5 yrly Vessel Planned Maintenance Checklist

Title Page

Vessel Serial Number
Customer Name
Date

CES 5 Yearly Vessel Planned Maintenance Checklist

Customer address
Functional Location
Vessel size
Vessel Contents
Vessel ZZ number
Vessel ZZ number:
Work order number
Name
Signature

To be completed by maintenance manager or equivalent:

Checked by:
Sign
Date

Equipment Checklist

VESSEL SERIAL NUMBER:

EQUIPMENT CHECKLIST

Pressure safety valves (PSV) & pressure relief valves (PRV) - New tags fitted
Bursting discs (BD) - Visual check of outlets - Re-tag

PSV, BD or PRV?
- PSV1
- PSV2
- PSV3
- PSV4
- BD1
- BD2
- PRV1
- PRV2
- PRV3
- PRV4
- PRV5
- PRV6
PSV/BD/PRV size:
Make:
Model:
Setting:
Install Date
Is 3-way valve piped correctly - Centre port? Refer to CESSUP-09-07-GSP
Are all valves labelled in accordance with P&ID?
Are all valves colour-coded handles and valve stems? (REFER AS1894)
Table 3.1 - Valve Colours and Functions
Please use with reference to AS 1894-1997
Are all valve handles satisfactory?
Are all valves operating ok and no leaks present?
Is thermocouple valve plugged?
Take vacuum reading?
How many microns?
Fit tag with date and reading to the thermocouple valve
Pressure indicator - BOC approved - blowout back (SPC-10-155-AU)
Pressure indicator - normal/safety valve/indication only labels
Pressure indicator - functional check of pressure indicator
Telemetry unit/contents indicator - BOC approved, where fitted - last test/zero check date/verify contents with BSC 1300 728 990
Fill connection - is a non-return valve present? Is it the correct fill connection?
Is a fill coupling dust cap fitted?
Fill connection condition - is it worn or cracked?
Fill connection - does the non return operate ok?
Fill connection - is a hose blowdown valve fitted?
Fill connection - is there a hose pressure relief valve?
Evacuation valve - is it plugged and wired?
Is the pressure build vapouriser condition ok?
Is the pressure building regulator condition ok and is orientation correct (vent hole must be pointing down so any moisture/water can drain out)?
Pressure building regulator - if any doubt about correct operation of regulator conduct functional test
Does vessel need cleaning?
Does vessel need painting?
Is the BOC logo legible and not faded?
Is there a product label visible?
Is the BOC telephone number visible and correct?
Is a first aid sign fitted?
Is the vessel ID number fitted and correct?
Is the vessel pipe work schematic fitted and correct?
Is a HAZCHEM placard fitted and is it legible and correct?
Is there a phone number on HAZCHEM and is it correct?
Is an 'OK Staff' tag fitted?
Does the pressure raising circuit operate correctly?
For LOX vessels, perform hydrocarbon test
Vessel tagged for last hydrocarbon test?
Last hydrocarbon test date:
Is the customer pipeline bracketed correctly with no visible damage?
Is a battery limit label fitted indicating BOC/customer ownership?
Statutory approval stamp registration number
Registration Number:
Is registration number highlighted in blue?
Is the condition of the 3-phase power outlet ok?
Is a RCD fitted at the 3-phase power outlet?
Please add any comments

Site Checklist

Are there any other potential site hazards?
If a sloping site, is the placarding visible and legible?
Is vehicle protection adequate?
Is the vessel foundation in good condition?
For LOX vessels, is tanker hardstand in good condition? (crack/oil/grease)
Is the surrounding area free from oil and debris?
If fenced, is the fence secure and in good condition?
Is a water tap and hose present?
Is site lighting adequate?
Where applicable, is remote fill point in line of sight to vessel?
Take photos of current installation, including: - icing on vapouriser - vessel pipe work - any general defects - from distance of 20 minutes showing surrounding area
Comments:

Vessel Location Checklist

ITEMS FROM WHICH SEPARATION IS REQUIRED (See related notes in the next section)

Notes to the table below: (references to 'clauses' are to AS 1984-1997)
Oxidiser (LOX, N2O) or Inert (LIN, LAR and CO2) product?
Vessel Size

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'S' = 1 'D' = 1 Total separation distance required = 2 metres
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'S' = 1 'D' = 1 Total separation distance required = 2 metres
Property Boundary (see note 4) 'S' = 1 'D' = 1 Total separation distance required = 2 metres
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'S' = 1 'D' = 1 Total separation distance = 2m
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'S' = 1 'D' = 1 Total separation distance required = 2m
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'S' = 1 'D' = 1 Total separation distance required = 2m
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'S' = 1 'D' = 1 Total separation distance required = 2m
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'S' = 1 'D' = 3 Total separation distance required = 4m
Building or structure with combustible exterior (see note 14) 'S' = 1 'D' = 3 Total separation distance required = 4m
Process equipment and machinery that is not part of the installation (see note 15) 'S' = 1 'D' = 3 Total separation distance required = 4m
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'S' = 1 'D' = 3 Total separation distance required = 4m
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'S' = 1 'D' = 3 Total separation distance required = 4m
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'S' = 1 'D' = 3 Total separation distance required = 4m
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'S' = 1 'D' = 5 Total separation distance required = 6m
Compressor or ventilator air intakes 'S' = 1 'D' = 5 Total separation distance required = 6m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'S' = 1 'D' = 10 Total separation distance required = 11m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'S' = 1 'D' = 10 Total separation distance required = 11m
Solid combustible material (see notes 5, 7 & 10 or 12) 'S' = 1 'D' = 10 Total separation distance required = 11m

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Property Boundary (see note 4) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'S' = 2 'D' = 2 Total separation distance required = 4 metres
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'S' = 2 'D' = 3 Total separation distance required = 5m
Building or structure with combustible exterior (see note 14) 'S' = 2 'D' = 3 Total separation distance required = 5m
Process equipment and machinery that is not part of the installation (see note 15) 'S' = 2 'D' = 3 Total separation distance required = 4m
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'S' = 2 'D' = 3 Total separation distance required = 4m
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'S' = 2 'D' = 3 Total separation distance required = 4m
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'S' = 2 'D' = 3 Total separation distance required = 4m
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'S' = 2 'D' = 5 Total separation distance required = 7m
Compressor or ventilator air intakes 'S' = 2 'D' = 5 Total separation distance required = 7m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'S' = 2 'D' = 10 Total separation distance required = 12m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'S' = 2 'D' = 10 Total separation distance required = 12m
Solid combustible material (see notes 5, 7 & 10 or 12) 'S' = 2 'D' = 10 Total separation distance required = 12m

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Property Boundary (see note 4) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Building or structure with combustible exterior (see note 14) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Process equipment and machinery that is not part of the installation (see note 15) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'S' = 3m 'D' = 3m Total separation distance required = 6 metres
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'S' = 3 'D' = 5 Total separation distance required = 8m
Compressor or ventilator air intakes 'S' = 3 'D' = 5 Total separation distance required = 8m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'S' = 3 'D' = 10 Total separation distance required = 13m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'S' = 3 'D' = 10 Total separation distance required = 13m
Solid combustible material (see notes 5, 7 & 10 or 12) 'S' = 3 'D' = 10 Total separation distance required = 13m
Vessel Size

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'D' = 1m
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'D' = 1m
Property Boundary (see note 4) 'D' = 1m
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'D' = 1m
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'D' = 1m
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'D' = 1m
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'D' = 1m
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'D' = 1m
Building or structure with combustible exterior (see note 14) 'D' = 1m
Process equipment and machinery that is not part of the installation (see note 15) 'D' = 1m
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'D' = 1m
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'D' = 1m
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'D' = 1m
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'D' = 2m
Compressor or ventilator air intakes 'D' = 2m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'D' = 3m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'D' = 3m
Solid combustible material (see notes 5, 7 & 10 or 12) 'D' = 3m

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'D' = 1m
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'D' = 1m
Property Boundary (see note 4) 'D' = 2m
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'D' = 2m
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'D' = 2m
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'D' = 2m
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'D' = 2m
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'D' = 2m
Building or structure with combustible exterior (see note 14) 'D' = 2m
Process equipment and machinery that is not part of the installation (see note 15) 'D' = 2m
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'D' = 2m
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'D' = 2m
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'D' = 2m
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'D' = 2m
Compressor or ventilator air intakes 'D' = 2m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'D' = 3m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'D' = 3m
Solid combustible material (see notes 5, 7 & 10 or 12) 'D' = 3m

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Continuous section of pipeline containing flammable gas or liquid, not interrupted by fittings e.g. valves, unions, flanges 'D' = 1m
Building or structure with non-combustible exterior, or sprinklered building of other construction (see notes 8 & 14) 'D' = 1m
Property Boundary (see note 4) 'D' = 3m
Street, road boundary or car park, other than for authorised vehicles (see notes 9 & 10 or 12 & 14) 'D' = 3m
Areas where open flames, smoking or other sources of ignition are permitted (see note 11) 'D' = 3m
Fixed installations of gases in cylinders (see notes 1, 8 & 14) 'D' = 3m
Other dangerous goods stores of other classes or subsidiary risks (see note 2) 'D' = 3m
Medium or high voltage electrical equipment greater than 415V e.g. substations, transformers or motor control centres (see notes 9, 10 & 11 or 12 &13) 'D' = 3m
Building or structure with combustible exterior (see note 14) 'D' = 3m
Process equipment and machinery that is not part of the installation (see note 15) 'D' = 3m
Fittings e.g. valves, unions and flanges in pipeline containing flammable gas or liquid 'D' = 3m
Openings to underground drains, pits, ducts, surface water drains or openings or systems below ground level 'D' = 3m
Openings in walls of adjacent buildings or structures (see notes 9 & 10 or 12 & 13) 'D' = 3m
Areas where personnel can congregate e.g. offices and lunchrooms (see notes 9 & 10 or 12 & 13) 'D' = 3m
Compressor or ventilator air intakes 'D' = 3m
Places of public assembly (see notes 9 & 10 or 12 & 13) 'D' = 3m
Areas of buildings where patients are confined to bed (see notes 9 & 10 or 12 & 13) 'D' = 3m
Solid combustible material (see notes 5, 7 & 10 or 12) 'D' = 3m

Defect Action Report

Defect Action Report Further work required - SAP work order to be raised

Description of defect and action required. Touch 'Add Defect' or plus symbol to begin. Add as many defects as required
Description of defect and action required
Who is responsible?
Priority

Follow up action to be completed by maintenance manager and/or CES manager

Actioned by:
Action description: W/O No./email to etc

Part List

List of Parts Used During This Planned Maintenance

Safety Valves

Part number:
Quantity:
Work order number:

Pressure Relief Valves

Part number:
Quantity:
Work order number:

Additional Parts

Touch 'Add Part' or the plus symbol to start, then 'Response' to choose a part from the drop-down list. If the part is not listed, please select 'Other' in drop-down list
Part description
- Bursting Discs
- Hydrocarbon Tag
- OK Staff
- Vacuum Tag
- Pressure Indicator Stickers
- Contents Gauge
- Valve Handle Paint
- Valve Labels
- Valve Stem Coloured Tape
- HAZCHEM Signs
- Pressure Indicators
- Contents Indicators
- Battery Limit Stickers
- Customer Isolation Stickers
- Valve Teflon Seats
- Other
Part number
Quantity
Work order number:
Product name/description
Part number
Quantity
Work order number:

5 yrly Vessel Planned Maintenance Checklist

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To be completed by maintenance manager or equivalent:

EQUIPMENT CHECKLIST

Site Checklist

ITEMS FROM WHICH SEPARATION IS REQUIRED (See related notes in the next section)

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Defect Action Report Further work required - SAP work order to be raised

Follow up action to be completed by maintenance manager and/or CES manager

List of Parts Used During This Planned Maintenance

Safety Valves

Pressure Relief Valves

Additional Parts

Related checklists

5 yrly Vessel Planned Maintenance Checklist

Free 5 yrly Vessel Planned Maintenance Checklist Checklist

Go digital today!

Convert your paper checklists into digital forms

To be completed by maintenance manager or equivalent:

EQUIPMENT CHECKLIST

Site Checklist

ITEMS FROM WHICH SEPARATION IS REQUIRED (See related notes in the next section)

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'S' + 'D' (metres), with reference to AS 1984 - 1997

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Minimum separation distance = 'D' (metres) with reference to AS 1894 - 1997)

Defect Action Report Further work required - SAP work order to be raised

Follow up action to be completed by maintenance manager and/or CES manager

List of Parts Used During This Planned Maintenance

Safety Valves

Pressure Relief Valves

Additional Parts

Related checklists