INTRODUCTION The purpose of the Plant Maintenance system is to manage and maintain the services and inspections of plant items. The system stores a wealth of information against each plant item including it's characteristic, function and relevant usage measurements. Each plant item may have multiple routine service or inspection schedules that are to be performed. The schedule intervals may be triggered by usage or time elapsed. Once the service or inspection is authorized, the system will produce the purchase order or work order for the work to be performed. The system records each service or inspection event, providing a detailed maintenance and inspection history for each plant item. The practical was conducted in Biodiesel pilot plant. Each student was divided into group and given task on observe and learn on how to conduct a maintenance on each part of equipment in plant biodiesel. The maintenance and inspection part were done by the technician that in charge of the task. Then after the inspection of the equipment are finished, they will run test the mechanical part and observe if it is ready for operation or otherwise. The required area for maintenance include boiler line, pre-treatment line, process line and compressor line while the equipment that will undergo maintenance and inspection process such as steam reducing valve, steam trap valve and motor pump. OBJECTIVE The objective of plant maintenance is i. To achieve minimum breakdown and to keep the plant in good working condition at the lowest possible cost. ii. To maintain the optimum productive efficiency of the plant equipment and machinery. iii. To observe the maintenance and inspection of biodiesel plant equipment. OBSERVATION That are many part to be considered during do the maintenance of the pump. The part that important to be checked on the pump is: 1. Leaks Be sure to look for any new or excessive leaks. Examine the gaskets for any dripping oil, and inspect the casing, pump, seal chamber, and piping for other leaks. Ensure there are absolutely no leaks at the mechanical seal, and look at the stuffing box for any drips or seepage. Should the stuffing box have excessive leakage, replace the packing, and recheck the box for leaks. The technician also want to ensure there is regular steam outflow in the glands and packing, and should take note if there appears to be more or less steam than usual. 2. Noises Keep the ears open for any kind of unusual or disturbing noises. If do hear something odd, record it and report it. The technician also want to make sure the cavitation and bearings aren’t any louder than usual. A noisy cavitation or bearing operation could indicate a problem. 3. Temperatures, Heating, and Cooling Every day, staff or student should check the temperature readout to make sure the pump is running at an optimal temperature. The ideal temperature depends on what fluids the pump is moving, but the temperature shouldn’t deviate too wildly from day to day. Even if the temperature readout looks fine, check the temperatures of various heating and cooling parts to confirm they’re working properly. Inspect the heat tracing to ensure it’s warm and working properly, and take a look at the water cooling gear to verify it’s chilly and effective. Use the hand to feel the jackets, coolers, and exchangers of the water cooling equipment. If they’re cool, they’re likely working correctly, but if they feel strangely warm or warmer than usual, there could be a problem. Try disassembling the water cooling equipment and cleaning it if necessary, and then hand-test the temperature of the system one more time. Also, check the temperature of the bearings to ensure they aren’t too hot. If notice something out of the ordinary, be sure to record and report your findings. 4. Oil On a regular basis, examine the oil and oil levels. It can get a look at the bearing frame through the sight glass. See if the oil is strangely watery or oddly colored, and check to see if there’s enough oil. If it looks like you need to replace the oil, make a note and ensure it’s exchanged with fresh oil as soon as possible. 5. Vibration While the vibration of the pump may not seem like a huge concern, keep a careful eye on it. Analyze the vibration daily, and let someone know if the vibration is off somehow. Out-of-theordinary vibration could indicate an alignment issue or some other problem. 6. Pressure, Power, Efficiency, Speed, and Flow There are a few numbers to should keep an eye on throughout each day. Regularly monitor the discharge and suction pressure, and if the numbers move drastically in either direction, report it immediately. The same goes for the pump’s efficiency and speed, as well as the power and flow of the pump. Keeping a close eye on these parameters can help you spot and correct potential problems early on. 7. Other Mechanical Parts During the inspection, examine the bearings and oil rings, as well as other parts, to ensure they’re in good condition. If needed, clean the bearing covers by wiping off excess grime. To keep the centrifugal pump in great shape, check the above elements every day. In addition to daily maintenance, it should also put quarterly and annual maintenance procedures in place to further ensure your pump’s smooth operation. If they are thinking of replacing your pump or if were experiencing issues with the current pump, contact a specialist in the industry. BOILER LINE Boiler preventive Maintenance 1. Check operation of controls, limits, and safeties. 2. Check blowdown. 3. Check flame safeguard control. 4. Check operation of feed pumps. 5. Check operation of condensate tank and feed controls. 6. Check operation of dearator. 7. Check operation of water softener. 8. Check operation of chemical systems. 9. Check operation of dampers and linkages 10. Minor adjustments of linkage. 11. Visually check combustion chamber. 12. Visually check valves, piping, and supports. 13. Visually check gas train and valves. 14. Visually check oil train and valves. 15. Check combustion efficiency using electronic analyzer. Keep the Boiler Clean As mentioned previously, any residue, such as soot or scale, that coats the heat transfer surfaces of the boiler will reduce its efficiency and also increase the likehood of equipment failure. Cleaning this surface according to manufacturer’s recommendations is important to maintaining optimum boiler performance and equipment life. Residue that coats the tubes of a boiler will interfere with heat transfer and elevate the flue gas temperature. If incomplete combustion occurs, the resulting soot accumulates on the combustion side of the tubes. Similarly, poor water treatment practices can result in scale accumulation on the water side of the tubes. Water Chemical Treatment Plan Good boiler water chemical treatment is essential to maintain efficient operation. Each chemical treatment plan must be customized based on dissolved minerals in the make-up water, the percentage of condensate returned, and the level presence or absence of a de-aerator. Dissolved solids in the boiler water and the level of treatment chemicals should be tested daily in small low pressure plants and hourly in larger high pressure plants. Instruments should be calibrated monthly. Anual inspections of boiler should include a thorough examination of the water side surfaces for evidence of scalling and corrosion. Even a thin layer of scale interferes with heat transfer and thereby decreases combustion efficiency. An upward trend in flue gas temperature over weeks or months usually indicates that a deposit has built up on either the fireside or waterside of the boiler heat exchange surfaces. If this condition is observed the boiler should be inspecte promptly. Minimize Boiler Blowdown Having too many total dissolved solids (TDS’s) in the boiler water can cause scale and reduce boiler efficiency. Therefore, it is necessary to maintain the solids below certain limits. As TDS concentration increases, it becomes more likely that the dissolved solids will precipate out of the water and form scale. Draining of the water, called boiler blowdown, is required to remove some of those dissolved solids and keep the TDS concentration below the level where they will precipate. Consistent and frequent small volume blowndown is a better practice than infrrequent high volume blowdowns, because it conserves energy, water and chemicals. Large steam boilers with steady loads should have continuous blowdown, where a small amount of water is drained continuously from the boiler while fresh make-up water is introduced. Inspect and Repair Insulation Insulation is critical for steam and condensate piping. Un-insulated pipes, valves or fittings carry a heavy energy penalty. Steam, condensate and hot water pipes in air conditioned spaces produce a double penalty if un-insulated because the heat loss from the pipes must be removed by additional air conditioning. Sample Maintenance Logs & Boiler Checklists Boiler best practices begin with maintaining regularly scheduled inspection logs and checklists to ensure proper equipment operation. Pressure, water temperature and flue gas temperatures should be recorded daily as they can serve as a baseline reference for system operation and troubleshooting problems. More detailed inspections and checks should be performed to document system performance, which can be very important since a gradual change in system operating conditions over time may not be readily apparent without the use of such documentation. PLANT BIODIESEL MAINTENANCE (PUMP) 1. Read the Installation, Operation and Maintenance Manual for your pump before installing, operating or performing maintenance on the pump or its related equipment 2. Overheated pumps can cause severe burns and injury. If overheating of pump casing occurs to stop pump immediately, Allow pump to cool to air temperature, Slowly and cautiously vent pump at drain plug, Refer to Installation, Operation and Maintenance Manual before restarting. 3. Do not operate pump without all guards and shields in place. 4. Cautiously approach any pump that has been in operation. 5. Pump only liquids for which the pump was designed 6. Do not pump flammable or corrosive liquids unless pump and piping are designed for such. 7. Operating pump with suction and/or discharge closed is one cause of severe overheating. 8. Note direction of rotation -- operating pump in wrong direction may cause impeller to unscrew and damage pump casing or other pump parts. 9. Check all lubricants before installation and operation and in accordance with maintenance programs. 10. Do not remove the cover plate, fill port cap, gauge port plug, or drain plug from any mover heated pump. Allow pump to cool to air temperature. Check pump temperature before opening cover plate, fill port, gauge port plug or drain plug. a) Pre-treatment Line (Pump) VE101-VE102 NO. 1. ITEMS P102 PICTURE REMARKS coupling in P102 TESTED Not Good Good motor pump has become weary if not exchanged will result in the rubber coupling will harden and emit the noise caused by the vibration 2. P103 No problem detected 3. P214 No Problem Good Good detected 4. P104 No Problem Detected 5. P217 Producing strange sounds at agitator or blender mixture because there was a potter wasp making nest Not Good b) Process Line (Pump) VE201-VE203 NO. ITEMS PICTURE REMARKS 1. P207 No Problem Detected 2. P218 No Problem Detected TESTED 3. P206 No Problem Detected 4. P203 No Problem Detected 5. P204 No Problem Detected 6. P101 (Transfer Pump) Issued noisy noise as there was no water through the pump Good AIR COMPRESSOR MAINTENANCE Read the User Manual. Tighten the Nuts and Bolts. Clean the Intake Valves. Inspect the Hoses. Change the Air Filter. Drain Condensate from the Tanks. Clean the Compressor Fuel Tank. Inspect the Air Compressor Shutoff System. DISCUSSION The importance of pumps to the daily operation of biodiesel plant processes necessitates a proactive maintenance program, which incorporates a preventative and predictive maintenance schedule. Most pump maintenance activities center on checking packing and mechanical seals for leakage, performing maintenance activities on bearings, assuring proper alignment, and validating proper motor condition and function without consideration for pump efficiency. Improving efficiency will decrease both maintenance and operating costs. CONCLUSION As a conclusion, the practical was conducted in Biodiesel pilot plant. Each student was divided into group and given task on observe and learn on how to conduct a maintenance on each part of equipment in plant biodiesel. The maintenance and inspection part were done by the technician that in charge of the task. Then after the inspection of the equipment are finished, they will run test the mechanical part and observe if it is ready for operation or otherwise. The required area for maintenance include boiler line, pre-treatment line, process line and compressor line while the equipment that will undergo maintenance and inspection process such as steam reducing valve, steam trap valve and motor pump. Maintenance involves functional checks, servicing, repairing or replacing of necessary devices, equipment, machinery and residential installations. Regular maintenance of equipment is an important and necessary activities. It is carried out in all sectors and workplaces including plant biodiesel. Maintenance can be a high risk activity The important benefit of a properly operated preventive maintenance are the equipment downtime is decreased and the number of major repairs are reduced. Next, better conservation of assets and increased life expectancy of assets, thereby eliminating premature replacement of machinery and equipment. In addition, maintenance also reduces overtime costs and more economical use of maintenance workers due to working on a scheduled basis instead of a crash basis to repair breakdowns. Lastly, not to mention that preventive maintenance can improve safety and quality conditions for everyone.