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

2. 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

3. 1. MECHANICAL EQUIPMENT/PLANT UTILITIES

4. 1. Mechanical Equipment/Plant Utilities
Static Equipment
Rotating Equipment
Vessel
Reactor
Boiler
Cooling tower
Pump
Compressor
Turbine

5. 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.

6. 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.

7. 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

8. Boiler Checklists

11. 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

12. Cooling Tower checklist

13. 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.

14. 1. Mechanical Equipment/Plant Utilities
Centrifugal
Pump

15. Pump Checklist

16. 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.

17. Compressor Checklist

19. 1. Mechanical Equipment/Plant Utilities
Turbine
Equipment that used to move other equipment such as blower, pump, compressors.
Divided: steam and gas turbine.

20. Turbine

21. Turbine

22. Turbine Maintenance

23. 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.

24. ELECTRICAL EQUIPMENT

28. BUILDING MAINTENANCE

29. 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.

31. Instrument for measuring/monitoring

32. Near-infrared spectroscopy (NIR) MACHINE

33. LUBRICATION

34. 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

35. 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)

36. 4. Lubrication - Types of LubricantNO
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

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

38. Lubrication Handling Checklist

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