address REP No: Equipment Name:
ICS CONTROL CONTAINER
FKS Material Number: Fault Reference Document: Reference Drawing Number(s): Task Description
Date
Comments
Parts Used
Date
Comments
Discipline
Man-hours:
Name:
Signature:
