FMDS0900 Maintenance and Inspection

FM Global 9-0
Property Loss Prevention Data Sheets 17-0

January 2014
Page 1 of 26
MAINTENANCE AND INSPECTION
Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 3

1.1 Changes .......................................................................................................................................... 3
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 3
2.1 Introduction ...................................................................................................................................... 3
2.1.1 Preventive (Time-Based) Maintenance Program ................................................................... 3
2.1.2 Predictive(Condition-Based) Maintenance (CBM) Program .................................................. 4
2.2 Operation and Maintenance ............................................................................................................. 4
2.2.1 General ................................................................................................................................... 4
2.2.2 Critical Plant Machinery Maintenance Strategy ..................................................................... 5
2.2.3 Managed Maintenance .......................................................................................................... 5
2.2.4 Failure Analysis ..................................................................................................................... 8
2.3 Contingency Planning ...................................................................................................................... 8
2.4 Training ............................................................................................................................................ 8
2.5 Foreign Material Exclusion ................................................................................................................ 8
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 8
3.1 Loss History ..................................................................................................................................... 8
3.2 Maintenance Programs .................................................................................................................... 9
4.0 REFERENCES ....................................................................................................................................... 9
4.1 FM Global .......................................................................................................................................... 9
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 9
APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 10
APPENDIX C SUPPLEMENTARY INFORMATION ................................................................................... 10
C.1 Program Review ............................................................................................................................ 10
C.1.1 General ............................................................................................................................... 10
C.1.2 Equipment Related .............................................................................................................. 11
C.1.3 Facility Related ................................................................................................................... 12
C.2 Contingency Planning ................................................................................................................... 12
C.2.1 Facility Contingency Plan ................................................................................................... 12
C.2.2 Equipment Contingency Plan .............................................................................................. 12
C.3 Risk Based Inspection (RBI): Overview ........................................................................................ 13
APPENDIX D FOREIGN MATERIAL EXCLUSION PROCEDURE ............................................................. 17
D.1 Purpose ........................................................................................................................................... 17
D.2 Applicability ..................................................................................................................................... 17
D.3 Responsibility .................................................................................................................................. 17
D.4 Definitions ........................................................................................................................................ 17
D.5 FME Level 1 .................................................................................................................................... 18
D.5.1 Additional Guidance for Level 1 ........................................................................................... 19
D.6 FME Level 2 .................................................................................................................................... 19
D.6.1 Additional Guidance for Level 2 ........................................................................................... 20
D.7 FME Level 3 .................................................................................................................................... 20
D.7.1 Additional Guidance for Level 3 .......................................................................................... 20
List of Figures
Fig. 1. Log-log plot of consequence vs. likelihood with lines of constant risk. .......................................... 16
©1995-2014 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
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17-0 Maintenance and Inspection
Page 2 FM Global Property Loss Prevention Data Sheets
List of Tables
Table 1. Typical Equipment and Facility Hazards .......................................................................................... 9
Table 2. Scenario Development, Consequence Measurement, and Risk .................................................. 15
Table 3. Semi-quantitative Risk Matrix ......................................................................................................... 16
©1995-2014 Factory Mutual Insurance Company. All rights reserved.

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Maintenance and Inspection 17-0
FM Global Property Loss Prevention Data Sheets Page 3
1.0 SCOPE
The purpose of this data sheet is to provide recommendations for developing effective loss prevention
maintenance and inspection programs for facilities, systems, and equipment. It also provides guidance for
evaluating the adequacy of existing maintenance and inspection programs, and making improvements to
existing programs.
Recommended maintenance and inspection for specific equipment, systems, and facilities can be found in
the data sheets for these items.
Design of equipment, systems, and facilities is beyond the scope of this data sheet. However, decisions made
at the design stage can have a great impact on the structure, cost, and effectiveness of any maintenance
and inspection program. Information on the design of maintainable assets (facilities, equipment, systems, etc.)
can be found in data sheets and other documentation specific to the application.
Information on evaluating maintenance and inspection programs and contingency planning are provided in
Appendix C.
1.1 Changes
January 2014. Added Section 2.5, Foreign Material Exclusion (FME) and Appendix D, Foreign Material
Exclusion Procedure.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 Introduction
The basic philosophy of managed maintenance and inspection is to maintain equipment and facilities in
reliable proper condition, identifying problems in their incipient stage, making appropriate adjustments, and
correcting problems at the first opportunity while minimizing unplanned shutdowns. This requires attention
to detail and considerable planned inspection and monitoring activity. For equipment, this includes idle,
shutdown, and operating periods; for buildings, both occupied and unoccupied facilities.
2.1.1 Preventive (Time-Based) Maintenance Program

A preventive (time-based) maintenance program requires scheduling maintenance activities at predetermined
time intervals, based on calendar days or runtime hours of machines. The equipment is to be available for
maintenance and inspection at the determined intervals, and the maintenance work is scheduled at a fixed
frequency.
When a preventive (time-based) maintenance program is adopted, the following actions are recommended:
A. Plan maintenance activities in advance, based on a fixed period of time. Have the equipment serviced
or overhauled independent of the machine’s condition.
B. Generate time-based maintenance tasks for both daily work and shutdown.
C. Preserve and enhance equipment reliability by scheduling planned maintenance activities and replacing
worn components as they become defective.
D. Apply maintenance to protective systems: alarms, trips, cutoffs, fire protection.
E. Check equipment’s condition, and perform partial or complete overhauls at specific periods of time.
F. Inspect and record equipment’s deterioration.
G. Generate a plan, and schedule to replace or repair worn parts at the next outage.
H. Classify/compile all maintenance activities under each equipment number.
I. Prioritize preventive maintenance activities and determine what tasks to perform and when.
J. Perform the maintenance activities while the equipment is in normal operation or do the work while
the equipment is shut down.
K. Determine who will perform preventive maintenance tasks: the operators, maintenance personnel,
in-house maintenance specialists, or outside experts.

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L. Document equipment condition and all inspection and maintenance activities.

M. Provide a tracking system.
2.1.2 Predictive(Condition-Based) Maintenance (CBM) Program

A predictive (condition-based) maintenance program is designed to observe the equipment’s condition
continuously, intervene when necessary, and warn immediately of any abnormal operation. The program also
aims to monitor and manage the health of the equipment.
If a monitoring system is adopted, the following actions are recommended:
A. Provide a monitoring system for early detection/prediction of a failure. Preserve and enhance equipment
reliability by replacing worn components before they actually fail.
B. Use recent technological advances in tools for inspection and diagnosis methods to enable even more
accurate and effective equipment maintenance.
C. Schedule and plan maintenance activities. Make it possible to prioritize and organize work so it can
be executed in a highly efficient way.
D. Determine who will perform the necessary maintenance tasks: the operators, the maintenance
personnel, in-house maintenance specialists, or outside experts.
E. Repair equipment when conditions warrant.
F. Document all inspection and maintenance activities.
G. Provide a tracking system.
H. Develop and institute the program with technical support from the OEM or a qualified individual within
the organization.
2.2 Operation and Maintenance
2.2.1 General
2.2.1.1 Create a clearly defined, written maintenance program that includes the following:
a) A policy statement and a maintenance manual, or equivalent, spelling out a definite assignment of
responsibilities and accountabilities
b) Preventive/predictive maintenance practices and procedures
2.2.1.2 Create maintenance practices and procedures that address:
a) equipment records.
b) maintenance requirements for each piece of equipment critical to production, for valuable equipment,
and for the facility itself.
2.2.1.3 Have facility personnel ensure the following: equipment is operated within design parameters and
preferably within control limits, equipment doesn’t exceed design parameters without concurrence of the
manufacturer; and all necessary testing and monitoring programs are implemented in a logical manner (i.e.,
following the manufacturer’s recommended practices and data sheets).
2.2.1.4 Planned inspection and testing activities are an integral part of equipment condition evaluation and
require the commitment and backing of both local and corporate management to ensure their success. Use
qualified personnel to perform repair work, and a thorough evaluation, testing, and inspection.
There are numerous tools and approaches for planning inspection and testing activities, many of which are
integrated into maintenance scheduling and planning tools. Refer to Appendix C.3 for an overview of
Risk-Based Inspection, a methodology used at some facilities.
2.2.1.5 Conduct visual inspection and routine services for building and support systems in accordance with
recognized engineering practices (i.e., periodic examination of roof areas to determine condition, build-up
of debris, condition of flashings, etc.). Give special consideration to seasonal concerns such as clearing roof

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drains, clearing snow from the lower areas of multilevel roofs, checking for freeze potential, and, in wind-prone
areas, checking the securement of roofs, wall panels, etc.
2.2.1.6 Supervise equipment to ensure performance is within its design specifications and control limits.
Monitor critical parameters during operations. Ensure operating personnel have the authorization to act
accordingly and respond properly to prevent and control damage during operation.
2.2.1.7 Review and evaluate operating records regularly.
2.2.1.8 Calibrate equipment and systems in accordance with the equipment manufacturer’s specifications.
2.2.1.9 Provide a schedule for all equipment and facilities requiring maintenance actions. Base the frequency
and extent of activity on the basis of experience with similar equipment and buildings and the
recommendations of equipment manufacturers, user groups, data sheets, and trade and technical
associations.
Document and carefully evaluate all abnormal occurrences and complete corrective measures (repairs,
modifications, improvements, etc.) in a timely manner.
2.2.1.10 Record all maintenance activity, operation history, and equipment modifications, as well as the types
and quantities of replacement parts (spares).
2.2.1.11 Upon completion, inspect and test repair work prior to operation. Establish and record new baselines
for monitoring.
2.2.1.12 Facilitate equipment identification with suitable tags attached permanently in visible locations, where
applicable.
2.2.2 Critical Plant Machinery Maintenance Strategy

For critical plant machinery and high-risk equipment in critical applications, include the following:
A. Performance monitoring: This is a very effective technique to determine the operational problems in
equipment. Monitoring the efficiency of the machines provides a good insight on their internal condition.
A decrease in efficiency or in flow capacity below baseline values in a machine warrants action to
determine the cause.
B. Root cause analysis: If only efficiency is affected, the cause is probably damage to, or deterioration
of, the internal components.
C. Thermograph monitoring: This is used to analyze active equipment. This method can detect electrical
and mechanical defects in generators, overhead lines, boilers, misaligned couplings, etc.
D. Corrosion monitoring: This ultrasonic technique is used on process equipment and pipelines to keep
track of the occurrence of corrosive wear.
E. Particle analysis: Worn machinery components, whether in reciprocating machinery, gearboxes, or
hydraulic systems, release debris. Collection and analysis of this debris provides vital information on the
deterioration of these components.
F. Lubrication analysis: Oil lubrication is critical to machinery operation. Ensure a precise diagnosis for
oil analysis and physical properties. A ferrographic analysis will authenticate the source of wear and
quantify the levels of contaminant particles present of any type of oil or grease used to lubricate any piece
of machinery, and the occurrence of certain particles can be connected to the operating condition of the
bearings and gears.
G. Vibration monitoring: This system is the most effective technique to detect mechanical defects in rotating
machinery.
H. Acoustic emission: This can be used to detect, locate, and continuously monitor cracks in structures,
pipelines, and pressure vessels.
2.2.3 Managed Maintenance

Managed maintenance applies to production equipment, support equipment, and facilities. Breakdown
(unplanned) maintenance is generally unacceptable. However, it can be an acceptable part of managed
maintenance when the equipment or facility:

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• is low cost,
• is readily available in the market place,
• has negligible time element/business interruption (TE/BI) impact, and
• presents minimal potential for consequential damage (whether from mechanical or electrical breakdown,
fire, collapse, etc.).
The necessary sophistication of a managed maintenance program varies with the complexity and size of a
facility. However, regardless of size, complexity, or sophistication, to be effective, the program has to contain
certain basic elements.
2.2.3.1 Generate a high-level, management-written statement of commitment (maintenance policy) to
preserve and protect your company’s assets. Ensure the statement mandates written procedures to be
distributed to and understood by all employees.
A sample policy statement reads ″It is the policy of XYZ Corporation to have a managed maintenance
program. Written maintenance policies and practices based on sound engineering practices and economic
principles describe the program. Documented maintenance decisions are to be made for all equipment,
systems, and buildings with priority given to critical support systems and/or production equipment.″
2.2.3.2 A written maintenance program describing the methods, policies and practices by which maintenance
is to be conducted should include the following, plus background and support information where necessary:
1. A statement of scope, purpose, and intent.
2. A description of the maintenance organization, including functional descriptions and assignment of
responsibilities.
3. In addition, the maintenance manual could address:
a) equipment and building records,
b) equipment and building maintenance requirements,
c) the work order system,
d) maintenance procedures,
e) maintenance reports and records,
f) maintenance schedules,
g) one-line electrical diagrams,
h) piping and instrumentation diagrams for mechanical systems; and
i) design information (including method for controlling and tracking revision levels).
2.2.3.3 List all facilities and equipment covered by the program in program master lists as defined in the
program. Keep the list up to date and use it as the foundation of the maintenance program.
Document the following data for each listed item:
1. Identification (item or building number)
2. Equipment manufacturer’s details (name, model, and serial number)
3. Technical details (rated speeds, rated power, capacities, frame size, etc.)
4. Location of building and systems plans, equipment manuals and drawings, technical manuals, and special
maintenance procedures
5. Location and condition of major spare parts
6. Local supplier or agent information
7. Protective devices and their functions
2.2.3.4 Analysis of Operations

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2.2.3.4.1 Identify equipment and system components with potential failure that can cause significant disruption
of operations.
Develop block or flow diagrams showing all important equipment, processes, and support services, e.g.,
HVAC, air, electrical, etc., including equipment important to facility operation and support and any other
equipment with a high replacement cost to be identified for priority attention.
Ensure that manufacturer’s technical manuals, industry standards, and data sheets are part of the overall
maintenance and inspection frequency program.
Provide input based on experience from maintenance personnel and operators. Document maintenance
requirements for each system, piece of equipment, major component, and building.
2.2.3.5 Planning and Scheduling
• Verify that maintenance is scheduled either by manual or automated means, ensuring that, whichever is
chosen, a work order is generated. Ensure the work orders are concise and clear, and provide adequate
information for the task required.
• Design the work order to include feedback, equipment maintenance work history records, and employee
identification.
• Unscheduled maintenance is normally handled via a maintenance work order. Provision for feedback on
this form is also essential and, like scheduled maintenance, required information should be entered into
the equipment record.
• Acknowledge the current status of all active work orders.
2.2.3.6 Records
Maintain records (historical data) pertinent to equipment and facilities covered by the program, including, at
a minimum, building blueprints, equipment nameplate data, purchasing information, age, design and
installation information, acceptance test data, and applicable data from the manufacturer’s technical manuals.
Also, record inspections and tests completed (and their results), scheduled and unscheduled maintenance
and cost, repair parts and materials used and cost, modifications and capital improvements completed, and
application changes.
2.2.3.7 Maintain a record of the spare parts available on site, as well as a list of names, addresses, and
telephone numbers of parts and equipment suppliers, technicians available to service, and rental possibilities
(if applicable).
2.2.3.8 Audit
Conduct an audit by experienced personnel, preferably from outside the maintenance organization. The audit
requires full review of the records to identify incomplete, nonsatisfactory maintenance activities and testing
frequencies.
Include the following in the audit:
• Percentage equipment operating records
• Maintenance activity records
• Maintenance activity backlog lists
• Previously made recommendations (FM Global, maintenance, manufacturer, etc.)
• Letters and bulletins from equipment manufacturers and FM Global
• Equipment records
• Planned dismantle inspections of major equipment
• Periodic tour through the facility
2.2.3.9 Contract Maintenance
Where contract maintenance services are used, outline exactly what services and servicing equipment are
provided. Also, have management identify which equipment and what activities remain the responsibility of the

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facility, and how facility and contractor personnel will interface. Have completed work records and service
requirements reviewed by management and documented to ensure contract requirements are met.
2.2.4 Failure Analysis

Root cause analysis is recommended to investigate significant equipment breakdowns or building problems.
The investigation report will identify the problems, and contain specific recommendations and corrective
action to prevent recurrence or similar incidents.
Apply these recommendations to similar equipment and facilities. Items pertinent to failure analysis include:
• Equipment records
• Percentage problem reports and repair/alteration history
• Statement of maintenance requirements
• Systems and equipment dismantle inspection reports
• Original equipment manufacturer (OEM) technical letters and bulletins
• Examine carefully maintenance records, including procedural details to ensure that there are no flaws or
omissions in the procedures that would allow a similar occurrence in the future
• The backlog of related maintenance items
• Any report(s) produced in connection with the failure, e.g,:
— Analysis/inspection of failed parts
— Description of symptoms
— Troubleshooting report
2.3 Contingency Planning

2.3.1 Develop a contingency plan or support service for equipment that is used, directly or indirectly, in the
production process or facility operation, which, being out of service, could result in significant interruption
of operations and/or damage to itself or other equipment.
Use the plan whenever such equipment is out of service. It can also be used to expedite maintenance outages.
2.4 Training
2.4.1 Conduct training programs for maintenance and operating personnel. Design the programs as an
ongoing process to maintain acceptable levels of competence and to familiarize personnel with the
performance characteristics of the equipment, as well as with mechanical components and the work of other
disciplines.
2.5 Foreign Material Exclusion

Implement a foreign material exclusion (FME) program and ensure it is strictly followed when maintenance
is conducted on pieces of equipment that are susceptible to foreign object damage (FOD), such as turbines,
generators, motors, and compressors. See Appendix D for best-practice guidance. Level 3 guidance is
particularly applicable to jobs that involve major disassembly of rotating equipment, especially gas turbines
generators. Introduction of foreign objects into these systems will most likely have devastating and costly
effects.
3.0 SUPPORT FOR RECOMMENDATIONS
3.1 Loss History

Loss experience with maintenance-related incidents is extensive. FM Global experience shows that, all too
often, maintenance is not effectively applied.
Loss data for a recent 10-year period indicated that inadequate maintenance (lack of maintenance and lack
of inspection) was a contributing factor in nearly all equipment losses.

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Typical equipment and facility hazards are shown in Table 1.
Table 1. Typical Equipment and Facility Hazards

Equipment Hazards Facility Hazards
Mechanical breakdown Escaped liquids
Electrical breakdown (primary) Fires
Pressure vessel breakdown Collapse
Service interruption Molten materials
Explosion
Freeze-ups
Windstorm damage
Most frequently reported reasons for the occurrences were:

• Testing/inspections not performed
• Maintenance not performed
• Inadequate maintenance
• Failure to document maintenance actions
• Electrical failures
• Improper installation or construction
• Failure to adapt to change of function or use
3.2 Maintenance Programs

3.2.1 Preventive (time-based) maintenance program: This type of program requires scheduling maintenance
activities at predetermined time intervals, based on calendar days or runtime hours of machines. The repair
or replacement of damaged equipment is carried out before problems occur. It is a good approach for
equipment that does not run continuously, and where the personnel/technicians have experience, knowledge,
and time to perform the preventive maintenance work.
3.2.2 Predictive (condition-based) maintenance (CBM) program: This program entails scheduling
maintenance activities only when a functional failure is detected. Performance and operational conditions
are monitored, using trends and an online monitoring system to identify the machine’s unhealthy components
and troublesome parts. The machine will be shut down at a time when it is most convenient, and the damaged
part will be repaired or replaced. The advantage of this approach is taking the appropriate corrective action,
and fixing the problems before the failure becomes costly and catastrophic. Scheduling the maintenance
allows for some lead-time to purchase parts for the necessary repair and work, thus reducing the need for
large inventories of spares.
4.0 REFERENCES
4.1 FM Global
Data Sheet 5-15, Electric Generating Stations
Data Sheet 11-1, Electric Power Generation - Steam Cycle
Data Sheet 13-3, Steam Turbine
Data Sheet 13-17, Gas Turbine
APPENDIX A GLOSSARY OF TERMS

Equipment critical to production: Equipment that, regardless of its replacement cost, would inhibit production
or otherwise adversely affect the operation of a facility.
FSE: Facilities, Systems, and Equipment.
Managed maintenance: Includes not only planning the maintenance program, but also implementing and
controlling it. Therefore, the term ’’managed maintenance’’ is preferred, over planned maintenance.

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RBI: Risk-Based Inspection.

Valuable equipment: Equipment having a high replacement cost, but that will not necessarily impact
production or facility operations.
APPENDIX B DOCUMENT REVISION HISTORY

Januuary 2014. Added Section 2.5, Foreign Material Exclusion (FME) and Appendix D, Foreign Material
Exclusion Procedure.
April 2011. Changes include the following:
• Recommendations have been added for critical plant machinery and high-risk equipment in critical
applications.
• New recommendations have been added for managing maintenance and services.
• Technical guidance has been added for time-based and condition-based maintenance programs.
May 2003. Revised section titled ‘‘3.1 Loss History’’. Also made minor editorial changes.
September 2002. An FM Global overview of Risk Based Inspection was added as Appendix C.3, Risk Based
Inspection an FM Global Overview, and a reference to this Appendix has been added to Recommendation
2.2.1.4. Also, the title and Scope of this Data Sheet have been editorially changed from Maintenance to
Maintenance and Inspection to highlight the importance of inspection in any maintenance program.
May 2001. Editorial changes only. No technical changes were made.
January 2000. The January 1995 edition of this document was reorganized to provide a consistent format.
No technical changes were made.
APPENDIX C SUPPLEMENTARY INFORMATION
C.1 Program Review

The following questions are suggested as a guide to evaluate an overall maintenance program. Based upon
response to the questions, improvements may be needed.
C.1.1 General
C.1.1.1 Is there a written maintenance policy statement? If yes,
1. Does it mandate written procedures and adherence to them?
2. Is it understandable?
3. Has it been distributed to all employees to whom it applies?
C.1.1.2 Is there a maintenance management program? If yes, does it address:
1. A work order and follow-up system
2. A maintenance system
3. Planning and scheduling
4. Organization
5. Training
C.1.1.3 Is the written maintenance program:
1. Usable (understandable)
2. Used
3. Up to date
C.1.1.4 Are there master maintenance lists for facilities and/or equipment? Are there complete building plans
available? If yes, have the lists and plans been updated within the last five years?

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C.1.1.5 Is the location of all building systems plans and equipment technical manuals known?
C.1.1.6 Are technical manuals and/or written procedures readily available to operating and maintenance
personnel? If yes, are they current and are they understandable?
C.1.1.7 Is there a work order system in place for:
1. Routine corrective maintenance
2. Planned maintenance
C.1.1.8 Do planned maintenance work orders contain:
1. Location of systems and/or equipment
2. Procedure (or reference)
3. List of required tools, parts, materials, test equipment
4. Adequate space for feedback
5. Expected time to complete task
C.1.1.9 Are persons doing maintenance required to document feedback information on the work order?
C.1.2 Equipment Related

C.1.2.1 Do equipment maintenance records contain:
1. Nameplate data
2. Modifications
3. Test information
4. Description of repairs, including frequency
5. Repair cost
C.1.2.2 Is equipment availability documented for all critical equipment, processes, and systems? If yes, is
this information used to adjust maintenance requirements?
C.1.2.3 Have breakdowns of critical and valuable equipment been thoroughly investigated and the results
documented? Was the root cause determined, and was corrective action taken to prevent recurrence?
C.1.2.4 Concerning equipment operating records:
1. Are they kept up-to-date?
2. Are operating limits indicated on logs?
3. Are completed logs reviewed by supervisors?
C.1.2.5 Is all valuable equipment and equipment vital to operations on a documented maintenance schedule?
If not, briefly describe priorities used.
C.1.2.6 For each piece of equipment receiving managed maintenance, is there documentation listing:
1. All required maintenance and testing
2. Frequencies for maintenance and testing
3. Craft and skill level required
4. Any related maintenance and testing
C.1.2.7 Are equipment inspections geared toward validating the maintenance effort and assessing equipment
operating condition?

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C.1.3 Facility Related

C.1.3.1 Is there a documented maintenance, inspection, and testing program for all property loss
prevention/control systems and equipment (e.g., sprinkler systems, CO2, fixed suppression)? If yes, are all
systems and equipment entered in the master maintenance list?
C.1.3.2 Are there documented records of completed maintenance actions, inspections, and tests (including
findings and results)?
C.1.3.3 Does the facility have an active Emergency Response Organization (ERO)? If yes, is the ERO call
list and list of assigned personnel current?
C.1.3.4 Does a freeze exposure potential exist? If yes, does a freeze prevention plan exist?
C.1.3.5 Does a roof overload potential exist from either snow, rainwater, or product? If yes, is there a plan
for drainage or accumulation removal?
C.1.3.6 Does a flood potential exist for this facility? If yes, is there a plan to minimize flood damage to
buildings and equipment (e.g., closing off ground level openings)? If provided, are berms, dikes, floodgates,
flood shields, pumps, equipment hoists, etc., considered in the maintenance plan?
C.1.3.7 Are all planned building occupancy changes evaluated for impact on existing structures, roof load
potential, and/or adequacy of fire protection?
C.1.3.8 Are the building roof systems regularly evaluated for leakage and wind damage potential. If yes,
are the results documented?
C.1.3.9 Is there a regular inspection and maintenance plan in place to ensure the continued structural integrity
of the buildings at the facility?
C.1.3.10 Is existing security adequate to deter theft and arson?
C.2 Contingency Planning

The purpose of a contingency plan is to prepare for an incident or loss so that a minimal amount of time
and expense is incurred to restore operations. With a properly prepared contingency plan, minimal time,
expense and frustration are spent recovering from the incident. The plan contains information needed to
expedite recovery and reduce the loss exposure.
C.2.1 Facility Contingency Plan

A facility contingency plan contains two parts: (1) an itemized index of the processes and equipment at the
location (a copy of the master maintenance list would be acceptable) and any associated hazard potential,
and (2) a contingency plan for each process or piece of equipment listed in the index.
To be effective, a facility contingency plan must also consider handling of fires, explosions, and the effects
of naturally occurring phenomena.
C.2.2 Equipment Contingency Plan

To be effective an equipment contingency plan contains at least the following for each listed piece of
equipment:
• Identification. Name plate data, plant equipment name and number, location (building number, floor, etc.).
• Installation, removal and dismantle specifications and requirements.
• Name(s) of employee(s) responsible and/or knowledgeable about or qualified to work on the equipment.
• Location of technical manuals and owners information.
• Supplier information (names, addresses, telephone and fax numbers, agreements concerning spares
availability and service.
• Transportation constraints (weight and height limits for roads, bridges, etc., special conveyance vehicle
requirements).

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• Plans/agreements with carriers and shipping companies (possible/potential shipping problems, agreements
to expedite).
• Building structural modifications required (removal of roof, walls, etc.).
• Special rigging requirements (crane, helicopter, bridging, etc.).
• Foundations, supports, frame sizes, and partial disassembly requirements. Can available (not identical)
spares be installed on existing foundation or support structure without major modifications?
C.3 Risk Based Inspection (RBI): Overview

Risk-Based Inspection (RBI) is a methodology used to prioritize inspections and was founded on the premise
that the most effective use of inspection activity and dollars is to focus first on those facilities, systems, or
equipment (FSE) that present the highest risk.
The following is an overview of RBI. Key features of RBI are presented including those aspects that are crucial
if a customer’s RBI program is to be an effective tool in focussing loss prevention and control efforts.
As used in RBI, ‘‘risk’’ is a qualitative, semi-quantitative, or fully quantitative measure determined by
multiplying the consequences of an event scenario by the likelihood of its occurrence. Used this way, an event
that has low consequences but a high likelihood of occurring can have the same or even higher ‘‘risk’’ than
an event that has greater consequences but a lower likelihood.
(This ‘‘risk’’ is somewhat different than the way the term is used by FM Global and the insurance industry
where ‘‘risk’’ is a qualitative or quantitative measure of the consequences if the scenario identified as a
‘‘hazard’’ occurs. Such risk doesn’t have to be expressed in dollars, and often isn’t. It could be the time duration
or extent of business interruption; area of impact, the number of buildings involved; the loss of market share;
etc.)
While the ASME Center for Research and Technology Development (CRTD) provided Development
Guidelines in the early 1990’s, the petroleum/chemical industries have led RBI application. API RP 581,
Base Resource Document on Risk-Based Inspection, first published in 1996 as a preliminary draft and
API RP 580, Risk-Based Inspection, published as a second draft in May 2000, are leading documents for
using this methodology. Additionally, ASME has created a draft document Inspection Planning Standard
Guidelines for Post Construction Pressure Containing Equipment that tracks much of the API material but
expands it beyond the petroleum and petrochemical industries. When properly applied, RBI can meet its
primary goal of overall plant budget reduction while at the same time accomplishing the synergistic goal of
focussing and enhancing loss prevention.
RBI is a performance based methodology. As such, guidelines created to assist users in applying RBI tell
what has to be done, but not how to do it. And while it is possible to provide both cost savings and higher
availability, it is also possible for RBI to reduce inspection costs but at the expense of larger loss exposures
and higher likelihoods of occurrence. This happens when an analysis understates or fails to fully quantify
an exposure, uses inappropriate methods for measuring consequence, makes incorrect assumptions when
establishing likelihood, or uses an inappropriate rating scheme.
RBI is a comprehensive program requiring long-term commitment from senior management to implement
and support.
Each of the following ten steps are essential to a successful program:
1. Define Scope of RBI program
The FSE covered by RBI have to be identified. In addition, the impact boundaries, which may include
both on- and off-site property, have to be defined.
2. Create database of operating history, current conditions, and future plans.
Current and past operating history (including normal operation, transients, startups, shutdowns, and
non- routine/upset conditions) is essential to understanding the present condition of FSE. Also, if changes
to the process or operating conditions are anticipated or inspection frequencies are being changed, these
factors have to be taken into account and be included in the database.
3. Develop event scenarios.

9-0
There are many ways to develop event scenarios and consequences and many practitioners of RBI have
very little exposure to or understanding of losses. Most significant losses propagate from a ‘‘chain of
events’’ that were often not considered prior to the loss.
4. Establish a cost estimate of the scenario consequences.
Here again, there are many ways to calculate cost. It is very important for the consequences to fully
represent the property damage and business impact effects of the event scenarios.
5. Determine the likelihood of occurrence.
Along with generic, manufacturer, and industry data, the likelihood of occurrence is strongly influenced
by the current condition and operating history of the FSE. The likelihood of a scenario involving a cascade
of events is the product of the likelihood of the initiating event times the probability of occurrence for each
cascading event in the scenario. Factors to be considered in the cascade of events include fire or
explosion following, human error, failure of a safety system, failure of the fire protection system, operating
and maintenance history, local factors, etc.
6. Calculate the event risk.
Risk is determined by the consequence and likelihood values. If consequences are expressed as
$/occurrence and the likelihood as number of occurrences/location-year, then risk (the product of
consequence times likelihood) is expressed as $/location-year.
7. Take corrective action to mitigate unacceptable risk.
Corrective actions (process changes, additional controls and/or safety devices, increased inspection
methods, scope, and/or frequency, etc.) are applied to FSE with unacceptably high risk levels to bring
the risk to an acceptable level.
8. Perform inspection ranking.
Inspections priorities are ranked from highest risk to lowest.
9. Conduct inspections.
Jurisdictional equipment may require more frequent inspections than dictated by risk ranking. This need
to receive special assessment and any departures from jurisdictional inspection frequencies requires
acceptance from the authority having jurisdiction.
10. Plan and conduct periodic reassessment and validation.
Reassessment and validation are vital to determine if actual conditions match expectations or if changes in
inspection frequency are needed to maintain an acceptable level of risk. Management of change is an
important part of this step. Equipment at the lowest and highest risk levels need to be periodically reassessed
to confirm the calculated risk is still valid.
The following example illustrates different ways the RBI methodology can be applied to calculate risk.
All of these are considered completely valid approaches by RBI ‘‘purists,’’ but clearly the approaches
give very different results and can provide very misleading indications of risk and loss potential. See Table
2.
Assume there is a pressure vessel containing a flammable material produced in a plant. The vessel is located
near process furnaces and a major separation process where finished materials are produced. The vessel
is estimated to have a leak frequency of once every 10 years. When there is a leak, there is a one in 10 chance
of an ensuing fire that affects 10 workers in the area and engulfs the separation equipment. In the event
of such a fire, ten homes near the plant will be evacuated as a precaution. There are no environmental impacts
as the combustion products dissipate into the atmosphere and escaping liquid is contained in a properly
designed drainage area.

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Table 2. Scenario Development, Consequence Measurement, and Risk

Consequence
(Assumed
Method values for
of example
Scenario Consequence Measurement Likelihood purposes Risk
Initiating event with fire following PD & TE 1/100 US $100 US $1
(deductibles and limits of liability years million million/year
do not apply)
Initiating event with fire following PD only 1/100 US$25 million US $0.25
years million/year
Initiating event only PD & TE 1/10 US$10,000 US $1000/
(no deductibles and no limits of years year
liability considered)
Initiating event with fire following Worker safety 1/100 10 workers 0.1 workers/
years affected year
Initiating event with fire following Community health 1/100 10 families 0.1 families/
years (32 people) year
evacuated
Initiating event with fire following Environmental impact 1/100 None Zero
years
Observations about Risk based on the example:

• All of these approaches to calculating risk are acceptable in terms of published ‘‘RBI methodologies.’’ Also
‘‘acceptable’’ is an approach where PD and TE costs are limited to the deductible; from the standpoint of
the customer, all costs beyond the deductible are borne by the insurance company and therefore are not
a cost to the owner/user. Clearly, use of any approach that does not fully quantify the PD & TE costs has
limited or no value to loss prevention and risk improvement.
• Worker Safety, Community Health, and Environmental Impact (often abbreviated as SHE) are legitimate
measurements of risk that are independent of PD & TE. As such, they can (and should) be independently
evaluated. Some practitioners advocate assigning dollar values to SHE risks and then combining them
with PD & TE to get a ‘‘total risk.’’ While theoretically attractive, assigning dollar values to worker safety/lives
and community health is highly subjective. And even environmental impact becomes subjective if an effort
is made to quantify ‘‘costs’’ beyond remediation costs and fines paid for exceeding allowable limits. By
keeping these categories separate, there is no possibility of having one cost/risk mask or overshadow
another. Inspection prioritization and ranking, at least in a semi-quantitative standpoint (very low, low,
medium, high, very high) can be based on the highest risk category for each measurement basis using a
semi-quantitative risk matrix.
• The example is very simplified. In an actual evaluation it would be necessary to look not just at the
probability of a leak with a fire following, but also an evaluation of the probability of how big a fire is likely
to develop along with the probability of fire control systems functioning/not functioning properly.
• Almost any initiating event can cascade to MFL proportions if enough things go wrong. However, in many
cases the likelihood/probability of this occurring is so small that the risk is less than that for a less severe
event that has a greater probability of occurring. As each step in the cascade of events is evaluated
(consequence and likelihood), the step producing the highest risk is the risk that should be associated with
the initiating event.
• Very, very low likelihood is not ‘‘zero.’’ Some practitioners of RBI declare any likelihood less than some
threshold to be ‘‘zero.’’ This is not acceptable because the risk associated with many high consequence
cascades of events will not be considered.
In order for the risk matrix, as shown in Table 3, to be semi-quantitative, a numerical range needs to be
assigned to each likelihood and consequence level. This is often done on an ‘‘order of magnitude’’ basis.

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Table 3. Semi-quantitative Risk Matrix
A 5 4 3 2 1
B 6 5 4 3 2
C 7 6 5 4 3
← Likelihood →
D 8 7 6 5 4
E 9 8 7 6 5
V IV III II I
← Consequence or Severity Rank →
Likelihood Consequence Risk

(letters) (Roman Numerals) (Arabic Numbers)
Most Likely: Category A Most Severe: Category I Greatest: Category 1
Least Likely: Category E Least Severe: Category V Lowest: Category 9
For fully quantitative measurements, a log-log plot as shown in Figure 1 can be used to plot risk. The diagonal
lines are lines of constant risk.
Fig. 1. Log-log plot of consequence vs. likelihood with lines of constant risk.

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APPENDIX D FOREIGN MATERIAL EXCLUSION (FME) PROCEDURE
D.1 Purpose
This procedure represents best-practice guidance to prevent foreign material from being introduced and left
behind in pieces of equipment that are open for maintenance or repair and are susceptible to foreign object
damage (FOD). The procedure also covers the control of items that are temporarily installed or used to
facilitate work, such as tools, blank flanges, filters, orifices, and cleaning materials.
NOTE:The most efficient way to prevent foreign object damage (FOD) is to maintain high-quality
housekeeping. Items cannot drop into an foreign material exclusion (FME)-controlled area if they are excluded
from work areas to begin with. Proper tool management is needed to accomplish the required work activities.
It is imperative that all personnel are aware of this policy and pay particular attention to all materials and
tools that are brought into the work area.
D.2 Applicability
This procedure and all of its provisions should be applied anytime a piece of equipment or system is opened
for maintenance and foreign materials could be introduced. This includes, but is not necessarily limited to,
turbines (gas or steam), generators, generator circuit breakers, transformers, piping systems, inlet air
systems, condensers, heat exchangers, pumps, large motors, compressors, and other large stationary
equipment. Different levels of foreign material exclusion (FME) apply to different jobs and applications. Though
there are different levels of FME recommendations, the general practices of FME should be adhered to during
all maintenance activities.
D.3 Responsibility
The day shift technical director (TD) should have primary responsibility and accountability for the
implementation of the foreign material exclusion (FME) program on any project; however, everyone on the
project should be fully versed in the program and understand the necessity of following the proper procedures.
The TD will also be responsible for obtaining concurrence at the start of each project with the owner’s
representative (OR) as to what inspection level will be required (e.g., visual vs. cameras). It is imperative
that the TD reinforce the FME procedure with all craft personnel during daily toolbox safety meetings.
The owner’s representative (OR) is responsible for overseeing the proper implementation of the foreign
material exclusion (FME) procedure by the technical director (TD), through direct interaction with the TD and
periodic audits of the program, as well as by routine spot checks for compliance.
All craft personnel, through coordination of the technical director (TD), are responsible for ensuring that covers
are in place and tags are hung and attached to particular openings, and that all such covers and tags are
properly entered on the appropriate form. Personnel should honor all foreign material exclusion (FME) tags,
and no FME tags should be removed unless removal is connected with a work activity. If such tags are
removed during the course of the work, they should be reinstalled unless component reassembly is imminent.
D.4 Definitions
Access control: Methods used to control the entry and exit of personnel, tools, and materials. These include
the use of boundary markers, signs, entry/exit logs, and monitors. Subject to the category of the foreign
material exclusion (FME) areas, boundary markers should consist of solid barriers such as temporary metal
walls, plexiglas walls, wire fencing, or, if appropriate, fabric curtains, FME tape, rope, etc.
Access control point: A point established along an foreign material exclusion (FME) boundary at which
entry of personnel, tools, and materials are permitted but controlled.
Close-out sheet: An Foreign Material Exclusion (FME) Barrier Log (Form 2) that is filled out and reviewed
with the owner’s representative (OR) upon removal of all FME barriers at the completion of the outage or
maintenance event. The close-out sheet should identify any discrepancies in the Foreign Material Exclusion
(FME) Drop List (Form 3) and the FME Barrier Log (Form 2) and sign-in/sign-out logs, as well as a description
of any findings during close-out inspections, how the inspections were conducted (e.g., visual, borescope),
and both the OR and the technical director (TD) should sign the close-out sheet. Completed close-out sheets
should become a permanent part of the outage record.

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Foreign material: Material that is not part of the system or component as designed, such as tape, tie-wire,
tie-wraps, welding rods, tools, pens, pencils, electrical wire, cable, paper/plastic labels, stickers, signs,
operations tags not properly secured, rags, plastic face shields, plastic bags, packaging, gasket material,
excess sealant materials, ear plugs, sawdust, chemicals, solvents, paints, personal items such as eyeglasses
or jewelry, or any other item that can affect the operation of the system or component.
FME audit: A periodic audit conducted by the owner’s representative (OR) and/or the technical director (TD)
during a maintenance event using the Foreign Material Exclusion (FME) Field Audit Checklist (Form 1) in
order to evaluate the proper implementation of the FME program.
FMEA: Foreign material exclusion area; a work area around an open access, instrumentation, electrical, or
mechanical component that should be surrounded by a physical boundary marker requiring specific controls
to prevent the intrusion of unwanted material into a system or component. These areas should be posted.
FME barrier: A plug, cover, cap, bag, tape, or other device used to close or cover an opening on a pipe or
in a piece of equipment in an effort to prevent foreign material exclusion (FME) intrusion.
FMEA boundary: A physical boundary around a task, usually consisting of a boundary marker and visible
signs identifying the specific area as an foreign material exclusion area (FMEA).
FMEA monitor: An individual responsible for access control in accordance with this procedure. The monitor
is responsible for verifying all items logged by the work group, and should therefore be competent,
well-trained, and fully aware of the consequences of foreign object damage (FOD) to the machine.
Lanyard: A strap, line, restraint wire, or similar used to secure an item in such a manner that it cannot become
a foreign object in an foreign material exclusion (FME)-controlled area if the person holding or using it loses
control of the item.
Owner’s representative (OR): The OR is responsible for overseeing the proper implementation of the foreign
material exclusion (FME) program by the technical director (TD), and conducts periodic audits of the program
in accordance with Foreign Material Exclusion (FME) Field Audit Checklist.
Technical Director (TD): The supervisor (whether an employee of the owner or of the contractor performing
the work) who has direct responsibility for overseeing the performance of the work being done on the
equipment, and therefore direct responsibility for implementing the foreign material exclusion (FME) program
during the outage.
D.5 Foreign Material Exclusion (FME) Level 1

FME Level 1 applies to components and systems that have a low probability of foreign material intrusion
and in which visual inspection and/or retrieval of foreign material is not impaired or restricted. In these cases,
the difficulty of inspecting and/or retrieving items is low and requires no extensive disassembly of components.
In general, the equipment involved in Level 1 is less vital and does not have critical tolerances related to
it.
The minimum requirements for FME Level 1 are as follows:
A. Take proper work precautions and use appropriate professional care.
B. Follow appropriate work procedures.
C. Locate soft barriers at all access points notifying personnel of FME requirements.
D. Upon disassembly, clean the equipment to be worked on or opened to prevent foreign material from
being introduced once the equipment is open.
E. Train all personnel on the requirements of the FME procedure, including the owner’s personnel, at
the beginning of each outage. Include a signed acknowledgement by everyone that they understand the
FME procedure.
F. Once the equipment is open, secure all areas that could be susceptible to foreign material using FME
barriers (covers, blanks, bladders, or other appropriate barricades). Ensure FME barriers are easily
recognizable so they will not be mistaken for a normal part of the equipment or system (typically bright
red or orange). Document all blanks and covers using an Foreign Material Exclusion (FME) Barrier Log
(Form 2). Ensure all blanks and covers have a unique tag identifier specifying the location and type of
barrier (e.g., plug, magnetic strip). Ensure that all FME barriers that are not easily observable (e.g., oil

9-0
drain lines, air extraction lines) include a tail that extends from the FME barrier to the outside of the machine
across the horizontal split line, with the identification tag at the end of the tail.
G. List all tools and equipment on an Foreign Material Exclusion (FME) Tool Log (Form 4) and ensure
they are accounted for at all times and not left in problematic areas.
H. Document any dropped or unaccounted-for tools on an Foreign Material Exclusion (FME) Drop List
(Form 3) and ensure they are recovered immediately, if possible.
I. Maintain a drop list at all times, and ensure all personnel immediately report (without fear of reprisal)
anything that has been dropped and cannot be immediately found or retrieved.
J. If new parts are to be installed, inspect and clean them thoroughly before installation.
K. Prior to removing any FME barrier, vacuum and clean the area around the FME barrier.
L. Upon reassembly, clear the Foreign Material Exclusion (FME) Drop List (Form 3). Again clear the blanks
and covers list at the appropriate time during the reassembly process (i.e., only remove blanks when that
section of the system is ready to be reassembled). Thoroughly inspect all parts and sections of the system
for foreign material.
M. Upon reassembly, all barriers should be removed. Clear the FME Barrier Log (Form 2). Any FME
barriers that cannot be accounted for should be reviewed by the technical director (TD) and the owner’s
representative (OR).
N. Thoroughly clean all lower-half cases (preferably vacuumed, but blown with plant air if necessary) prior
to final inspection.
O. Prior to closure or reinstallation, have all cases, piping, openings and drains visually inspected and/or
borescoped by the TD and witnessed by the OR.
P. Prior to reinstallation, have all small-bore piping and tubing blown out, and all large-bore piping swabbed
or blown out.
Q. Prior to closing up the equipment for the last time, ensure all items are cleared off the FME Drop List
(Form 3). If all items have not been accounted for, then the TD and the OR should discuss the drop list
and mutually agree as to the appropriate course of action.
D.5.1 Additional Guidance for Level 1

A. All equipment parts, both in the foreign material exclusion area (FMEA) and outside the area, should
be neatly laid up, and smaller parts should be bagged or boxed and labeled. Part lists should be
maintained, including a part count if there is more than one identical part. All parts that need to be replaced
should be recorded using an Foreign Material Exclusion (FME) Materials Log (Form 5).
B. Any foreign materials (debris, tools, rags, etc.) found when opening the equipment should be registered
and placed in a controlled access area to allow for investigation and assessment by technical personnel.

FME Level 2 applies to components and systems in which there is a possibility of foreign material intrusion,
and in which visual inspection and/or retrieval of foreign material is minimally impaired or restricted. Level
2 applies to jobs that involve turbines and other critical rotating equipment, such as pumps and motors, that
have tight, critical clearances, as well as piping systems that feed such systems.
A. Adhere to all of the FME Level 1 requirements.
B. Ensure personnel entering the FME area have empty pockets. Allow only necessary items in the FME
area; all personal items (e.g., cell phones, watches, jewelry, pens, knives, and wallets) should be left
outside.
C. Provide a personal effects storage locker or bin.
D. Ensure all tooling in the work area is organized neatly and accounted for on a personal level (i.e., each
person tracks their own tools: “take out what you take in”).

9-0
E. Have all removed piping capped or plugged on both ends and tagged with location and other pertinent
identifiers.
F. Instruct all personnel to verify that the bottoms of their boots are clean and free of debris prior to entering
the work area. Have the foreign material exclusion area (FMEA) monitor visually inspect the boots of all
personnel entering the work area, especially during the reassembly process.

A. A foreign material exclusion (FME) Monitor should be used to control access to the work area, and to
inventory all materials going into and out of the work area. Access to the work area should be restricted
when the FME Monitor is unavailable.
B. Any loose objects (including jewelry) not needed to perform a specific task in the work area should
be left with the FME Monitor or in the personal effects storage locker or bin.
C. FME logs should be cleared at the end of each shift, with the exception of long-term tools.
D. All parts in the work area should be neatly bagged or boxed and labeled.
E. Tooling should be tied off if there is a potential that it could be dropped into an area from which it cannot
easily be retrieved.
F. The technical director (TD) should, on a regular basis but at least weekly, conduct an FME audit,
including an audit of the tags, FME barriers, foreign material exclusion area (FMEA) login/logout books,
and an inspection of all piping that has not yet been installed.
G. The owner’s representative (OR) should conduct an audit of the FME program at least weekly.
H. Safety glasses should be on lanyards.
I. Slip-on safety boots or boot covers, without shoe laces, are preferred. If slip-on safety boots are not
used, laces and buckles should be taped down.
J. When borescoping hard-to-see areas, the TD and OR should decide ahead of time whether a recorded
video or borescope pictures will be filed with the outage report.

FME Level 3 applies to components and systems in which there is a possibility of foreign material intrusion,
and in which the difficulty of inspecting and/or retrieving items is high, possibly requiring extensive
disassembly of components. Level 3 applies to jobs that involve major disassembly of rotating equipment,
specifically turbines and generators. The introduction of foreign material into these systems would most likely
have devastating and costly effects.
A. Adhere to all of the FME Level 1 and FME Level 2 requirements.
B Have the owner’s representative (OR) conduct an audit of the FME program at least weekly.
C. When working on electrical generators or large electric motors, do the following:
1. Ensure a supply of clean, warm, dry air to the generator to alleviate moisture ingress into the
generator.
2. Provide an enclosure or cover (e.g., a tent or tarp) in addition to side barriers to protect against
dust, moisture, birds roosting over the open equipment, etc.
3. When rotors are moved to a “clean area,” apply the FME program to this area as well.
4. Ensure all personnel working in the foreign material exclusion area (FMEA) have boot covers and
lint-free overalls with no pockets.
5. Ensure all tools are on lanyards, and the lanyards are on the wrists of the personnel using the tools.

9-0

A. An access-control point should be established, and all personnel should be required to sign in and
out of the area, providing a complete inventory of all items, including long-term and short-term tools and
parts brought into the work area.
B. An FMEA Monitor should be assigned to enforce access control and verify inventory into and out of
the FMEA work area.
C. All tools, including flashlights, should have lanyards, and everything should be tied off to prevent them
from falling into the open equipment.
D. All flashlights should be taped at both ends to prevent either the battery compartment or the light bulb
compartment from opening.

Form 1. Foreign Material Exclusion (FME) Field Audit Checklist
Page 22
17-0
9-0
Plant Site/Job: Date: Technical Director: Time:
Task Yes No N/A Comments

1 Are FME boundaries established and marked?
2 Is appropriate signage in place?
3 Is an FME monitor utilized?
4 Are FME barriers installed properly?
5 Are FME tags attached to FME barriers?

6 Are FME tags filled out properly?
7 Are any FME barriers missing?
8 Is the FME log filled out properly?
11 Are supervisory personnel enforcing FME procedures?
12 Are employees following FME procedures?
Is removed piping (including tubing) capped/covered on
both ends?
13 Is removed piping (including tubing) tagged and identified?
14 Is the drop list up to date?
Maintenance and Inspection

FM Global Property Loss Prevention Data Sheets
15 How many items are on the drop list?
16 Is the FMEA log book up to date?
17 Is there a bin/locker for personal effects?
18 Is generator/electrical FME policy in effect?
19 Is generator/electrical equipment covered and supplied with
heated and dried air?
20 Are personnel wearing boot covers and lint-free coveralls in
the generator area?
Comments:
Completed by: Owner’s Representative:

Form 2. Foreign Material Exclusion (FME) Barrier Log
FM Global Property Loss Prevention Data Sheets

Maintenance and Inspection
Plant Site/Job: Date: Technical Director:
Tag # Install Date Location Type of Barrier Installed By Removed By Removal Date Inspected By Signed
1
Where was FME barrier installed? (Bearing drain line, steam injection, extraction line, etc.)
Page 23
17-0
2
What type of FME barrier was used? (Plugs, magnetic strips, pipe caps, etc.)
9-0
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Form 3. Foreign Material Exclusion (FME) Drop List
Item Date Lost Description Where Lost Date Retrieved

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Form 4. Foreign Material Exclusion (FME) Tool Log
Tool
Number Description Date In FMEA Date Out FMEA Person’s Name

9-0
Form 5. Foreign Material Exclusion (FME) Materials Log
Materials Description Date In FMEA Date Out FMEA Person’s Name

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Property Loss Prevention Data Sheets 17-0

MAINTENANCE AND INSPECTION

1.0 SCOPE ................................................................................................................................................... 3

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1.1 Preventive (Time-Based) Maintenance Program

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

L. Document equipment condition and all inspection and maintenance activities.

2.1.2 Predictive(Condition-Based) Maintenance (CBM) Program

2.2 Operation and Maintenance

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

2.2.2 Critical Plant Machinery Maintenance Strategy

2.2.3 Managed Maintenance

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

2.2.4 Failure Analysis

2.3 Contingency Planning

2.5 Foreign Material Exclusion

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Loss History

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

Typical equipment and facility hazards are shown in Table 1.

Table 1. Typical Equipment and Facility Hazards

Most frequently reported reasons for the occurrences were:

3.2 Maintenance Programs

APPENDIX A GLOSSARY OF TERMS

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

RBI: Risk-Based Inspection.

APPENDIX B DOCUMENT REVISION HISTORY

APPENDIX C SUPPLEMENTARY INFORMATION

C.1 Program Review

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

C.1.2 Equipment Related

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

C.1.3 Facility Related

C.2 Contingency Planning

C.2.1 Facility Contingency Plan

C.2.2 Equipment Contingency Plan

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

C.3 Risk Based Inspection (RBI): Overview

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

Table 2. Scenario Development, Consequence Measurement, and Risk

Observations about Risk based on the example:

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

Table 3. Semi-quantitative Risk Matrix

Likelihood Consequence Risk

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

APPENDIX D FOREIGN MATERIAL EXCLUSION (FME) PROCEDURE

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

D.5 Foreign Material Exclusion (FME) Level 1

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

D.5.1 Additional Guidance for Level 1

D.6 Foreign Material Exclusion (FME) Level 2

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

D.6.1 Additional Guidance for Level 2

D.7 Foreign Material Exclusion (FME) Level 3

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

D.7.1 Additional Guidance for Level 3

©1995-2014 Factory Mutual Insurance Company. All rights reserved.

Task Yes No N/A Comments