CPB 20004: Plant Utility n Maintenance
CHAPTER 4
Typical Maintenance & Inspection in a
Process Plant
1
CPB 20004: Plant Utility & Maintenance
Typical Maintenance and Inspection in a Process
Plant
1.
2.
3.
4.
5.
Mechanical Equipment & Plant Utilities
Electrical Equipment
Building and Structures
Instrument for Measuring / Monitoring
Lubrication
1. MECHANICAL
EQUIPMENT/PLANT
UTILITIES
1.
Mechanical Equipment/Plant
Utilities
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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.
• FMA = Factories Machinery Act.
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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.
1.
Mechanical Equipment/Plant
Utilities
• VESSEL
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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
BOILER
CHECKLISTS
1.
Mechanical Equipment/ Plant
Utilities
• Cooling Tower
• 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
checklist
1.
Mechanical Equipment/Plant
Utilities
• Pump
• 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.
Centrifugal
Pump
1.
MECHANICAL
EQUIPMENT/PLANT UTILITIES
PUMP
CHECKLIST
1.
Mechanical Equipment/Plant
Utilities
• 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.
Compressor
Checklist
1.
Mechanical Equipment/Plant
Utilities
• Turbine
• Equipment that used to move other equipment such as
blower, pump, compressors.
• Divided: steam and gas turbine.
Turbine
Turbine
Turbine
Maintenance
1.
Mechanical Equipment/Plant
Utilities
Compressors
• Lubrication: Checked regularly
• Air filters: Replaced regularly
• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters
ELECTRICAL EQUIPMENT
BUILDING
MAINTENANCE
PURPOSE OF 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.
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
How?
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Reduced friction & power requirement (bearing, plug valve)
Reduced wear
Heat Dissipation
Rust & Corrosion Prevention
Prevent Contamination & Solid Deposition
4. Lubrication
• SELECTION OF LUBRICANT
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Part Requirement (types, temperature, pressure)
Load and Application (speed, duration)
Specification (viscosity, additive)
External influence (in contact with contamination)
4. Lubrication - Types of Lubricant
NO
FLUID
PROPERTIES
APPLICATION
1
Mineral oil
Pure mineral oil that free from Anti friction
reactive compound.
Rolling element
bearing
2
Polyglycol
For high temperature process Hydraulic &
condition. Stable against
Brake oil
oxidation
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 Bearing
against contaminant
6
Gas
Sealant between 2 intact
material
Sealant
4. Lubrication
PROPERTIES OF LUBRICANTS
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Viscosity
Oiliness
Flash and Fire Point
Carbon deposits
Anti corrosives
Additives
LUBRICATION HANDLING CHECKLIST
SUMMARY
Do checklist for
each section or
equipment