Maintenance of boiler II

Ensure to get everything because failing to maintain something can be hazardous.

Cleaning
Lack of cleanliness of the plant indicating of nothing but trouble. Cleaning is part of preventive maintenance program. This include cleaning burners, operating soot blowers and cleaning oil strainers.

Instructions & specifications

1. Read the manual first and every time before you perform any maintenance unless you know the book by heart.
2. Prepare checklist that helps you make sure follow the instructions. It is awfull to forget the step and out of sequence with the component failure being a result.
3. If you don't have the manual, contact the manufacturer to get one.
4. A checklist can save the time and prevent failure.
5. You will loss a several days simply because you refused to take a few minutes to look at the instructions.

Example of incidents at Iwo Jima, a Navy aircarft carrier in Oct of 1990, when 10 people were killed because a valve bonnet blew off in a confined engine room. -> use the right material.

Lock-Out, Tag Out

Refer to OSHA.

1. Hung near the eguipment so it's easliy seen and used.
2. Each valve is closed or opened and locked the number of the lock is marked on the diagram with non-permanent marker.
3. All keys for those lock are placed in one box which has lid secured.
4. To follow confined space procedures.

Lubrication

1. Second most important element of preventive maintenance.
2. Sampling of oil - condition of lub oil.
3. Use of synthetic oils can save cost.
4. Use wrong oil can result instantaneous breakdown to the equipment.
5. Keeping an update chart that covers everthing in the plant is important.
6. Paying attention to proper lubrication schedules can save time in the long run.
7. Don't over-lubrication or insufficient attention to others machine mainly due to improper schedule, that result unnecessary lubrication.
8. Suggest to install recording of running hour to determine when lubrication is necessary.
9. Tracking the service been done in a log book.
10. Frequency of operation to be consider. The continously running can result constant heating and coolingg of the bearing results in swell and shrinkage of the lubricant & can result in air & moisture mixing with it to degrade the lubricant and rust the bearing.
11. Require lubricant oil replacement.
12. Greasing - over greasing result the bearing shaft seals failure - forced them to upset + additional forced around the shaft.
13. The grease eventually block cooling air flow passes within the equipment. Don't forget to put plug or cap.
14. Follow the recommendations by manufacturer - volume of greasing.
15. Use proper grease.
16. Grease function -> support the loads, speed.
17. Failure to clean grease fitting before attaching the grease gun. Use a clean free rag to wipe off the fitting. Prevent anything to protect the lubricants. Clean the fitting before attacging the grease gun. Eliminating contamination of greasing.
18. Mark all grease, lubricant, proper storage.
19. Oil lubricant - replace of fitler, coolers, control of temperature according the manufacturer's instructions.
20. Temperature is critical to lubricant system - can break the properties.
21. Cleanliness is the next important factor because clearances in bearings and gears are so small the the particle of dust can span the clearance to produce damage in the equipment. A little contamination of lubricating system can result in total system failure costing thousand times more than oil.