A quality document for maintenance was developed to assist project managers for a contract maintenance provider to understand the requirements for the delivery of their services. The manual was intended to form part of the quality system of the company, bridging between the general procedures observed under ISO9000 and the day-to-day running of the operation. The methods and systems incorporated into the document cover work flow, reliability analysis, inspections, the CMMS and financial management.

The management and associated costs of inventory is an area of increasing concern. In the case study presented in this paper, considerable effort was allocated to managing the stores holdings in a cost effective way. The task remains to continually balance the investment in holdings versus avoiding costs due to not having a spare immediately available. A risk based approach was adopted to assign a level of criticality to a spare in order to determine whether or not to continue holding it. However, even after establishing a criticality system, it was proven necessary to implement an ongoing audit process which refreshed the required holding levels.

Risk management is a pervasive tool which can be employed by both production and maintenance groups as a basis for communicating a perception and to use a priority-setting tool in the absence of detailed information. Used correctly, the quantifiable description of risk such as a risk level or safety index, can streamline work and consequent investment to provide that work. This paper describes a simple approach to quantifiable risk assessment which can be tailored for smaller companies and form the basis for more sophisticated approaches by larger organisations. Examples and systems are provided as to how the recognition of risk can be exploited in optimising maintenance systems.

Russian refineries are used groups of ten thousand pumping units, basically centrifugal pumps, both Russian and foreign production. It’s power ranges from tens kilowatts to tens megawatts. Technological settings of primary oil processing, catalytic cracking, catalytic reforming and others contains a different number of units, which ranges from groups of ten to hundred units depending on powers of settings.

Specialists never raised doubts the necessity an anti-accident protection a powerful compressor and other unique machines, but not a pumps, which high concentration in modern technological settings however often was reason of damages and other production troubles. Really, if we take probability of pump trouble-free operation in day equal 0.99, then for the group of machines, containing 100 units, refusal probability close to 1, and the technological system herewith practically disabled.