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    CPB 20004: Plant Utility N Maintenance

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    Boujemaa Bouhouda
    This document discusses typical maintenance and inspection activities in a process plant. It covers 5 main sections: 1) Mechanical Equipment and Plant Utilities, 2) Electrical Equipment, 3) Building and Structures, 4) Instrument for Measuring/Monitoring, and 5) Lubrication. For each section, it provides examples of equipment and discusses important maintenance considerations, such as checking for proper operation, wear, leaks, calibration, and compliance with regulations to protect employee safety. Checklists are also provided for specific tasks like inspecting boilers, pumps, turbines, and other critical equipment.

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    CPB 20004: Plant Utility N Maintenance

    Uploaded by

    Boujemaa Bouhouda
    68 views39 pages
    This document discusses typical maintenance and inspection activities in a process plant. It covers 5 main sections: 1) Mechanical Equipment and Plant Utilities, 2) Electrical Equipment, 3) Building and Structures, 4) Instrument for Measuring/Monitoring, and 5) Lubrication. For each section, it provides examples of equipment and discusses important maintenance considerations, such as checking for proper operation, wear, leaks, calibration, and compliance with regulations to protect employee safety. Checklists are also provided for specific tasks like inspecting boilers, pumps, turbines, and other critical equipment.

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    This document discusses typical maintenance and inspection activities in a process plant. It covers 5 main sections: 1) Mechanical Equipment and Plant Utilities, 2) Electrical Equipment, 3) Building and Structures, 4) Instrument for Measuring/Monitoring, and 5) Lubrication. For each section, it provides examples of equipment and discusses important maintenance considerations, such as checking for proper operation, wear, leaks, calibration, and compliance with regulations to protect employee safety. Checklists are also provided for specific tasks like inspecting boilers, pumps, turbines, and other critical equipment.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    68 views39 pages

    CPB 20004: Plant Utility N Maintenance

    Uploaded by

    Boujemaa Bouhouda
    This document discusses typical maintenance and inspection activities in a process plant. It covers 5 main sections: 1) Mechanical Equipment and Plant Utilities, 2) Electrical Equipment, 3) Building and Structures, 4) Instrument for Measuring/Monitoring, and 5) Lubrication. For each section, it provides examples of equipment and discusses important maintenance considerations, such as checking for proper operation, wear, leaks, calibration, and compliance with regulations to protect employee safety. Checklists are also provided for specific tasks like inspecting boilers, pumps, turbines, and other critical equipment.

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    CPB 20004: Plant Utility n Maintenance

    CHAPTER 4
    Typical Maintenance & Inspection in a
    Process Plant

    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
    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
    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
    LUBRICATION HANDLING CHECKLIST
    SUMMARY

    Do checklist for
    each section or
    equipment

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