Chapter 3a

CPD 30103 Plant Maintenance & Inspection UniKL MICET
MICET
Chapter 3 (a)
Typical Maintenance
and Inspection in a
Process Plant
Universiti Kuala Lumpur 1
Malaysian Institute of Chemical and Bioengineering Technology

CPD 30103 Plant Maintenance & Inspection SCET
MICET
Content
3.0 Typical Maintenance &
Inspection in a Process Plant
3.1 Mechanical Equipment
3.2 Electrical Equipment
3.3 Building and Structures
3.4 Plant Utilities
3.5 Instrument for Measuring / Monitoring
3.6 Lubrication
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Topic Outcomes
It is expected that students will be able to:

Define the function of each equipment
Discuss the typical problems of each
equipment encountered
Summarize the maintenance activity to
maintain the performance of each equipment
Differentiate between daily, weekly, monthly
and yearly maintenance inspections of each
equipment
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Content
3.4 Plant Utilities
3.6 Lubrication
4
Introduction
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MECHANICAL
EQUIPMENT
Static Equipment
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Static Equipment are stationary equipment which

are non moving but help in many process
operations.
Static equipment play an important role in any
plant since the use of any equipment becomes a
vital cog in operations.
In an oil refinery, common static equipment used
are:
i. Vessel, tank, distilling column
ii. Reactor, boiler, Heat Exchangers, valves
iii. Steam Traps, cooling tower, furnaces,
iv. evaporation column
v. Piping Systems etc
Rotating Equipment
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Rotating Equipment is a common classification of

mechanical components used to add kinetic energy
to any process in order to make a material move.
It can only function with the help of regularly
moving component parts.
Most machinery items can be classified as
rotating, even though they may not actually go
around
In an oil refinery, common rotating equipment
used are:
Steam Turbines, Pumps, Gear Boxes,
Motors, Compressor, Blowers, Cooling tower
fans
Static Equipment
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Pressure Vessel
Based on the *ASME Code Section
VIII, pressure vessels are containers
for the containment of pressure,
either internal or external.
This pressure may be obtained from an
external source, or by the application
of heat from a direct or indirect
source, or any combination thereof
*American Society of Mechanical Engineers (ASME)
Pressure Vessel
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Pressure vessels include:

compressed gas storage tanks (i.e., air, oxygen,
nitrogen tanks, etc.),
anhydrous ammonia tanks, hydro pneumatic
tanks,
autoclaves, hot water storage tanks,
chemical reactors and refrigerant vessels, etc
designed for:
i. a pressure greater than 15 psi and a volume
greater than 5 cubic feet in volume or
ii. one and one-half cubic feet in volume with a
pressure greater than 600 psi
Pressure Vessel
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Pressure Vessel Inspections:

i. Dimension
ii. Mill Under tolerance of Plates and Pipes
iii. Tolerances for Formed Heads
iv. Out of Roundness of Shell
v. Nozzles and Attachments Orientation, Projection,

elevation, levelness
vi. Weld Mismatch
vii. Weld Reinforcement
All other pressure vessels

i. External inspections every two years.
ii. Internal inspections are conducted if considered
necessary by the inspector of record.
Pressure Vessel
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CPD 30103 Plant Maintenance & Inspection Reactor SCET
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Definition:
i. Equipment for
reaction take part.
ii. Main equipment to
produce the product.
Maintenance, Periodic
Testing and Inspection
as function in accordance
with the design intents
and requirements
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Periodic testing includes:

i. Inspection
ii. Operability check
iii.Calibration
Preventive Maintenance:
i. Schedule inspection
ii. Schedule Testing and Servicing
iii.Schedule Overhauls
iv. Replacement activities
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Cut-away view of a stirred-tank chemical Chemical reactor with half coils wrapped
reactor with a cooling jacket around it
CPD 30103 Plant Maintenance & Inspection Boilers SCET
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Definition:
a closed vessel in which water or other
liquid is heated, steam or vapor is
generated, steam is superheated, or any
combination thereof, under pressure or
vacuum, for use external to itself, by
the direct application of energy from
the combustion of fuels, from
electricity or nuclear energy
CPD 30103 Plant Maintenance & Inspection Boilers SCET
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How often do I have to have my boiler

inspected?
High Pressure Boilers: Internal inspection annually
and external inspection 3~9 months after internal
inspection
Heating boilers/hot water supply
boilers/commercial water heaters: external
inspection every two years.
Proper maintenance and operation of boilers
systems is important with regard to efficiency and
reliability.
Fire-tube Boiler, Water-tube Boiler, Electric
Boiler
Fire-tube Boiler
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Water-tube Boiler
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Fire-tube vs. Water-tube Boiler
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Boiler typical problems
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i. No heat or hot water potential causes include broken

diaphragms and airlocks, failure of motorised valves, issues
with the thermostat or low water levels.
ii. Leaking and dripping a variety of issues could cause your
boiler to leak water. It will depend on where the water is
leaking from to determine the cause.
iii. Strange banging, whistling or gurgling noises air in the
system is a common cause, alternatively it could be that the
water pressure is too low or its kettling. Pump failure,
particularly in older systems, could also be responsible for
strange banging noises.
iv. Pilot light goes out could be a broken thermocouple which is
removing the gas supply to the pilot light, a draught blowing
the pilot light out or a deposit built up in the pilot light.
v. Losing pressure a water leak in the system is the most
common reason for a loss of pressure. But it could also mean
that the pressure relief valve needs replacing.
Boiler typical problems
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vi. Frozen condensate pipe Thawing a frozen condensate

pipe should ideally be done by a qualified engineer.
vii. Thermostat issues if the thermostat is losing accuracy
or turning the heating on/off when its not supposed to it might
be time to invest in a newer, more energy efficient one.
viii. Kettling hearing a strange rumbling noise? When time
scale builds up on your boilers heat exchange you get kettling.
ix. Radiators not getting hot corroded pipework can cause
sludge to gather in the system, preventing the free flow of hot
water to the radiators. Chemically cleaning or flushing the
system will remove these deposits.
x. Boiler keeps switching itself off could be low water
pressure, a problem with the thermostat or a lack of water
flow due to a closed valve, air or the pump not circulating the
water in the system properly
Boilers Daily Checklist
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Boilers Daily Checklist
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Boilers Weekly Checklist
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Boilers Weekly Checklist
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Boilers Annually Checklist
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Cooling Tower
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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.
is a heat rejection device which
rejects waste heat to
the atmosphere through the cooling of a
water stream to a lower temperature.
Cooling towers may either use
the evaporation of water to remove
process heat and cool the working fluid to
near the wet-bulb air temperature
Cooling Tower
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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
Common applications include cooling
the circulating water used in oil
refineries, petrochemical and
other chemical plants, thermal
power stations
Cooling Tower Types
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Direct or open cooling tower

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
Cooling Tower Types
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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
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Cooling Tower
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Cooling Tower typical problems
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Lowering of Cooling Capacity

Motor stoppage
Sudden lowering of motor speed (rotations per minute)
Fan Stoppage
Rise in water Temperature

Water flow above specified flow
Air flow below specified flow
Fresh air intake not sufficient
Sprinkler jammed/water not being sprinkled and
distributed
Oil Leakage
In case of gear speed reducer oil leakage
Cooling Tower typical problems
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Temperature Rise
Motor getting over heated
Lowering & unbalance of voltage (electric) supply
High surrounding temp
Less Water Flow

Filter chocked
Sprinkler pipes chocked
Pump too small
Less Air Flow

Fan speed low
Fan blade angle incorrect
Inlet air chocked
Cooling Checklist Daily/Weekly
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Cooling Checklist Monthly/Annually
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Rotating Equipment
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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.
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CPD 30103 Plant Maintenance & Inspection Pump SCET
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CPD 30103 Plant Maintenance & Inspection Pump SCET
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Pump typical problems
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i. Pump Speed Problem due to normal wear

and tear. It also relates to temperature,
pressure, flow, vibration and power draw.
ii. Hydraulic Imbalance in a Double Suction
Pump - frequent failure of the mechanical
seal or bearing (when packing is fitted) at
the end of the shaft closest to the
suction pump shaft or the piping
arrangement.
iii.Cavitation a unique rumbling/rattling
noise and high vibration levels due to
pitting damage to the impeller and a
slight reduction in the pressure being
developed by the pump
Pump typical problems
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iv. Discharge Recirculation (low flow

rates) due to pitting damage at the tip
of the vanes and sometimes at the cut-
water of the casing.
v. Air entrainment due to variety of
conditions where the vapor bubbles are
already in the liquid before it reaches
the pump
Pump Checklist
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Compressor
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A gas compressor is a
mechanical device that
increases the pressure of a
gas by reducing its volume.
It runs tools and machinery,
provides power for material
handling systems, and
pneumatic system.
Compressor
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Compressors are similar to pumps:

both increase the pressure on a fluid
and both can transport the fluid
through a pipe. As gases are
compressible, the compressor also
reduces the volume of a gas.
Liquids are relatively incompressible,
so the main action of a pump is to
pressurize and transport liquids.
Compressor
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Compressor
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Centrifugal compressor
Electric motor
Gearbox
Compressor
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Compressor
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Compressor typical problems
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Excessive vibration
Dry gear coupling
Excessive bearing clearance
Improperly assemble parts
Loose or broken bolting
Operating in critical speed range
Shaft misalignment
Worn or damaged coupling
Inadequate Oil Lubricant

Compressors rely on the lubrication system to provide a
uniform oil film between closely fitting parts (e.g.,
piston rings and the cylinder wall). Partial or complete
failure of the lube system results in catastrophic
failure of the compressor.
Compressor typical problems
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Valve failure
Valve failure is the dominant failure mode for
reciprocating compressors. Because of their high
cyclic rate, which exceeds 80 million cycles per year,
inlet and discharge valves tend to work harden and
crack.
Imbalance
Force in the direction of the piston movement, which is
displayed as impacts in a vibration profile as the piston
reaches top and bottom dead center of its stroke
Effect on couple, or moment, caused by an offset
between the axes of two or more pistons on a common
crankshaft.
Compressor Basic Checklist
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Lubrication:
Checked regularly
Air filters:
Replaced regularly
Condensate traps:
Ensure drainage
Air dryers:
Inspect and replace filters
Compressor Routine Maintenance
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LUBRICATION
The most important check for any
compressor is the lubrication system
Keep the compressor well lubricated;
check the oil level at least once every 8
hr of operation.
Use only oil and greases as recommended
by the compressor manufacturer.
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VALVES
Reciprocating compressor valves must be kept in
first-class operating condition, as leaking or broken
valves cause excessive operating temperatures and
loss of air delivered.
PISTON RINGS
Piston-ring wear usually is very slow when the rings
are properly lubricated, but operating time will
eventually wear
BEARINGS
Check bearings for heat and noise after starting
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CLEANING
An important item for proper
compressor maintenance is keeping
the compressor clean on the outside
surfaces.
Dirt and oil will make an insulation
which obstruct heat dissipation to
atmosphere.
Compressor Checklist
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Compressor Checklist
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CPD 30103 Plant Maintenance & Inspection Turbine SCET
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Turbine is a machine for producing

continuous power in which a wheel or
rotor, typically fitted with vanes or
blades, is made to revolve by a fast-
moving flow of water, steam, gas, air,
or other fluid.
Divided:
i. steam turbine
ii. gas turbine
iii. turbine engine
Steam Turbine
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Steam Turbine
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Gas Turbine
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Turbine Engine
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Turbine Schedule Maintenance
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Turbine Schedule Maintenance
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Content
3.4 Plant Utilities
3.6 Lubrication
66
Electrical Equipment
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Electrical Equipment Maintenance &
Inspection Actions
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Inspection Actions
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Inspection Actions
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Electric Motor
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The principle function of an electric

motor is to convert electric energy into
mechanical energy.
The conversion is accomplished by two
main component- the stator and rotor.
The stator is the stationary component
and the rotor is the rotating
component.
These components are separated by a
small air-gap clearance to avoid
mechanical rubbing.
Electric Motor Main Components
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i. Stator
ii. Rotor
iii. Shaft with coupling
iv. Bearing
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The stator is generally made up of a

winding, the frame, and the laminated
steel punching (core iron).
The stator coils can be random wound
(loops of wire) or form wound (pre-
formed diamond shape) coils of magnet
wire.
The rotor is usually made up of
laminated steel punching (core iron),
coils or rotor bars, shorting rings and a
shaft.
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Stator
Rotor
Coupling
Shaft
Electric Motor 3 Main Categories
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AC Induction Motors:
i. Squirrel-cage, An AC motor is an
electric motor driven by
ii. Wound rotor an alternating current (AC)
Synchronous Motors:
i. Cylindrical rotor
ii. Salient pole
DC Motors:
Shunt wound,
DC motor is any of a class of
i. electrical machines that converts
direct current electrical power into
ii. Series wound, or mechanical power. The most common
types rely on the forces produced by
iii. Compound wound magnetic fields
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AC Induction Motors:
i. Squirrel-cage,
ii. Wound rotor
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Synchronous Motors:
i. Cylindrical rotor
ii. Salient pole
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DC Motors:
i. Shunt wound,
ii. Series wound, or
iii. Compound wound
Common Application Chart
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% of Failures by Major Components
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*IEEE - Institute of Electrical and Electronics Engineers

*EPRI - Electric Power Research Institute
Motor Failure by Significant Cause
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Motor Failure - Symptoms
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Overheated
High vibration
Causes of Failure
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Most conditions that cause electric motor

failure will be cleared in the form of
vibration or excessive temperature.
Vibration can be caused by conditions which
are electrical as well as mechanical.
When an open bar develops in the rotor
winding or a short happens in the stator
winding, the effect on motor operation may
show up as a slightly higher vibration
reading.
Causes of Failure
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the cause of vibration can be

contributed to misalignment or
bearing wear/defect.
Some times motors can be
damaged in handling or have a
manufacturing defect which will
appear as a vibration problem
over a period of time because
of residual stress.
Causes of Failure - Summary
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i. Corrosion
ii. Excessive moisture
iii. High ambient temperature
iv. Inadequate lubricant
v. Manufacturing defect
vi. Misalignment
vii. Mishandling
viii. Shelf life (residual stress)
Mode of Failure - Results
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Broken
rotor bars
Broken shaft/ parts
Damage to bearing
Reduce components life

Preventive Maintenance
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Scheduled routine inspection

Document maintenance program
Grease-Lubricated bearing only when

scheduled
Oil-Lubricated bearing every 2000hr
operation or at least annually.
Predictive Maintenance
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Scheduled monitoring with trend

analysis to the potential problems:
i. vibration,
ii. temperatures,
iii. oil contamination (wear particles),
The goal of predictive maintenance
is to extended the life of
machinery by eliminating failures.
Benefit of Predictive Maintenance
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Repetitive problems are identified

and eliminated
Equipment installations is
performed to precise standard
Performance verification assures
that new and rebuilt equipment is
free of defects.
Predictive Technologies
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Vibration spectrum analysis for

rotating equipment
Oil and wear analysis
Thermography for all electrical

equipment
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Content
3.4 Plant Utilities
3.6 Lubrication
91
Purpose of Building Maintenance
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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.
Building Maintenance
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Low Sloped of Membrane Roof
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Membrane roofing is
a type
of roofing system for
buildings and tanks.
It is used on flat or
nearly flat roofs to
prevent leaks and
move water off
the roof.
Membrane roofs are
most commonly made
from synthetic
rubber,
thermoplastic (PVC
or similar material),
or modified bitumen
Roof Maintenance
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This chapter is concerned with the

inspection and basic maintenance of
low-sloped roofs.
Flat roofs are a great way to keep a
building safe from water.
A flat roof system works by
providing a waterproof membrane
over a building.
Roof Maintenance
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Low sloped or flat roof systems are

subdivided by membrane type into
three major categories:
i. Conventional built-up roof systems
ii. Modified-bitumen roof systems
iii. Single-ply roof systems

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Roof Survey & Defect
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Identification
roof inspections should be made at

least twice a year.
additional inspections after major
disturbances such as heavy storms.
addition of new roof equipment,
repairs or modifications to existing

rooftop equipment
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Identification
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Identification
Housekeeping
Debris, abandoned equipment, and unused
materials should not be allowed to
accumulate or be stored on the roof.
Surfacing
Surfacing defects include deteriorated
coating, alligatoring, exposed felts, and
eroded granules, aggregate, or ballast.
Roof Defect Identification
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Deteriorated coatings are

characterized by flaking, chalking
or erosion, pin holing, and loss of
adhesion.
Flaking
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Alligatoring is surface cracking of the

bitumen on a built-up roof. It resembles the
pattern of an alligator hide, and the cracks
may extend through the full thickness of the
surfacing bitumen to the felts. Some uncoated
modified bitumen membranes exhibit surface
crazing similar in appearance to alligatored
bitumen.
Alligatoring
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Exposed felts are recognized by the absence of any

surfacing materialsthe membrane felts are simply
open to view. The areas affected may be small, due to
local conditions such as wind or water erosion, or
large, due to overall weathering and aging of the roof.
Exposed felts
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Membrane
Membrane damage includes physical
damage (holes, tears, cuts); fish
mouths; loose, dry, or easily
delaminated laps; membrane chalking,
crazing, or erosion; roofing blisters,
cracks, splits, and ridges; and failed,
temporary, or incompatible repair
materials.
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Membrane Flashings
Flashings are continuations of the
membrane that provide watertight tie-
ins of the roof membrane to adjacent
building components.
Flashing problems account for the
majority of roof leaks, and if flashings
are improperly designed, they are a
constant source of maintenance.
Roof Maintenance Prevention
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Housekeeping
Cleaning of Roof Surfaces
the cleaning required because of the natural
buildup of dust and leaves on the roof.
Roof Drains
All drains should be checked and the strainers
cleaned at least twice a year.
Corrosion and Rusting of Metals
When galvanized sheet metal loses its
protective coating and starts to rust, it is
necessary to clean it thoroughly and protect it
with paint.
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Chapter 3a

Enviado por

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Formatos disponíveis

CPD 30103 Plant Maintenance & Inspection UniKL MICET

Malaysian Institute of Chemical and Bioengineering Technology

It is expected that students will be able to:

Static Equipment are stationary equipment which

Rotating Equipment is a common classification of

Pressure vessels include:

Pressure Vessel Inspections:

iii. Tolerances for Formed Heads

iv. Out of Roundness of Shell

v. Nozzles and Attachments Orientation, Projection,

vii. Weld Reinforcement

All other pressure vessels

Periodic testing includes:

How often do I have to have my boiler

i. No heat or hot water potential causes include broken

vi. Frozen condensate pipe Thawing a frozen condensate

In a spray-filled tower, this is

Direct or open cooling tower

Indirect or closed cooling tower

An indirect or closed cooling tower

Lowering of Cooling Capacity

Rise in water Temperature

Less Water Flow

Less Air Flow

i. Pump Speed Problem due to normal wear

iv. Discharge Recirculation (low flow

Compressors are similar to pumps:

Inadequate Oil Lubricant

Turbine is a machine for producing

The principle function of an electric

The stator is generally made up of a

*IEEE - Institute of Electrical and Electronics Engineers

Most conditions that cause electric motor

the cause of vibration can be

Reduce components life

Scheduled routine inspection

Grease-Lubricated bearing only when

Scheduled monitoring with trend

Repetitive problems are identified

Vibration spectrum analysis for

Thermography for all electrical

Protecting health and safety of

Retaining value of investment

Maintaining the building in a

This chapter is concerned with the

Low sloped or flat roof systems are

ii. Modified-bitumen roof systems

iii. Single-ply roof systems

roof inspections should be made at

repairs or modifications to existing

Deteriorated coatings are

Alligatoring is surface cracking of the

Exposed felts are recognized by the absence of any

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