Maintenance procedures

Color Coding. New machinery and equipment must conform to OSHA standards and OEM specifications for color coding. Color coding can also help to speed up maintenance procedures. Examples include lubrication information, orientation, timing marks, torque requirements, etc. 

Monitoring by Electromechanical Instrumentation. According to basic engineering principles, no process can be conducted safely and effectively unless instantaneous information is available about its conditions. AH sterilizers are equipped with gauges, sensors (qv), and timers for the measurement of the various critical process parameters. More and more sterilizers are equipped with computerized control to eliminate the possibiUty of human error. However, electromechanical instmmentation is subject to random breakdowns or drifts from caUbrated settings and requires regular preventive maintenance procedures. 

Energy conservation directly reduces CO2 emissions. The elimination of fugitive hydrocarbon emissions as a result of improved maintenance procedures is also a tangible step that the industry is taking. 

Selecting the Sampling Point The selection of the sampling point is based primarily on supplying the analyzer with a sample whose composition or physical properties are pertinent to the control function to be performed. Other considerations include selecting locations that provide representative homogeneous samples with minimum transport delay, locations that cohect a minimum of contaminating material, and locations that are accessible for test and maintenance procedures. 

Another difficulty is assessing the potential for human errors. If redundancy is accompanied with increased complexity, the resulting increased potential for human errors must be taken into consideration. Redundant systems require maintenance procedures that can correct problems in one part of the system while the remainder of the system is in full operation. When conducting maintenance in such situations, the consequences of human errors can be rather unpleasant. 

A major consideration in the apphcatiou of diaphragm pumps is the realization that diaphragm failure will probably occur eventually. The consequences of such failure should be reahstically appraised before selection, and maintenance procedures should be established accord-ingly. 

Improper operation of a process may result in the vessel s exceeding design temperature. Proper control is the only solution to this problem. Maintenance procedures can also cause excessive temperatures. Sometimes the contents of a vessel may be burned out with torches. If the flame impinges on the vessel sheh, overheating and damage may occur. 

Introduction Review and audit processes are used in the chemical process industry to evaluate, examine, and verify the design of process equipment, operating procedures, and management systems. These processes assure compliance with company standards and guidelines as well as government regulations. Reviews and audits can encompass the areas of process and personnel safety, environmental and industrial hygiene protection, quality assurance, maintenance procedures, and so on. 

CCPS G-32. Guidelines for "Writing Effective Operating Maintenance Procedures. American Institute of Chemical Engineers, Center for Chemical Process Safety, New York. 

Existing maintenance procedures must be reviewed for several reasons. Typically, these are established based upon manufacturers recommended practices for stock equipment such as pumps, centrifuges and some reactors. However, a new toll can introduce special cleaning and preparation steps as well as possible material of construction incompatibilities. If the toller is using new equipment, special maintenance practices and tools may also be required. 

If special materials of construction are needed, provisions need to be in maintenance procedures to make sure these materials are used. If there are prohibitions on certain materials of construction, the procedures need to have provisions to make sure that they are not used. These considerations are especially true if there are multiple operations involved in the tolling unit. Answering the questions below can help determine which maintenance procedures need to be written and the level of detail required ... 

Standard operating procedures, maintenance procedures, emergency response plan procedures, administrative procedures, safe work practices... 

Job Specific Job-specific topics include training on new or revised operating, safety and maintenance procedures related to the toll. It could include emergency response plan training or laboratory technician training as well if those procedures were changed. 

The maintenance team, that is to say, the mechanics, were found competent and they followed the correct maintenance procedures. This information eliminates the defects by maintenance. 

In the event of failures due to lubrication problems, the failures should be thoroughly analyzed to determine if they were indeed caused by lubricant failure or incorrect maintenance procedures. Once the problem has been isolated, corrective action can be initiated to prevent subsequent similar failures—whether it requires changing lubricants or procedures. 

Maintenance is not a glamorous procedure however, its importance is second to none. Maintenance procedures are always controversial, since the definition of upkeep varies with the individual interpretation of each maintenance supervisor. The latitude of maintenance ranges from strict planning and execution, inspection and overhaul, accompanied by complete reports and accounting of costs, to the operation of machinery until some failure occurs, and then making the necessary repairs. 

As with any power equipment, gas turbines require a program of planned inspections with repair or replacement of damaged components. A properly designed and conducted inspection and preventive maintenance program can do much to increase the availability of gas turbines and reduce unscheduled maintenance. Inspections and preventive maintenance can be expensive, but not as costly as forced shutdowns. Nearly all manufacturers emphasize and describe preventive maintenance procedures to ensure the reliability of their machinery, and any maintenance program should be based on manufacturer s recommendations. Inspection and preventive maintenance procedures can be tailored to individual equipment application with references such as the manufacturer s instruction book, the operator s manual, and the preventive maintenance checklist. 

Beyond these items, the balance of the maintenance procedure should include the customary bearing and seal checks. 

Direct hydrogen cyanide (HCN) gas in a fuel oil gasification plant to a combustion unit to prevent its release. 4. Consider using purge gases from the synthesis process to fire the reformer strip condensates to reduce ammonia and methanol. 5. Use carbon dioxide removal processes that do not release toxics to the environment. When monoethanolamine (MEA) or other processes, such as hot potassium carbonate, are used in carbon dioxide removal, proper operation and maintenance procedures should be followed to minimize releases to the environment. 

A team consists of two or more people that know the process technology, design, operating procedures, practices, alarms, emergency procedures, test and maintenance procedures, routine and non-routine tasks. They must consider authorization and procurement of parts and supplies, safety and health standards, codes, specifications and regulations. The team leader provides m.iriagcment and goals to the process the team and consultants construct and interpret the analyses. 

Equipment used to process, store, or handle highly hazardous chemicals must be designed constructed, installed and maintained to minimize the risk of release. A systematic, scheduled, test and maintenance program is preferred over "breakdown" maintenance " that could compromise safety. Elements of a mechanical integrity program include 1) identification and categorization of equipment and instrumentation, 2) documentation of manufacturer data on mean time to failure, 3 ) test and inspection frequencies, 4) maintenance procedures, 5) training of maintenance personnel, 6) test criteria, and 7) documentation of test and inspection results. 

Maintenance, whether routine or unscheduled contributes to system unavailability. The frequency and duration can be obtained from the maintenance procedures. Take care that oulagcx iihsociated with preventive maintenance are not already included in the time intervals assipitctl u> testing. 

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