1 CHAPTER 4 Typical Maintenance & Inspection Typical Maintenance & Inspection in a Process Plant in a Process Plant CPB 20004: Plant Utility n CPB 20004: Plant Utility n Maintenance Maintenance
Jan 11, 2016
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CHAPTER 4Typical Maintenance & Inspection in a Typical Maintenance & Inspection in a
Process PlantProcess Plant
CPB 20004: Plant Utility n MaintenanceCPB 20004: Plant Utility n Maintenance
Typical Maintenance and Inspection in a Process Plant 1. Mechanical Equipment & Plant Utilities 2. Electrical Equipment 3. Building and Structures 4. Instrument for Measuring / Monitoring 5. Lubrication
CPB 20004: Plant Utility & MaintenanceCPB 20004: Plant Utility & Maintenance
1. MECHANICAL EQUIPMENT/PLANT
UTILITIES
• Static Equipment• Rotating Equipment• Vessel• Reactor• Boiler• Cooling tower• Pump• Compressor• Turbine
1. Mechanical Equipment/Plant Utilities
• STATIC EQUIPMENT• Comply with FMA Regulation (CF Requirement).• More concentrate in prevention and any modification
must obtained the approval from DOSH.
1. Mechanical Equipment/Plant Utilities
• FMA = Factories Machinery Act.
• Moving part.• Design and specification (head, types of fluid, capacity).• Operating condition (pressure, noise, vibration,
lubrication, mechanical seal, belting, roller, alignment, cooling system).
• Efficiency of the equipment.
• VESSEL• Equipment for storage.• Normally store liquid chemical.• Include pressure vessel.• Should have a strength of stress and strain
especially at welding part.
1. Mechanical Equipment/Plant Utilities
• Reactor• Equipment for reaction take part.• Main equipment to produce the product.
• Boilers• Boilers are fuel-burning appliances that produce either hot water or
steam that gets circulated through piping for heating or process uses.• Proper maintenance and operation of boilers systems is important with
regard to efficiency and reliability.– Fire-tube Boiler– Water-tube Boiler– Electric Boiler
1. Mechanical Equipment/Plant Utilities
BOILER BOILER CHECKLISTSCHECKLISTS
• A cooling tower is a specialized heat exchanger in which two fluids (air and water) are brought into direct contact with each other to affect the transfer of heat.
• In a “spray-filled” tower, this is accomplished by spraying a flowing mass of water into a rain-like pattern, through which an upward moving mass flow of cool air is induced by the action of a fan
• Cooling Tower
1. Mechanical Equipment/ Plant Utilities
Cooling Cooling Tower Tower
checklistchecklist
• Used to transfer liquid form one location to another. • Centrifugal pumps basically consist of a stationary pump
casing and an impeller mounted on a rotating shaft.• The pump casing provides a pressure boundary for the
pump and contains channels to properly direct the suction and discharge flow.
• The pump casing has suction and discharge penetrations for the main flow path of the pump and normally has a small drain and vent fittings to remove gases trapped in the pump casing or to drain the pump casing for maintenance.
• Pump
1. Mechanical Equipment/Plant Utilities
Centrifugal Pump
1. MECHANICAL EQUIPMENT/PLANT UTILITIES
PUMP PUMP CHECKLISTCHECKLIST
• COMPRESSORS• It runs tools and machinery, provides power for
material handling systems, and ensures clean, breathable air in contaminated environments.
• A plant’s expense for its compressed air is often thought of only in terms of the cost of the equipment.
• Energy costs, however, represent as much as 70% of the total expense in producing compressed air.
1. Mechanical Equipment/Plant Utilities
CompressorCompressor Checklist Checklist
• Equipment that used to move other equipment such as blower, pump, compressors.
• Divided: steam and gas turbine.
• Turbine
1. Mechanical Equipment/Plant Utilities
Turbine
Turbine
TurbineMaintenance
Compressors
• Lubrication: Checked regularly
• Air filters: Replaced regularly
• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters
1. Mechanical Equipment/Plant Utilities
ELECTRICAL EQUIPMENT
BUILDING MAINTENANCE
– Protecting health and safety of occupants and public at large
– Retaining value of investment
– Maintaining the building in a condition in which it continue to fulfill its functions; and Presenting a good appearance.
PURPOSE OF BUILDING MAINTENANCE
INSTRUMENT FOR MEASURING/MONITORING
NEAR-INFRARED SPECTROSCOPY (NIR) MACHINE
LUBRICATION
4. LUBRICATION
• Use as lubricant between same or different type of material that is in contact to each others
• Application; plug valve, gland packing, mechanical seal, bearing and etc• Present in gas or liquid or solid form• Reason; protection to the equipments, parts in order to sustain
production, minimize downtime and maintenance cost
• Reduced friction & power requirement (bearing, plug valve)• Reduced wear• Heat Dissipation• Rust & Corrosion Prevention• Prevent Contamination & Solid Deposition
How?
• SELECTION OF LUBRICANT• Part Requirement (types, temperature, pressure)• Load and Application (speed, duration)• Specification (viscosity, additive)• External influence (in contact with contamination)
4. Lubrication
NO FLUID PROPERTIES APPLICATION
1 Mineral oil Pure mineral oil that free from reactive compound.
Anti friction Rolling element bearing
2 Polyglycol For high temperature process condition. Stable against oxidation
Hydraulic & Brake oil
3 Silicon Oil Non organic lubricant and used for special application.
Electric Motor, Anti friction Bearing
4 Diester Low viscosity and excellent corrosion resistance
Air craft turbine Oil
5 Grease Solid form and good protector against contaminant
Bearing
6 Gas Sealant between 2 intact material
Sealant
4. Lubrication - Types of Lubricant
PROPERTIES OF LUBRICANTS
• Viscosity• Oiliness• Flash and Fire Point• Carbon deposits• Anti corrosives• Additives
4. Lubrication
LUBRICATION HANDLING CHECKLIST
SUMMARY
Do checklist for each section or equipment