1

CHAPTER 4Typical Maintenance & Inspection in a Typical Maintenance & Inspection in a

Process PlantProcess Plant

CPB 20004: Plant Utility n MaintenanceCPB 20004: Plant Utility n 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

CPB 20004: Plant Utility & MaintenanceCPB 20004: Plant Utility & Maintenance

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.

1. Mechanical Equipment/Plant Utilities

• 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.

• 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

1. Mechanical Equipment/Plant Utilities

BOILER BOILER CHECKLISTSCHECKLISTS

• 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

1. Mechanical Equipment/ Plant Utilities

Cooling Cooling Tower Tower

checklistchecklist

• 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.

• Pump

1. Mechanical Equipment/Plant Utilities

Centrifugal Pump

1. MECHANICAL EQUIPMENT/PLANT UTILITIES

PUMP PUMP CHECKLISTCHECKLIST

• 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.

1. Mechanical Equipment/Plant Utilities

CompressorCompressor Checklist Checklist

• Equipment that used to move other equipment such as blower, pump, compressors.

• Divided: steam and gas turbine.

• Turbine

1. Mechanical Equipment/Plant Utilities

Turbine

Turbine

TurbineMaintenance

Compressors

• Lubrication: Checked regularly

• Air filters: Replaced regularly

• Condensate traps: Ensure drainage

• Air dryers: Inspect and replace filters

1. Mechanical Equipment/Plant Utilities

ELECTRICAL EQUIPMENT

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.

PURPOSE OF BUILDING MAINTENANCE

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

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

How?

• SELECTION OF LUBRICANT• Part Requirement (types, temperature, pressure)• Load and Application (speed, duration)• Specification (viscosity, additive)• External influence (in contact with contamination)

4. Lubrication

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

4. Lubrication - Types of Lubricant

PROPERTIES OF LUBRICANTS

• Viscosity• Oiliness• Flash and Fire Point• Carbon deposits• Anti corrosives• Additives

4. Lubrication

LUBRICATION HANDLING CHECKLIST

SUMMARY

Do checklist for each section or equipment