CPD 30103: Plant Maintenance & Inspection

CHAPTER 3
Typical
Maintenance
& Inspection
in a Process
Plant
1
CPB 20004: Plant Utility n Maintenance

Typical Maintenance and Inspection in a Process

Plant
1. Mechanical Equipment & Electrical
Equipment
2. Building and Structures & Plant Utilities
3. Instrument for Measuring / Monitoring
4. Lubrication
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).
• Load Test, hydrostatic test, pop test
• More concentrate in prevention and any
modification must obtained the approval from
DOSH.

• FMA = Factories Machinery Act.

 1. Mechanical Equipment/Plant
Utilities

• Rotating Equipment
• 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.

Pressure
Vessel
 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.
 1. Mechanical Equipment/Plant
Utilities

• Boiler - Fire-tube Boiler

• Fire-tube boilers rely on hot gases circulating through the
boiler inside tubes that are submerged in water.
• These gases usually make several passes through these
tubes, thereby transferring their heat through the tube
walls causing the water to boil on the other side.
• Fire-tube boilers are generally available in the range 20
through 800 boiler horsepower (bhp) and in pressures up
to 150 psi.
 1. Mechanical Equipment/Plant
Utilities

• Boiler - Fire-tube Boiler

 1. Mechanical Equipment/Plant
Utilities

• Boiler – Water-tube Boiler

• Most high-pressure and large boilers are of this type.
• In the water-tube boiler, gases flow over water-filled
tubes.
• These water-filled tubes are in turn connected to large
containers called drums.
• Boiler pressures range from 15 psi through pressures
exceeding 3,500 psi.
 1. Mechanical Equipment/Plant
Utilities

Water-tube
Boiler
 1. Mechanical Equipment/Plant
Utilities

• Boiler - Electric Boiler

• Electric boilers are very efficient sources of hot water or
steam, which are available in ratings from 5 to over
50,000 kW.
• They can provide sufficient heat for any HVAC
requirement in applications ranging from humidification
to primary heat sources.
 1. Mechanical Equipment/Plant
Utilities

Electric
Boiler
 Boiler
Checklist
s
 1. Mechanical
Equipment
• 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
 1. Mechanical Equipment/Plant
Utilities

Cooling
Tower
 1. Mechanical Equipment/Plant
Utilities

• Cooling Tower - Direct or open cooling tower type

• This type of system exposes the cooling water directly to
the atmosphere.
• The warm cooling is sprayed over a fill in the cooling
tower to increase the contact area, and air is blown
through the fill.
• The majority of heat removed from the cooling water is
due to evaporation.
• The remaining cooled water drops into a collection basin
and is recirculated to the chiller
Direct or open
cooling tower
 1. Mechanical Equipment/Plant
Utilities
• Indirect or closed cooling tower
• An indirect or closed cooling tower circulates the water
through tubes located in the tower.
• In this type of tower, the cooling water does not come in
contact with the outside air and represents a “closed”
system.
Cooling
Tower
checklis
t
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
 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.
Compresso
r
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
1. Mechanical Equipment/Plant
Utilities

• Turbine Maintenance
• Scheduled maintenance inspections are necessary for
safe and efficient turbine operation.
• Actual intervals between inspections cannot be specified
rigorously because maintenance scheduling is dependent
on factors best known by those directly involved with the
turbine and its particular application.
• The actual frequency of required maintenance inspections
can only be determined after carefully considering turbine
performance records, maintenance history, corrosion,
erosion rates, tests, observations and anticipated service
demands.
• The established inspection schedule will usually be
consistent with the availability of the turbine, necessary
manpower and an adequate supply of repair parts.
• At the same time, scheduled inspections must be frequent
enough to avoid unsafe operating conditions.
 Turbine
Maintenan
ce
1. Mechanical Equipment/Plant
Utilities

Water Systems - Daily Operation

Checks
• Service Water Tank

– JBA water pressure

– Service tank level
– Tank condition

• Service water pump and other pumps is they are

running.
 check suction & discharge pressure
 check abnormal condition
 check motor power
 check lubricant
 check pump seal leaks
1. Mechanical Equipment/Plant
Utilities

9. Maintenance Practices - Compressors

• Lubrication: Checked regularly
• Air filters: Replaced regularly
• Condensate traps: Ensure drainage
• Air dryers: Inspect and replace filters
 2. Building Maintenance

What is Building and Structure Maintenance?

• BS 3811: 1984
– Building Maintenance is The combination of all
technical and associated administrative actions
intended to retain an item in, or restore it to, a
state in which it can perform its required function.

• HMSO publisher (1972)

– Work undertaken in order to keep, restore or
improve every facility, i.e. every part of a building,
its services and surrounds, to a currently accepted
standard and to sustain the utility and value of the
facility.
2. Building Maintenance
• Purposes of Building Maintenance

• Seeley (1992, p.11)

– 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.
 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
4. Lubrication

Types of Friction
• Sliding friction
• Rolling friction
• Fluid friction
 4. Lubrication

• Lubrication Theory
• When lubricating oil is applied to each of the component
surfaces, a thin film of oil is formed, filling up the
depressions and covering the projections.
• Due to the film of oil between the two surfaces, sliding,
not friction, will occur.
• This condition is called fluid lubrication.
• In theory, the oil forms in layers of globules, one layer
adhering to each metal surface and any number of
layers of globules in between.
4. Lubrication

• The layers in between

roll over each other when
the bearing surfaces
move.
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 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 Electric Motor,
used for special application. Anti friction
Bearing
4 Diester Low viscosity and excellent Air craft turbine
corrosion resistance Oil
5 Grease Solid form and good protector Bearing
against contaminant
6 Gas Sealant between 2 intact Sealant
material
4. Lubrication

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

Grease
• Grease is made by adding a metallic soap to lubricating
oil, effectively thickening it to the point that it turns into
grease.
• Classification of grease
 penetration number
 dropping / melting point,
 metallic base, and
 the thickening
 4. Lubrication

Grease
& Oil:
Comparison
Wear
Elements
in
Lubricants
and Their
Sources
4. Lubrication

Some Indicative Combinations of wear Elements

Lubrication Handling Checklist
Lubricant Management Program
4. Lubrication

Electrical Motor
• Dirt and Corrosion
• Lubrication
• Heat, Noise and Vibration
• Winding Insulation
 4. Lubrication

Dirt and Corrosion

• Thick dirt insulates the frame and clogged passage; reduce
cooling air flow & heat can reduce insulation life and
causes failure
• Wet or corrosive environment can become a hazardous to
the wiring and terminal in the electrical system.

Lubrication
• Based on manufacturer recommendation
• Cleaning thoroughly to prevent contamination
• Too much grease can over pack bearing and cause hot
run
• Divide by two; oiling sleeve bearing & greasing ball and
roller bearing
Heat, Noise and Vibration
• Heat (primary cause is aging of the insulator)
• Why ?? (wrong motor, poor cooling system, overloaded,
excessive friction)
• Noise is integrated with vibration problems
• Problems; shake winding loose & crack the insulator
• Cause; (motor misaligned, mechanically or electrical)

Winding Insulation
• Protection against excessive dirt, abrasive, moisture &
oil
• Testing winding can identify deteriorating insulation.
• Prevention by installing ground fault (insulation), hence
can detect voltage leaking.
 Assignment

Why do we need maintenance and why

maintenance is very important to manufacturing
plant. Review and elaborate on the following
areas:-
a. Safety
b. Quality
c. Schedule
d. Cost

* Eq. much better