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Ongoing Maintenance Program — Pressurised Vessels

   
Document No. JDS-PRO-010
Revision B
Date 2026-03-25
Status APPROVED
Author Nils Johansson

1. Purpose

This procedure defines how to set up, run, and maintain an Ongoing Maintenance Program for pressurised vessels. It is the master procedure for pressure vessel supervision within JDS.

It turns the JDS system into an operational tool: every step of the maintenance cycle produces a JDS document, every inspection is tracked, and every finding is closed.

In plain language: This is the master procedure for running a pressure vessel maintenance program. Follow it from top to bottom for a new client. Follow the annual cycle for ongoing work.

2. Scope

This procedure applies to:

It covers the full lifecycle:

SET UP → INVENTORY → CLASSIFY → PLAN → INSPECT → REPORT → UPDATE → REPEAT

3. Roles and Responsibilities

Role Responsibility
Operator Ensure the maintenance program is in place, fund inspections, act on findings
Program Manager Run the program day-to-day — this role uses JDS
Accredited Inspector Perform Class A inspections (accredited inspection bodies)
Competent Person Perform Class B inspections (documented competence per JDS-PRO-009)

4. Setting Up a New Program

Step 1 — Create the Client Folder

Create a new client folder under 03-active-programs/:

03-active-programs/
└── [client-name]/
    ├── JDS-LOG-MEC-NNN_inventory.md       ← Equipment register (from TMP-LOG-002)
    ├── JDS-LOG-MEC-NNN_inspection-plan.md ← Annual inspection plan (from TMP-LOG-004)
    ├── inspections/                        ← Inspection reports (JDS-RPT-MEC-NNN)
    ├── supervision/                        ← Supervision checklists (JDS-LOG-MEC-NNN)
    ├── certificates/                       ← Scanned certificates from inspectors
    └── vessel-files/                       ← One subfolder per vessel
        ├── PV-001/                         ← Manufacturer docs, drawings, history
        ├── PV-002/
        └── ...

Step 2 — Build the Equipment Register

  1. Use template JDS-TMP-LOG-002 (Supervision Inventory Template)
  2. Walk the site and record every pressure vessel
  3. Photograph every nameplate
  4. Fill in all mandatory fields (marked M)
  5. Register the document in jds/registry/document-register.md

Step 3 — Classify Every Vessel

For each vessel, determine:

Decision How
Is it in scope? Maximum allowable pressure > 0.5 bar AND pressure-volume product > 50 bar·L
What is the fluid group? Group 1 (dangerous) or Group 2 (other)
What is the risk class? Class A (higher risk, requires accredited inspector) or Class B (lower risk)
What PED category? I, II, III, IV, or Art. 4.3

Record the classification in the equipment register.

Step 4 — Build the Inspection Plan

  1. Use template JDS-TMP-LOG-004 (Annual Inspection Plan Template)
  2. For each vessel, enter the inspection intervals:
Risk Class External Internal Pressure Test
Class A 2 years 6 years 12 years
Class B 2 years 6 years —
  1. Calculate next due dates from the last inspection (or commissioning date for new vessels)
  2. Book accredited inspectors for Class A items at least 3 months ahead

Step 5 — Establish Supervision Routines

  1. Use template JDS-TMP-LOG-003 (Supervision Checklist Template)
  2. Define a monthly or quarterly walk-around checklist
  3. Assign responsible person for each walk-around
  4. File completed checklists in the supervision/ folder

5. Annual Maintenance Cycle

Once set up, the program runs on an annual cycle:

Q1 (January–March) — Planning

Task Document Template
Review inspection plan for the year JDS-LOG-MEC-NNN TMP-LOG-004
Book inspectors for planned inspections — —
Review overdue items from previous year Inspection plan —
Update equipment register if vessels added/removed JDS-LOG-MEC-NNN TMP-LOG-002

Q2–Q3 (April–September) — Execution

Task Document Template
Perform scheduled inspections JDS-RPT-MEC-NNN TMP-RPT-003
Perform routine supervision JDS-LOG-MEC-NNN TMP-LOG-003
Test safety devices per schedule Safety device register —
Document findings and corrective actions JDS-RPT-MEC-NNN —

Q4 (October–December) — Review & Close Out

Task Document Template
Verify all planned inspections were completed Inspection plan —
Close out all findings and corrective actions CA log JDS-PRO-008
Update equipment register with latest results JDS-LOG-MEC-NNN —
Prepare inspection plan for next year JDS-LOG-MEC-NNN TMP-LOG-004
Archive completed inspection reports inspections/ —

6. Performing an Inspection

Before the Inspection

  1. Prepare the vessel: isolate, depressurise, drain/clean if internal
  2. Gather previous inspection reports for the inspector
  3. Prepare access (scaffolding, lighting, ventilation for confined spaces)
  4. Complete a pre-inspection risk assessment

During the Inspection

  1. The accredited inspector (Class A) or competent person (Class B) performs the inspection
  2. Document all findings in real-time
  3. Photograph significant findings

After the Inspection

  1. Receive the inspection certificate from the inspector
  2. Create an inspection report: JDS-RPT-MEC-NNN (use TMP-RPT-003)
  3. Update the equipment register:
    • Last Inspection → today’s date
    • Next Due → calculated from interval
    • Result → APPROVED / APPROVED WITH REMARKS / REJECTED
    • Certificate Ref → new certificate number
  4. File the certificate in certificates/
  5. If findings require action: create corrective actions per JDS-PRO-008
  6. Log the update in the project CHANGELOG

7. Handling Findings

Result Action
Approved Update register, file certificate, no further action
Approved with remarks Update register, create monitoring actions, set follow-up date
Rejected Take vessel OUT OF SERVICE immediately, create corrective action, do not return to service until re-inspected and approved

All findings follow JDS-PRO-008 (Corrective Action Procedure).

8. Document Map — What JDS Produces

Activity JDS Document Type Template
Equipment inventory LOG (register) JDS-TMP-LOG-002
Annual inspection plan LOG (plan) JDS-TMP-LOG-004
Routine supervision LOG (checklist) JDS-TMP-LOG-003
Inspection report RPT (report) JDS-TMP-RPT-003
Risk assessment RPT (assessment) JDS-TMP-RPT-001
Corrective action CA log entry JDS-PRO-008
Competence records Training log JDS-PRO-009

9. JDS Tools

Task Command
Validate all documents python3 scripts/jds-validate.py
Generate inspection report PDF python3 scripts/md2pdf.py <report.md>
Generate letter to inspector/client python3 scripts/md2letter.py <letter.md>
Check all links and registrations python3 scripts/jds-validate.py --fix

10. References

Document Purpose
JDS-PRO-004 Inspection Planning Procedure
JDS-PRO-008 Corrective Action Procedure
JDS-PRO-009 Competence Management Procedure
JDS-MAN-MEC-001 Documentation Guide — What Records to Keep
JDS-LOG-MEC-001 Equipment Register (Framework Template)
JDS-LOG-MEC-002 Pressure Vessel Inventory Guide

Regulatory traceability: For a full mapping of how this procedure satisfies specific regulatory requirements, see the Regulatory Traceability Matrix.

Revision History

Rev Date Author Description
A 2026-03-25 N. Johansson Initial release — complete ongoing maintenance procedure
B 2026-03-25 N. Johansson Language authority update — all terminology now JDS English. Regulatory traceability separated to dedicated matrix document.