CHAPTER 4 CPB 20004: Plant Utility n Maintenance Typical Maintenance & Inspection in a Process Plant 1 1 1

CPB 20004: Plant Utility & 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

1. MECHANICAL EQUIPMENT/PLANT UTILITIES

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. 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.

1. Mechanical Equipment/Plant Utilities 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

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.

1. Mechanical Equipment/Plant Utilities Centrifugal Pump

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 Good and proper maintenance practices will dramatically improve the performance efficiency of a compressor system. Here are a few tips for efficient operation and maintenance of industrial compressed air systems: Lubrication: Compressor oil pressure should be visually checked daily, and the oil filter changed monthly. Air Filters: The inlet air filter can easily become clogged, particularly in dusty environments. Filters should be checked and replaced regularly. Condensate Traps: Many systems have condensate traps to gather flush condensate from the system. Manual traps should be periodically opened and re-closed to drain any accumulated fluid and automatic traps should be checked to verify they are not leaking compressed air. Air Dryers: Drying air is energy-intensive. For refrigerated dryers, inspect and replace pre-filters regularly as these dryers often have small internal passages that can become plugged with contaminants.

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? Reduced friction & power requirement (bearing, plug valve) Reduced wear Heat Dissipation Rust & Corrosion Prevention Prevent Contamination & Solid Deposition

Selection of Lubricant 4. Lubrication Selection of Lubricant 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 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

Properties of Lubricants 4. Lubrication Properties of Lubricants Viscosity Oiliness Flash and Fire Point Carbon deposits Anti corrosives Additives

Lubrication Handling Checklist

Do checklist for each section or equipment SUMMARY Do checklist for each section or equipment