REPORT MAINTENANCE

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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.
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