62: Out-of-date Documents Used
Definition/Typical Issues
Were the documents out of date? Did documents fail to reflect the current status of the system? Was there a failure to update drawings and documents when changes were made?
Was there a problem with the system for controlling documents? Did the system fail to provide appropriate methods for keeping documents up to date? Was there a failure to keep all official copies of the document updated? Were unofficial copies or outdated copies used in the field?
Examples of documents that are addressed by this node include:
- Original equipment manufacturers' manuals
- Material requirements
- Bill of materials
- Drawings
Examples
Example 1
- An operator was using an out-of-date process drawing in the field because it contained all of his markups. The markups were required to correct errors on the drawing and to add information the drawing did not contain. As a result, equipment was improperly isolated for maintenance.
Example 2
- Drawings of the new pulverizer were not submitted to the drawing control system. As a result, field walkdowns were needed to design a modification to the system.
Example 3
- Two system modifications were being implemented concurrently; however, the design engineers did not know this. The drawings did not indicate that changes were pending from these two modifications. As a result, changes implemented by the first modification were undone by implementation of the second modification.
Example 4
- An acid spill occurred during the opening of a line break. Lockouts had been made based on current drawings. The drawings were not up to date and did not show an acid stream that had been tied into the line 3 months earlier. The system that existed for controlling documents was not adequate. The organization was 6 months behind on updating marked-up drawings and distributing new copies to all official document holders.
Typical Recommendations
- Develop a system to control plant drawings, including timely updates and in-process modifications.
- Make current documents readily available to personnel.
- In addition to controlling changes, update information when it becomes obsolete or is impacted by a change to the process or process equipment.
- Periodically audit to verify that all official copies are updated.
Cross-References
| Version 10 Element(s) | |
|---|---|
| Node ID | Node Name |
| 104 | Documentation Content LTA or Not Kept Up-to-date |